PrefaceThis manual is provided as a guide to personnel involved with the operation, maintenance and repair of this rotary blasthole drill. We recommend that such personnel review and become familiar with the general procedures and information contained within this manual. In addition, we recommend that this manual be kept readily available for reference when repairs or maintenance are necessary.
Due to the complexities of mining equipment and the environment in which it operates, situations may arise which are not directly discussed in detail in this manual. When such a situation arises, past experience, availability of equipment, and common sense play a large part in what steps are to be taken. In addition, a P&H MinePro Ser-vices Representative is available to answer your questions and assist you upon request.
Changes to this manual are made by direction of the P&H Mining Equipment Knowledge and Development Department Manager through recommendations of Instructors, Technical Writers, Engineers, Service Personnel, and results of the manual review process. All changes shall ensure effective user comprehension and fulfillment of the topic being described. Use the form below to enter all change information contained on the PDF enclosed on your manual CD.
BD120149 Mechanical Systems Manual Blasthole Drill Safety
Section 1
Blasthole Drill Safety
1.1 General Information
Since the earliest days of mining, the job of digging iron and other useful materials out of the earth has been con-sidered one of the world's most dangerous occupations. Public concern about the toll of deaths, injuries and destruction in mine accidents has prompted passage of much-needed safety legislation and intensified the search for safer methods and improved training practices and technology. Growing cooperation among industry, labor and government also has contributed to making mining safer and more healthful, especially in recent years.
Safety and health in the mining industry has improved greatly since the early 20th Century. Total mining fatalities reached the lowest level in history in 2004. Listed below are safety information websites that can assist in prevent-ing mining accidents and injuries:
1.1.1 Safety Websites
www.msha.gov. The U.S. Department of Labor’s Mine Safety and Health Administration (MSHA) helps to reduce deaths, injuries, and illnesses in the nation's mines with a variety of activities and programs. The agency develops and enforces safety and health rules applying to all U.S. mines, helps mine operators who have special compliance problems, and makes available technical, educational and other types of assistance. MSHA works cooperatively with industry, labor, and other federal and state agencies toward improving safety and health conditions for all min-ers. MSHA's responsibilities are spelled out in the Federal Mine Safety and Health Act of 1977.
www.osha.gov. The U.S. Department of Labor’s Occupational Safety and Health Administrations (OSHA) mission is “to assure, so far as possible, every working man and woman in the nation safe and healthful working condi-tions.” By authorizing enforcement of the standards developed under the Occupational Safety and Health Act of 1970; by assisting and encouraging the States in their efforts to assure safe and healthful working conditions; by providing for research, information, education, and training in the field of occupational safety and health; and for other purposes.
www.cdc.gov/niosh. The National Institute for Occupational Safety and Health (NIOSH) is the Federal agency responsible for conducting research and making recommendations for the prevention of work-related disease and injury. The Institute is part of the Centers for Disease Control and Prevention (CDC).
NIOSH is responsible for conducting research on the full scope of occupational disease and injury ranging from lung disease in miners to carpal tunnel syndrome in computer users.
Blasthole Drill Safety BD120149 Mechanical Systems Manual
1.2 Safe Operating Practices for Users of P&H Mining Equipment - Large Rotary Blasthole Drills
NOTICE
A review of many safety sources including MSHA, NIOSH, OSHA, ANSI, and various individualmine safety policies was conducted to develop these safe operating practices recommenda-tions. The purpose of these recommendations is to assist and support our customer in theirsafety efforts in preventing accidents.
1.2.1 Introduction
P&H drills are carefully designed, manufactured, and tested. When used properly by qualified operators, they will give safe, reliable service. There are P&H offices worldwide to answer any questions about P&H products or their safe use. The World Sales and Service Headquarters for P&H Mining Equipment is:
P&H Mining Equipment4400 West National AvenueP.O. Box 310Milwaukee, WI 53201 USATelephone: (414) 671-4400
Because drills are complex and contain massive pieces of equipment, they also have the potential for accidents if safe operating practices are not followed. This section is intended to help prevent accidents which could result in injury, death, or property damage.
General safe practices for working machinery must be followed as well as safe operating practices. The following P&H Mining Equipment recommendations are provided to supplement customer/owner, local or national safety codes, rules or procedures.
1.2.2 Qualifications for and Conduct of Operators
The following P&H Mining Equipment recommendations are presented for the purpose of reducing the possibility of personal injury, either to the operator, or to those who work on or in the area adjacent to the drill. This documenta-tion is general in nature, and your drill may not be equipped with all devices mentioned.
BD120149 Mechanical Systems Manual Blasthole Drill Safety
The operator of this drill is urged to read this section carefully, and to avoid the hazardous operating conditions described. All situations described in the following have, at one time or another, contributed to serious accidents.
However, it is impossible to foresee all such conditions, and it must remain the responsibility of the mining com-pany and the operator to anticipate and avoid any unsafe conditions not described in detail in this manual. It is understood that safety rules within individual mining companies vary, and that, if a conflict exists, the rules of the company take precedence over the suggestions contained herein.
1.2.2.1 Operators of P&H Rotary Blasthole Drills
P&H Mining Equipment strongly recommends that only the following qualified personnel be permitted to operate a drill:
1. Designated qualified operators who have met the requirements of the operation tests and physical and mental conditions.
2. Trainees under the direct supervision of a qualified operator.
3. Qualified maintenance and test personnel when required to do so in the performance of their duties.
4. Inspectors qualified to operate the drill.
1.2.2.2 Operator Qualifications
P&H Mining Equipment strongly recommends that operators and operator trainees meet the following qualifica-tions:
1. Operators of P&H rotary blasthole drills must be required by the employer to pass a written examination which accurately measures practical knowledge of the drill, and an evaluated demonstration of the proper methods and techniques to be used in operating the drill, facilitated by a P&H Factory Authorized Trainer.
2. An operator must have vision of at least 20/30 Snellen in one eye and 20/50 Snellen in the other, with or with-out corrective lenses. Good depth perception is required.
Figure 1-1: Look closely to see what’s in the water...
Blasthole Drill Safety BD120149 Mechanical Systems Manual
3. An operator must be able to distinguish colors, regardless of the position of the color, if color differentiation is required for operation of the drill.
4. An operator must have adequate hearing for the specific operation, with or without hearing aid.
5. An operator must have sufficient strength, endurance, agility, coordination, and speed of reaction to meet the demands of drill operation.
6. Evidence of physical defects or emotional instability that could render a hazard to the operator or others, or which in the opinion of a qualified person could interfere with the operator’s performance, may be cause for disqualification. In such cases, specialized clinical or medical judgements and tests may be required.
7. Evidence that an operator is subject to seizures or loss of physical control is reason for disqualification. Spe-cialized medical tests may be required to determine these conditions.
8. Evidence that an operator is under the influence of alcohol or drugs is cause for disqualification.
9. An operator who is taking medication prescribed by a medical doctor must provide written assurance from that doctor that the medication will not affect the operator's ability to operate the drill in a safe manner.
10. The operator must have a good attitude towards safety at all times.
1.2.2.3 Operator’s Conduct
SAFETY FIRST
Safety must always be the operator's primary concern. An operator must refuse to operate thedrill when a known unsafe condition exists. Consult your supervisor when safety is in doubt.
1. The operator must read and understand the Operator's Manual and be familiar with all instructions and signs on the drill.
2. The operator must see that the drill is in proper order before operating.
3. When physically or otherwise unfit, an operator must not engage in the operation of the drill.
4. The operator must not engage in any practice that will divert attention while actually engaged in operating the drill.
5. The operator will ensure that people, other mining equipment, and material are kept out of the work area. Do not operate the drill when people are on the drilling platform.
6. The operator must give a warning signal prior to starting, operating, or traveling the drill.
7. All controls must be tested by the operator before beginning a new shift. If any control does not operate prop-erly, the operator must contact the appropriate maintenance department and have the controls repaired before operating the drill.
8. If adjustments or repairs are necessary, or any defects are known, the operator must promptly report the defects to the appropriate maintenance department who will be responsible for the repair of the drill. The oper-ator must also notify the next operator of any remaining uncorrected defects upon changing shifts.
BD120149 Mechanical Systems Manual Blasthole Drill Safety
1.2.2.4 Operator’s Functional Checks
The operator must make a safety check before starting to work each shift to see that the drill is in proper order. Some things to check are:
• Check for warning tags or lockout tags on the starting controls; do not operate the controls until the tag has been removed by the person who placed it there, or by a qualified person. Consult your minesites specific lockout-tagout procedures.
• Check with mine maintenance and operations management to see that periodic maintenance and inspec-tions have been performed and all necessary repairs made.
• Consult with mine management that scheduled inspection of load carrying members such as wire rope (dip-per trip lines, hoist rope, suspension lines), boom, dipper handle and dipper has been conducted.
• Check that all equipment guards are in place and all inspection and cover plates are closed and locked.
• Look inside, outside and underneath the drill to make sure everything is clear before starting or energizing the drill.
• After starting the drill, check all gauges and indicators for proper readings and operation.
• Test all controls for proper operation and controllability before drill operation or travel, including a thorough check of the brakes.
• Check audible warning devices and alarms used for backup warning for proper operation.
• During operation, be alert for unusual noises or vibrations; look and smell for unusual smoke or fumes.
1.2.3 Responsibilities of All Crew Members
Any unsafe condition or practice must be reported to the job supervisor and drill operator. Everyone who works around drills, including support people and maintenance personnel, must obey all safety hazard signs and watch out for their own safety and the safety of others in the area. Crew members setting up machines or handling main-tenance and repairs are expected to know proper procedures including lockout and tagout procedures.
Watch for hazards during operations and alert the operator of potential safety hazards such as the unexpected presence of people, other equipment in the area, unstable ground, bank conditions, or approaching storms.
1.2.4 Planning the Job
Most accidents can be avoided by careful job planning. The person in charge must have a clear understanding of the work to be done, consider dangers or hazards, develop a plan to do the job safely, and then explain the plan to all concerned. Factors such as the following should be considered:
• How can the drill trail cable be safely moved at the work site?
• Is there other equipment, power lines, or structures which must be moved or avoided during movement of the drill?
• Is the surface strong enough to support the drill and load?
BD120149 Mechanical Systems Manual Blasthole Drill Safety
1.3 Operation Near Electrical Lines Precautions
DANGER!
Keep clear of power lines when machine is in operation. Death or injury could resultshould any part of the machine comes within minimum distance of an energized powerline specified by local, state and federal regulations.
Working in the vicinity of electrical power lines presents a very serious hazard and special precautions must be taken. Safe operating practices require that you maintain the maximum possible distance from the lines and never violate the minimum clearances.
Before working in the vicinity of power lines, the following precautions should be observed:
• Contact the owners of the power lines or the nearest electric utility before beginning work.
• Machine operator and electrical utility representative must jointly determine what specific precautions are taken.
• Machine operator and electrical utility representative must confirm that all precautions are taken and fol-lowed.
• Even when power lines are known to be locked out and tagged out, consider them to be energized.
• Inform all ground personnel to stand clear of the machine at all times.
Use a signal person to guide the machine into close quarters. The sole responsibility of the signal person is to observe the approach of the machine to the power line. The signal person must be in direct communication with the operator and the operator must pay close attention to the signals
1.4 Safety Decals and Signs
1.4.1 General
Hazard Indicators and Safety Hazard Decals and Signs identify potential safety hazards and prevent accidents by displaying standard symbols, headers and pictographs or custom graphics. Headers, graphics, and layouts of indi-cators, decals, and signs conform to current ANSI guidelines, and are consistent with the industry standards for such devices commonly used for high voltage, personal protection, confined space, and bilingual applications.
1.4.2 Hazard Indicators
DANGERS, WARNINGS, CAUTIONS, NOTICES, and SAFETY FIRSTS are used on signs and decals, and throughout our manuals to emphasize important and critical instructions. In written documentation, DANGERS, WARNINGS, CAUTIONS, and SAFETY FIRSTS will precede the paragraph or item to which they apply. NOTICES will follow the paragraph or item to which they apply. DANGERS, WARNINGS, CAUTIONS, NOTICES and SAFETY FIRSTS are identified and defined as follows:
Blasthole Drill Safety BD120149 Mechanical Systems Manual
DANGER!
Indicates an imminently hazardous situation which, if not avoided, will result in death orserious injury. This signal word is limited to the most extreme situations.
WARNING!
Indicates a potentially hazardous situation which, if not avoided, could result in death orserious injury.
CAUTION!
Indicates a potentially hazardous situation which, if not avoided, may result in minor ormajor injury.
CAUTIONA Caution without a Safety Alert Symbol (Triangle and Exclamation Point) is used towarn of hazards that result only in property damage.
NOTICE
Used to indicate a statement of company policy directly or indirectly related to the safety of per-sonnel or protection of property. This signal word is not associated directly with a hazard or haz-ardous situation and is not used in place of DANGER, WARNING, or CAUTION.
SAFETY FIRST
Used to indicate general instructions relative to safe working practices, remind of proper safetyprocedures, and indicate the location of safety equipment.
1.4.3 Safety Hazard Decals and Signs
Safety Hazard Decals and Signs use hazard indicators discussed in the preceding paragraphs, and also display pictographs to show, both graphically and verbally, where potential safety hazards exist around the rotary blasthole drill. These decals and signs do not represent every possible hazard. They are not intended to be a substitute for safe working practices and good judgement.
The following Safety Hazard Decals and Signs are examples of those found on a typical rotary blasthole drill. Be certain everyone working on, or near, the drill understands, and knows how to avoid, the hazards they represent. Do not remove, cover, paint over, or deface these Safety Decals or Signs. If they become damaged or obscured, request replacement decals and signs from your local MinePro Services office.
BD120149 Mechanical Systems Manual Blasthole Drill Safety
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Safety Hazard Decals and Signs are located throughout the drill in various locations. Table 1-1 describes all Safety Hazard Decals and Signs used on the P&H Model 120A Rotary Blasthole Drill. The “Item Number” is the item num-ber indicated on engineering drawing R7243, SIGN INSTL; the number in parentheses is the P&H part number.
Item Number Safety Hazard Decal/Sign Description
5(32Z2536D2)
Yellow and black cautiontape.
In compliance with officiaregulations that state “Yellow shall be the basicolor for designating caution and for marking physical hazards such asStriking against, stum-bling, falling, tripping, and caught in between.”
20
(32Q1770D1)
This CAUTION decal alerts personnel that abnormal performance can cause personnel injury or property dam-age.
Do not open switch dur-ing normal operation.
21
(32Q1752)
This WARNING decal alerts personnel that haardous voltage inside cacause severe injury or death.
Keep all doors and coverclosed.
Do not open unless qualfied and authorized.
Disconnect power to all circuits.
Use lockout and tagout procedures before servicing.
Table 1-1: Safety Hazard Decals and Signs (Ref. Drawing R7243)
Blasthole Drill Safety BD120149 Mechanical Systems Manual
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It
47
(32Q1934)
This WARNING decal alerts personnel to an open serviceway.
Falling objects and unex-pected machine move-ment can cause severe injury or death.
Do not enter when machine is in operation.
Always notify operator of your presence.
Keep hands, body and clothing away from machine.
Use pathways, hold hand-rails and watch your step.
48R57305D1)
This WARNING decal alerts personnel to poten-tial arc-flash hazards.
Wear proper personal protective equipment while working inside energized cabinet.
See NFPA 70E.*
*NFPA 70E is a booklet published by the National Fire Protection Associa-tion. NFPA 70E: Electrical Safety in the Workplace is available for sale at www.nfpa.org/catalog
50
(32Q1937)
This DANGER decal alerts personnel to hazardous voltage.
Will cause severe injury or death.
Insure that all high volt-age is removed from the machine before servicing.
em Number Safety Hazard Decal/Sign Description
Table 1-1: Safety Hazard Decals and Signs (Ref. Drawing R7243)
WARNING!
BD0324a01
32Q1934
Always notify machine operator of yourpresence.
FALLING OBJECTS AND UNEXPECTED MACHINEMOVEMENT CAN CAUSE SEVERE INJURY OR DEATH.
OPEN SERVICEWAY.
DO NOT ENTER WHEN MACHINE IS IN OPERATION.
Keep hands, body and clothing away frommachine.
Use pathways, hold handrails and watchyour step.
POTENTIAL ARC-FLASH HAZARDS.
Wear proper personalprotective equipment whileworking inside energizedcabinet (see NFPA 70E).
R57305D1
ES04423a01
BD0325a01
HAZARDOUSVOLTAGE.
WILL CAUSE SEVEREINJURY OR DEATH.
Insure that allhigh voltage isremoved from themachine beforeservicing.
BD120149 Mechanical Systems Manual Blasthole Drill Safety
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51
(32Q1939)
This WARNING sign alertpersonnel of an open seviceway.
Falling objects and unexpected machine move-ment can cause severe injury or death.
Do not enter when machine is in operation.
Always notify machine operator of your pres-ence.
Keep hands, body and clothing way from machine.
Use pathways, hold handrails and watch your ste
52
(32Q1942D1)
This WARNING decal alerts personnel that rotating parts and haz-ardous voltage inside cacause severe injury or death.
Keep fingers clear of rotating machinery.
Disconnect power to all circuits before opening covers.
Use lockout and tagout procedures before servicing.
54
(32Q1930)
This DANGER decal alertpersonnel that hazard-ous voltage will cause severe injury or death.
Do not service unless qualified and authorized
Insure that all high volt-age is removed from themachine before servicingswitch.
Item Number Safety Hazard Decal/Sign Description
Table 1-1: Safety Hazard Decals and Signs (Ref. Drawing R7243)
ES03028a01
FALLING OBJECTS AND UNEXPECTED MACHINE MOVEMENT CAN CAUSE SEVERE INJURY OR DEATH.
OPEN SERVICEWAY.
DO NOT ENTER WHEN MACHINE IS INOPERATION.ALWAYS NOTIFY MACHINE OPERATOR OF YOURPRESENCE.KEEP HANDS, BODY AND CLOTHING AWAYFROM MACHINE.USE PATHWAYS, HOLD HANDRAILS ANDWATCH YOUR STEP
32Q1939
ES02930a01
ROTATING PARTS AND HAZARDOUS VOLTAGE INSIDE.
CAN CAUSE SEVERE INJURY OR DEATH.
Use lockout and tagout procedures before servicing.
Keep fingers clear of rotating machinery.
Disconnect power to all circuits before opening covers.
R42190D1
DL0116a0132Q1930
HAZARDOUSVOLTAGE.
WILL CAUSE SEVEREINJURY OR DEATH.
DO NOT SERVICEUNLESS QUALIFIEDAND AUTHORIZED.
Insure that allhigh voltage isremoved from themachine beforeservicing switch.
Blasthole Drill Safety BD120149 Mechanical Systems Manual
1.4.3.2 Description
Safety Hazard Decals and Signs are located throughout the drill in various locations. Figure 1-2 through Figure 1-16 illustrate the location of safety decals and signs on the drill. An index of the figures are shown in the bulleted list below. The callout numbers can be cross referenced to the item numbers in Table 1-1.
• Mast and Drilling Deck, Figure 1-2
• Mast Hoist Cylinder Boots, Figure 1-3
• Machinery House Exterior Panels, Figure 1-4
• Machinery Deck Layout (Overview), Figure 1-5
• Operator’s Cab Door (Drill Deck), Figure 1-6
• Oil Separator, Figure 1-7
• Main Transformer (right side), Figure 1-8
• Main Transformer (front view), Figure 1-9
• Fan Room Door, Figure 1-10
• Machinery House Door (front) (outside), Figure 1-11
• Lube Room Door (outside), Figure 1-12
• Power Skid (typical both sides), Figure 1-13
• PLC Cabinet, Figure 1-14
65
(R49498D1)
This CAUTION decal alerts personnel that this machine can be remote controlled.
Only one operator shall control the machine and the remote control box at the time.
66
(R49499D1)
This CAUTION decal alerts personnel that this machine can be remote controlled.
Only one operator shall control the machine and the remote control box at the time.
Item Number Safety Hazard Decal/Sign Description
Table 1-1: Safety Hazard Decals and Signs (Ref. Drawing R7243)
BD187a01
THIS MACHINE CAN BE REMOTE CONTROLLED.ONLY ONE OPERATOR SHALL CONTROL THE MACHINE
AND THE REMOTE CONTROL BOX AT THE TIME.R49498D1
BD188a01
THIS MACHINE CAN BE REMOTE CONTROLLED.ONLY ONE OPERATOR SHALL CONTROL THE MACHINE
LEGEND01. Auxiliary Cabinet, Figure 1-1902. Hoist/Rotary Junction Box, Figure 1-2003. DC Hoist Drive Cabinet, Figure 1-2104. DC Rotary Drive Cabinet, Figure 1-2205. High Voltage Junction Box, Figure 1-23
06. 460V Load Center, Figure 1-2407. 120V Load Center, Figure 1-2508. High Voltage Cabinet (side view), Figure 1-2609. High Voltage Cabinet (front view), Figure 1-2710. Operator’s Cab (Inside), Figure 1-28
This manual provides the information required to repair and maintain the P&H Mining Equipment Model 120A Rotary Blasthole Drill.
2.1.1 Part Numbers
Repair parts information is provided in the LinkOne electronic parts manual that is prepared for your drill. The drill serial number is located inside the operator's cab.
Part numbers are sometimes shown in this manual to identify specific assemblies and the information and proce-dures that apply to that specific assembly. Since this book is not updated on a continuous basis, do not use these part numbers to order repair parts.
NOTICE
Always obtain the part numbers from the up-to-date LinkOne electronic parts manual.
All information in this manual, including descriptions, specifications, and illustrations is for P&H model 120A Rotary Blasthole Drill, Serial Number BD120149, at the time of publication. Product improvements, owner modifications, or other changes introduced after this manual was published are not covered.
2.2 Questions concerning the drill or this manual should be referred to your P&H MinePro Services representative.
2.3 Description
2.3.1 General
The rotary blasthole drill is designed to drill blast holes. These holes are then filled with explosives, which fracture the material for most efficient removal. The drill can be equipped for single-pass drilling or multiple-pass drilling by coupling additional lengths of drill pipe to form a drill string. This drill only drills vertical holes.
All drill motions use electric motors with the exception of the propel motion, which uses hydraulic power. Power for the drill is provided by a double-shafted electric motor, coupled on one end to the air compressor and on the other end to the hydraulic pump drive transmission (PDT).
2.3.2 Drill Description
The Model 120A rotary blasthole drill (hereafter, the drill) produces pulldown bit load up to 150,000 lbs and has been optimized to drill single-pass or multi-pass holes up to 22" (55.88 cm) in diameter (see Figure 2-2). The total machine weight is approximately 365,000 lbs (165,564 kg). The standard pipe rack provides storage for one 65-foot (19.8-meter) pipe with 2-inch (50 mm) pipe wall thickness and up to 10.75 inches (273 mm) diameter. A sec-ond pipe rack is available as an option. Refer to Figure 2-3 for the drill deck plan.
LEGEND01. Valve Bank 302. Valve Bank 203. Valve Bank 104. Auxiliary Cabinet05. Water Tank06. PLC Cabinet07.T-Tank08. DC Hoist Cabinet09. DC Rotary Cabinet10. High Voltage Cabinet11. Main Transformer12. Control Load Center13. Auxiliaries Load Center14. Compressor Oil Cooler15. Hydraulic Tank16. Hydraulic Oil Cooler17. Grease Reservoir18. Lube Control Panel19. Valve Bank 420 Valve Bank 521. Low Pressure/Head Brake
Pumps22. Propel Pumps23. Auxiliary Hydraulic Pump24. Main Motor25. Main Air Control Panel26. Compressor27. Mast Cylinder (2)28. Operator’s Cab
The Model 120A is powered by the 700HP main AC electric motor, which is configured for the voltage and fre-quency available at the mine site. The electrical system remains operational even when the mine voltage fluctuates up to plus 10% or minus 15% from nominal.
The hydraulic pump drive transmission (PDT) and the main air compressor are both driven by the main AC motor rotating at 1,800 RPM (at 60 Hz; at 50 Hz, the motor rotation is 1500 RPM). The motor is designed to function well within the voltage fluctuation level specified.
The main air compressor is a rotary screw type which provides a rated output of 3,600 scfm. It is coupled to the main electric motor by means of a flexible coupling to ensure smooth operation. The main motor, air compressor and PDT are mounted on a skid to isolate the assembly from mainframe distortion that may occur while leveling or propelling the drill.
2.3.5 Undercarriage and Propel 100J6626F4
The two crawler frames are attached to the underside of the main frame by a fixed rear axle and an oscillating front axle. This arrangement tends to increase stability and also to isolate the main frame from excessive loading when propelling over rough terrain. The heavy duty crawler units are rated for a drill weight of over 200 tons.
The crawler shoes are of lug-and-tumbler design. There are 58 crawler shoes per crawler, approximately one-third of which are cleated, and two-thirds uncleated. The two crawlers are independently driven by drive tumblers with
planetary transmissions directly bolted to the crawler frame. An individual “plug-in” hydrostatic motor powers each planetary transmission. The transmissions are nested within the drive tumbler for protection from travel damage in rough areas.
Each planetary transmission has an integral spring-set, hydraulically released wet-type multiple disc parking brake. The propel motor can be manually disengaged from the transmissions to allow towing the drill with the optional towing package installed.
The crawlers can be counter-rotated to provide maximum maneuverability for tight turns and rapid travel from point to point.
2.3.6 Rotary Carriage R54410F4
Two electric drive motors drive the rotary driveshaft through the rotary gearcase (see Figure 2-8). The rotary drive shaft protrudes from the bottom of the rotary gearcase for connection to the drill string.
The rotary motor output shaft fits into the rotary gearcase first reduction pinion shaft, which is supported by bear-ings on both the top and the bottom. An oil pump on the bottom of the first reduction shaft provides lubrication for the upper bearings in the gearcase.
A rotary air swivel ensures sealed air flow through the rotary drive shaft. The rotary air seal also prevents water from entering the rotary gearcase oil when the drill is configured with water injection for dust suppression.
2.3.7 Pulldown Mechanism 916J204F1
Pulldown is accomplished by means of a rack and pinion drive (see Figure 2-8). The rack is mounted vertically on the mast and the drive pinion on the rotary carriage shipper shaft.
The rotary carriage guide rollers are provided with an eccentric arrangement for adjustment of rack/pinion gear backlash and alignment with the mast. An electric DC motor drives the hoist/pulldown pinions through the pulldown transmission.
2.3.8 Drill Pipe Storage
Drill pipe can be stored in the parallelogram-style pipe rack. The drill features two pipe racks. The main rack is 11.3 meters in length, while the additional rack is 8.4 meters. The racks are hydraulically controlled to move inward or outward. A mechanical mechanism is used to lock the drill pipe into place while stored.
2.3.9 Mast and Back Braces R14102F6
The mast chords utilize structural steel members. The mast safety sling ensures retention of a falling drill pipe with-out structural damage to the mast.
The mast is raised and lowered by two hydraulic cylinders and is locked in the vertical position by two hydraulically actuated mast lock pins located below
the drilling deck. The position of these pins is monitored by the Programmable Logic Controller (PLC).
The back braces fold and unfold automatically when the mast is raised and lowered. Two back brace locking col-lars slide over the folding knee joints between the upper and lower back braces to keep the back braces rigid, lock-ing the mast in the vertical drilling position.
2.3.10 Winch 23U52D1
A hydraulic motor driven winch is mounted on the machinery deck, between the mast hoist cylinders and generally below Valve Bank 2. The winch is used to handle tools and lift loads on the drilling platform. It features a one-way clutch, so that the winch will hold a load, yet will automatically release when the load is hoisted. The winch has a 11,000 lb. (5443 kg) lifting capacity. Winch wire rope feeds through guide sheaves mounted on a support bar on the mast crown. Either of two remote pendant controls (one outside the operator’s cab, the other inside) can be used to operate the winch.
2.3.11 Deck Wrenches GH5007463
The drill is equipped with opposing hydraulic ram type deck wrenches which are used to hold the drill string and prevent counter-rotation while adding or removing items from the drill string.
2.3.12 Operator’s Controls
The controls are arranged in functional groupings with frequently used controls located more closely to the opera-tor. Refer to the Operator’s Manual for details. A Graphical User Interface (GUI) provides continuous information for the operator.
2.3.13 Hydraulic Systems
The hydraulic systems are electric-over-hydraulic.
2.3.13.1 Main Hydraulic System R57531
Two identical axial piston pumps with crossover-center variable displacement provide speed and direction control for the hydraulic motors that drive the propel motion. These two hydraulic circuits are closed-loop.
The double vane auxiliary pump controls the many auxiliary cylinders, e.g., jacks, mast raise, deck wrenches, mast locks, deck hatch, back brace locks, etc.
2.3.14 Automatic Lubrication System 944J461F5
The automatic lubrication system is powered by a hydraulically driven pump controlled by the PLC. The system delivers lubricant from an on-board tank to injectors, which measure and deliver lubricant to selected points around the drill at regular intervals. The operator can manually initiate a lubrication cycle from the GUI when required.
2.3.15 Bailing Air System R45797
The purpose of the bailing air system is to blow drill cuttings out of the drill hole and to cool the rock bit bearings. The compressor output is adjustable to allow for optimum bailing air velocity.
Compressor inlet valves control the air draw into the rotary screws. These valves are hydraulically closed during start-up. During operation, the inlet valves modulate air intake by means of pneumatic controls.
2.3.16 Towing System
The drill can be towed. The final drive is designed to allow the propel brakes to be released and the propel motors to be disengaged from the transmission while towing the drill. Refer to for details.
Dust curtains surround the area beneath the drilling platform to contain the dust and chips created by drilling. The optional hydraulically operated rear dust curtains are operated from the operator’s cab. Along the sides of the drill, the curtains are fixed.
2.3.18 Serial Number Location
The drill serial number is located inside the operator’s cab.
2.4 Sign Maintenance
Signs of various types are located wherever required on the drill to warn personnel of potential hazards, identify controls and components, and to provide useful information.
Because these signs aid in the safe and efficient operation of the drill, inspection of all signs must be a part of the inspection program.
If signs are dirty, missing, or illegible, clean or replace them.
Self addressed comment forms have been included at the rear of this manual. Please use them to communicate questions, suggestions, or comments regarding this manual.
2.6 Material Safety Data Sheets (MSDS)
In order to transfer MSDS information from our suppliers to our customers, P&H Mining Equipment will provide this service upon customer request. All customer requests must be specific because of the volume and complexity of the MSDS system.
To identify the appropriate MSDS, one of the following must be included: P&H part number, vendor trade name, or vendor name.
Address inquiries concerning MSDS to your P&H MinePro Services representative.
2.7 Warranty
The terms of warranty for your drill are defined in the warranty document which accompanies each drill, including any special vendor operating or maintenance instructions.
The warranty does not cover any damage caused by failure to follow operating instructions, abuse (including oper-ation of the drill in excess of rated capacity), improper maintenance, accident, or unauthorized modification of the equipment.
The warranty will be voided (in whole or part) if the drill is operated under any of the following conditions:
1. With hydraulic pressure in excess of the maximum allowable pressure limits. The maximum allowable pres-sures are provided in the Maintenance Manual.
2. Under unsafe operating conditions.
3. With accessories not designed, furnished, or approved by P&H Mining Equipment.
4. With modifications which affect the operation or capacity of the blasthole drill.
2.8 Drill Terminology
Certain commonly used drill terms are defined below.
AIR SYSTEM (BIT OR MAIN). The sole function of the main air system is to supply a large volume of compressed air to the drill bit for cooling and to blow drill cuttings out of the drill hole.
AUXILIARY HYDRAULIC SYSTEM. The auxiliary hydraulic system supplies pressure and controls to operate most of the open loop hydraulically operated equipment, including the leveling jacks, pipe racks, breakout wrench, deck hatch, mast hoist cylinders, anchor pin cylinders, deck wrench cylinders, winch, back brace locks, and the optional hydraulically operated dust curtain.
AUTOMATIC GREASE LUBRICATION SYSTEM. Hydraulic oil is supplied from the auxiliary hydraulic system to operate a hydraulic oil powered grease pump. The grease pump supplies all of the automatic grease lubrication points on the drill.
BACK BRACES. The back braces are jointed tubular steel supports which support the mast in the drilling position.
BACK BRACE LOCKING COLLARS. The locking collars slide over the back brace knee joints to prevent the back braces from folding when the mast is in the raised position.
BREAKOUT WRENCH (Optional). The breakout wrench is mounted on the lower portion of the mast. It is a hydraulically operated pipe wrench controlled from the operator’s cab and used to loosen pipe joints.
CABLE REEL (Optional). The function of the cable reel is to wind in or spool out the stored high-voltage trail cable when propelling the drill.
COLLARING. Collaring is the procedure used to pilot a new drill hole. The pilot hole helps to center the drill string and minimizes material break-out and fall-in.
CRAWLER TRACK. The crawler track is an assembly of crawler shoes and pins which provides a continuous path on which the drill is propelled.
DECK WRENCHES. Deck wrenches are mounted on the deck on opposite sides of the deck bushing. They consist of a pair of opposed hydraulic rams that extend to grip and support drill pipe while adding or removing drill bits, sta-bilizers, or an additional section of drill pipe.
DRILL BIT. The drill bit is a rotated tool used to penetrate rock formations. It is driven by drill pipe(s) in the drill string via the rotary carriage.
DRILL PIPE. Drill pipe is a section of steel pipe, threaded male on one end and female on the other, on which the drill bit, stabilizer, or another drill pipe is mounted.
DRILL STRING. The drill pipe, stabilizer, drill bit, and other components comprise the drill string.
DRY DUST CONTROL SYSTEM (Optional). This system is designed to vacuum dust and small debris from inside the dust curtain area into a hopper which is dumped away from the drilling area.
DUST CURTAIN. A standard fixed dust curtain encloses the area around the drill string immediately below the drill-ing platform. It restricts the travel of flying rock chips and dust which result from drilling. Available as an option, a hydraulic cylinder can raise a portion of the dust curtain to prevent it from pushing cuttings into the blasthole when relocating the drill.
FRONT/REAR. The front of the drill is the end opposite the operator’s cab. The rear of the drill is the operators cab end.
HOIST/PULLDOWN SYSTEM. An electric motor which powers a rack and pinion drive through the hoist/pulldown transmission. It provides continuous drill bit loading when drilling and lifts the drill string from the hole when done.
HOIST BRAKE. The dual-disc, spring-set, hydraulic-released hoist brake is mounted on the pulldown gearcase intermediate shaft. It is used to stop and hold vertical movement of the rotary carriage.
JACK PADS. Jack pads are metal plates attached to the lower end of the leveling jack spud. The jack pads provide a large surface area on which the leveling jack can bear.
LEVELING SYSTEM. Four leveling jacks are located at the four corners of the main frame. They are controlled from the operator’s cab or the optional remote propel controller. The two rear jacks (closest to the operator’s cab) are independently adjustable. The two front jacks are connected in parallel and operate as a self-equalizing pair.
The optional auto-leveling system, when activated, automatically raises the drill to the lowest possible level operat-ing plane.
MACHINERY HOUSE. The machinery house is the enclosed room in which the power unit, electrical cabinets, and the majority of the hydraulic system and air system components are located. The machinery house is pressurized and filtered (standard) and can be heated by thermostatically controlled fans (optional).
MAIN HYDRAULIC SYSTEM. The main hydraulic system propels the drill. It primarily consists of two closed-loop hydrostatic pumping systems with hydraulic motors, valves, filters, strainers, and propel motion controls. The sys-tem also provides pressure to release the propel parking brakes and to control propel motor speed/torque setting.
MAST. The mast is a welded structural steel assembly that supports and guides the rotary carriage. The pipe racks, winch, and breakout wrench are also secured to and supported by the mast. The mast is raised or lowered by two hydraulic cylinders.
MAST ANCHOR PINS. The mast anchor pins are hydraulic cylinder-operated locking pins used to secure the mast in the vertical position. They are located on the frame beneath the drilling deck.
MAST CROWN. The mast crown is located at the top of the mast. It ties the mast legs together and supports the winch sheaves.
MAST RAISING CYLINDERS. These two cylinders are deck mounted and are used to raise and lower the mast.
MAST PIVOT PINS. The mast pivot pins are the pins about which the mast rotates when it is being raised or low-ered.
OPERATOR’S CAB. The operator’s cab contains the operating controls, indicators, gauges and the Graphic User Interface (GUI). All drill operations are controlled from the operator’s cab.
PIPE RACK. The pipe rack is a mechanism located within the mast which can store a 65 ft. (19.8 m) length of drill pipe.
PIPE SLING. The pipe sling is a permanent frame mounted part way up the mast to restrain pipe sections from fall-ing if one should become uncoupled from the rotary carriage or pipe rack.
POWER SUPPLY CABLE (TRAIL CABLE). The trail cable is the power conductor located between the front of the drill and the power sub-station. All electrical energy is supplied to the drill via this cable.
POWER UNIT. The hydraulic pump drive transmission (PDT) and the main air compressor are mounted on oppo-site ends of the main AC electric motor, on a common sub-base. The motor provides the power to drive all of the drill functions. For purposes of this manual, the power unit is defined as the AC motor and the PDT. The air com-pressor is not considered to be part of the power unit.
PROPEL BRAKES. Each crawler drive has a spring-set, hydraulically released parking brake that automatically releases when pressure is applied to the hydraulic propel motor. The brakes are integral with the propel transmis-sions.
PROPEL SYSTEM. The drill is mounted on and propelled by individually powered and controlled crawlers. The rear axle is stationary and is bolted rigidly to the main frame. A floating equalizer axle at the front enables the crawl-
ers to maintain footing over rough terrain. Steering is accomplished by individual control of the speed and direction of travel of the left and right crawlers.
PROPEL DIRECTION. The drill is propelled forward when the drilling platform and operator’s cab trail the drill in the direction of travel. The drill is propelled to the rear when the drilling platform and operator’s cab lead in the direction of travel.
PULLDOWN. Pulldown is the downward force applied to the rotary bit by the hoist/pulldown motor while drilling.
PUMP DRIVE TRANSMISSION (PDT). All of the pumps that power the main and auxiliary hydraulic systems, except the hoist brake pump and the low pressure pump, are mounted on and driven by the PDT. The PDT is a gear reducer having multiple output shafts, all driven from a common input shaft. Each hydraulic pump is flange mounted and direct coupled to a PDT output drive shaft. The PDT is coupled to the main AC drive motor as one of the components of the POWER UNIT.
ROTARY CARRIAGE. The rotary carriage provides rotary and vertical motion to the drill string. Reversible DC motors drive the rotary gear reducer to impart bi-directional rotary motion to the drill string. A DC pulldown motor provides vertical motion to lift or lower the drill string.
SINGLE-PASS DRILLING. Single-pass drilling is the process of drilling a blasthole to a depth no greater than the distance the rotary carriage can travel from top to bottom of the mast, using a single length of drill string. The drill string does not have to be removed from the drill while traveling to the next drill hole location.
WATER INJECTION SYSTEM (Optional). The water injection system supplies an adjustable flow of water into the bailing air stream to control dust created by drilling.
WINCH. A winch is provided for tool handling on the drilling platform. The winch is mounted inside the machinery house beneath the A Frame; wire rope feeds upward, passes over two guide sheaves mounted on the mast crown and back down to the drilling platform. The winch has a built-in clutch designed so that when hydraulic power is removed, the clutch will engage and the load will stop. When hydraulic power is applied, the clutch releases, allow-ing the drum to rotate in a controlled manner.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
Section 3
Auxiliary Hydraulic System
3.1 General
This section describes the auxiliary hydraulic system and provides information for adjustment, removal, and instal-lation of the major hydraulic components.
Only the hydraulic portions of the various subsystems are described in this section. The mechanical components that take their movement from the auxiliary hydraulic system will be discussed in the mechanical sections that per-tain to them. For example, the hydraulic circuit that moves the mast anchor pins is discussed here; discussion of the mast anchor pins themselves is in the mast section.
3.2 Theory of Operation
The auxiliary hydraulic system provides controlled hydraulic pressure and flow to the following assemblies:
• Back brace locks
• Dust curtain
• .Deck wrench
• .Mast anchor pins
• Mast hoist cylinders
• Pipe racks
• Pipe rack gates
• Pipe rack holdbacks
• Deck Hatch
• Breakout Wrench
• Levelling jacks
• Auxiliary winch
All directional valves on the three valve banks in this system are operated by electrical solenoids, which receive operating signals from a programmable logic controller (PLC) located in a dedicated cabinet inside the machinery house. See Figure 2-3.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
3.2.1 Hydraulic Tank R6908D1
The auxiliary tank, located in the lubrication room on the forward right portion of the machinery deck, provides oil for all hydraulic functions on the drill, including both the main hydraulic system and the auxiliary hydraulic system.
The hydraulic tank is partitioned by a baffle to separate the suction lines from the return lines. The baffle plate is ported to permit cross-flow of oil from the return side to the suction side of the tank.
Refer to Subtopic 3.3.2 for maintenance information regarding the hydraulic tank.
Figure 3-2: Hydraulic Tank
01
0304
06
0908
BD0361a01
02
05
07
10
11
LEGEND01. Suction Filters02. Temperature Probe03. Hydraulic Tank04. Low Level Switch
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.2.1.1 Suction Filters R16280D1
The pump suction filters are located at the rearward end of the hydraulic oil tank.They feature a Handwell Valve which serves as a shut-off valve for the suction line of the auxiliary hydraulic pump. To shot off the oil flow, turn the knob anticlockwise until it stops. The Handwell Valve includes a limit switch to prevent the start-up of the drill when the valve is closed.
The suction filter is equipped with a vacuum by-pass valve that permits oil to flow around the filter element if the element becomes excessively fouled. The indicator switch is not a visual switch. When the filter goes into bypass, the switch will inform the PLC, which will issue a fault on the GUI.
Refer to Subtopic 3.3.3 for maintenance information regarding the suction filters.
3.2.1.2 Temperature Probe 89Z724D2
The temperature probe is a resistive temperature device (RTD) that detects the temperature of the hydraulic oil in the tank and transmits that information to the PLC. It is installed on the rearward side of the hydraulic tank above
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
the Handwell valves. The temperature probe controls the operation of the oil cooler fans. When the oil temperature reaches 140°F (60°C), the fans turn on.
Refer to Subtopic 3.3.4 for maintenance information regarding the temperature probe.
3.2.1.3 Low Level Switch R16982D1
The low level switch is located on the top of the hydraulic tank. The unit is a float type switch that detects when the oil level has reached the allowable minimum. Functionally, the switch provides input to the programmable logic controller (PLC). When a low hydraulic oil level condition is indicated, the PLC shuts down the main drive motor to the pump drive transmission and records a fault on the GUI.
Refer to Subtopic 3.3.5 for maintenance information regarding the low level switch.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.2.1.4 Hydraulic Tank Breather 1046Z994
The hydraulic tank breather is mounted at the top of the tank. The breather is fitted with a synthetic 3-micron filtra-tion medium to filter out contaminants when the oil cools and air is drawn through the breather into the tank.
The breather should be replaced during each Preventive Maintenance period.
3.2.1.5 Magnetic Rod R17038D1
A magnetic rod is installed into the top of the tank. The rod extends into the tank and attracts metal contaminants, holding them in suspension and preventing them from entering more sensitive hydraulic components.
The magnetic rod should be cleaned at each Preventive Maintenance period.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
3.2.1.6 Return Filters 46Z529
The two return line filters for the hydraulic systems are flange-mounted on top of the hydraulic tank. The two filters are identical, and can be serviced without removal from the tank.
The filters are rated at 80 gpm (303 lpm) and contain two 3-micron filter elements, mounted in tandem. Return oil flows through the center of the element and exits the outside to tank. The filter is equipped with a bypass valve that begins to bypass unfiltered oil at 25 psi (1.7 bar). A dirt alarm gauge is mounted to the body of each filter to indicate the operating condition of the filter elements. The gauge faces are marked with red and green areas. Red indicates the need to replace the filter elements.There is also a bypass indicator that informs the operator via the GUI that the filters are in a bypass condition.
Refer to Subtopic 3.3.8 for maintenance information regarding the return filters.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.2.1.7 Level and Temperature Gauge R16998D1
The level gauge is a sight glass used in conjunction with the associated placard to determine the appropriate level based on the condition of the drill (i.e., mast up or down, jacks up or down, etc.). At the lower end of the sight glass is a thermometer that indicates oil temperature.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
3.2.1.8 Filter Panel R34567F2
An additional oil reservoir and filter panel is mounted to the right of the PDT. This additional oil reservoir contains 80 gallons (303 liters) that can be used to replenish the oil in the air compressor as well as in the hydraulic tank.Three-micron filters provide additional filtration before the oil is returned to the reservoir.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.2.2 Auxiliary Hydraulic Pump 37U153D1
Hydraulic flow for the auxiliary hydraulic system is produced by a vane-type, double hydraulic pump. This pump is driven by a mechanical pump drive transmission (PDT). The PDT is driven by the main AC electric drive motor.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
Oil for the auxiliary hydraulic pump comes from the hydraulic tank, through a suction filter and a Handwell valve. The pump delivers 20 gpm (76 lpm) from the lower-volume cover-end pump, and 37 gpm (140 lpm) from the higher-volume shaft-end pump. The pump shaft is driven at 2070 rpm via the gear ratio of the PDT.
The output flow from the lower-volume pump section is directed into the pressure inlet port of valve bank 1 and valve bank 2.
The output flow from the higher-volume pump section is directed into the pressure inlet port of valve bank 3.
When the Auto Level System is operating, or when the operator manually operates all four of the leveling jacks simultaneously, the oil supply to the pressure inlet port of valve bank 3 comes from two sources. The first source is the full output from the low pressure/higher volume pump section. The second supply source is an interruptible flow of high pressure oil from the B 1 port of valve bank 1.
In addition to valve banks 1 and 2, the lower-volume section of the pump also supplies flow to the hydraulic pipe rack gate.
Oil discharged from the three valve banks combines with the pump and motor drain lines from the main hydraulic system. This combined stream of hot oil flows through an air-blown heat exchanger for cooling, then returns to the tank by way of a pair of low pressure filters. The oil cooler has a built-in check valve to allow for bypass of oil in the event the cooler core oil flow were to be restricted.
3.2.2.1 Theory of Operation
Fluid enters the pumping cartridge through the inlet port and is discharged through pressure plates to the outlet ports. The action of the pumping cartridge is illustrated in Figure 3-13 The rotor is driven within the cam ring by the driveshaft, which is splined to the pump drive transmission. As the rotor turns, centrifugal force on the vanes, aided by under-vane pressure fed from the outlet port, causes the vanes to follow the elliptical inner surface of the cam ring.
Radial movement of the vanes and turning of the rotor cause the chamber volume between the vanes to increase as the vanes pass the inlet section of the cam ring. This results in a low pressure condition which allows atmo-
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
spheric pressure to force fluid into the chambers. This fluid is trapped between the vanes and carried past a sealing land to the outlet section of the cam ring. As the outlet section is approached, the chamber volume decreases and the fluid is forced out into the system. The intra-vane design provides a means of controlling the outward thrust of the vane against the cam ring to maintain the tip loads within reasonable limits. In the intra-vane cartridge, full sys-tem pressure is continuously applied for outward vane thrust only over the area between the vane and the insert. This area is small, and thrust is correspondingly light. During vane travel through the pressure areas, full system pressure is also applied against the bottom of the vane. The valving of pressure to and from the bottom area of the vane is through holes drilled in the rotor, as shown in Figure 3-14. This selective application of pressure maintains the vane in constant radial hydraulic balance in all positions.
The cam ring is shaped so that the two pumping chambers are formed 180 degrees apart (refer to Figure 3-13). Thus, opposing hydraulic forces, which would impose side loads on the driveshaft, cancel each other out.The pres-sure plate seals the pump chamber, as shown in Figure 3-15. System pressure is effective against the area at the back of the plate, which is larger than the area exposed to the pumping cartridge. Thus, an unbalanced force holds the plate against the cartridge, sealing the cartridge, and providing the correct running clearance for the rotor and vanes. The pressure plate also contains passages for feeding pressure to the space between the vanes and inserts.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
3.2.3 Valve Bank 1 36R198D3
Valve Bank 1 is mounted between the two mast hoist cylinders inside the machinery house (see Figure 2-3). Seven hydraulic circuits are controlled by the valve assemblies mounted on valve bank 1: the relief unload/oil diverter, mast hoist, mast anchor pins, deck wrench, dust curtain, back brace lock, and the cable reel. Refer to Figure 3-17.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
One of the primary functions of valve bank 1 is to control the maximum hydraulic pressure available to the three valve banks, and to implement the timing of when high pressure is available for system operation. This function is managed by the relief unload/oil diverter valve. The relief/Unload Oil Diverter Valve is a three-position, four way valve. The valve is solenoid actuated with manual override in both directions. It is spring-centered, and the center is open. When in the spring-centered open position, this valve allows oil from the auxiliary pump to bypass the sys-tem pressure relief valve, flowing directly back to the tank without building pressure. This is an energy-saving pro-vision for periods when the auxiliary hydraulic circuits are at rest.
Whenever the operator initiates movement for any of the devices controlled by the valves on either Valve Bank 1 or on Valve Bank 2, the PLC causes the relief unload/oil diverter valve A solenoid to energize. This causes the valve to shift so that oil from the P port of the valve flows to the A port and to the blocked port A1. Oil flow backs up against the pressure relief valve and system pressure builds to the maximum setting of the relief valve (2900 psi (200 bar)). This establishes the maximum pressure available to the equipment using the high pressure flow stream.
WARNING!
Do not exceed the maximum relief valve setting of 2900 psi. Pump and hoses have amaximum specified pressure of 3000 psi. Overpressurizing the system could result inequipment failure, which could result in severe personal injury or death. Do not exceed2900 psi.
When the operator activates the Auto Level System, or when all four leveling jacks are manually operated simulta-neously, the PLC causes the B solenoid to energize. Oil flow from the P port of the valve flows to the B port and through valve bank port B1, where the oil is diverted out of valve bank 1 and merges with the high volume flow stream to valve bank 3.
3.2.3.2 Pressure Transducer and Pressure Switches
Mounted to the right of valve bank 1 on the bulkhead below valve bank 2 are the pressure transducer and pressure switches that monitor pressures in the auxiliary hydraulic system.
The pressure transducer (Item 01, Figure 3-19) senses pump discharge pressure and indicates system operating pressure to the PLC. The hydraulic pressure switch (Item 02, Figure 3-19) confirms that the auxiliary pump is oper-
Figure 3-19: Pressure Transducer and Pressure Switches
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
ating at pressure. The relief pressure switch (Item 03, Figure 3-19) senses when system pressure is excessive, and automatically shuts down the pump drive.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
The mast hoist valve assembly controls the direction and flow rate of oil to and from the large-bore mast-raising cylinders. It is a three-position, four way valve. The valve is solenoid actuated with manual override in both direc-tions. It is spring-centered, and the center is open to tank. When in the spring-centered open position, this valve blocks pressure from the pump and opens all other ports to tank. Flow control valves in both the hoist and lower cir-cuit control the speed of cylinder movement.
Flow Control for the Extend (Raise) circuit is set for 20 GPM; this causes the mast cylinder to extend in 76.5 sec-onds. Flow Control for the Retract (Lower) circuit is set for 13 GPM; this causes the mast cylinder to retract in 79.2 seconds.
CAUTIONCounterbalance valve pressures are pre-set at the factory. Changing the settings cancause severe equipment damage. Do not adjust counterbalance valve pressure settings.If adjustments are necessary, contact your local P&H MinePro Services.
Each mast cylinder circuit is equipped with dual counterbalance valves to prevent uncontrolled movement in either the up or down direction should a malfunction disrupt oil flow. Counterbalance valve pressures are pre-set at the factory and are not to be adjusted.
When the operator places the mast hoist button in the RAISE position, the PLC causes solenoid A to energize. The valve spool shifts so that oil from the P port of the valve flows to the A port of the valve and out the A2 port of the valve bank. Oil flows through the 20 GPM flow control valve and over the check valve portion of the directional flow control valve into the head end of the hydraulic cylinders. As pressure increases, the crossover ports on counter-balance valves cause the valve ports on the opposite line to open. Oil from the rod end of the cylinders is then able to flow through the counterbalance valves, over the directional flow control valve and back to tank.
When the operator places the mast hoist button in the LOWER position, the PLC causes solenoid B to energize. The valve spool shifts so that oil from the P port of the valve flows to the B port of the valve and out the B2 port of the valve bank. Oil flows through the 13 GPM flow control valve and over the check valve portion of the directional flow control valve into the rod end of the hydraulic cylinders. As pressure increases, the crossover ports on coun-terbalance valves cause the valve ports on the opposite line to open. Oil from the head end of the cylinders is then able to flow through the counterbalance valves, over the directional flow control valve and back to tank.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.2.3.4 Mast Anchor Pins
The mast anchor pin valve controls the direction of oil flow to two anchor pin cylinders. It is a three-position, four way valve. The valve is solenoid actuated with manual override in both directions. It is spring-centered, and the center is closed. When this valve is in its centered position, the closed lines tend to keep the pins in their current
Figure 3-21: Mast Anchor Pins
R57349-2d
Numbers in the circles refer to the Bill of Material (Subtopic 3.2.6). Numbers in the triangles refer to the System Data Sheet (Table 3-1).
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
position. A limit switch on the rod end sends a signal to the PLC when the pins are in the engaged position. Pins should extend in 1.8 seconds and retract in 1.0 second.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.2.3.5 Deck Wrench
The deck wrench valve assembly controls the direction and maximum operating pressure of oil flow to the two deck wrench cylinders.It is a three-position, four way valve. The valve is solenoid actuated with manual override in both
Figure 3-22: Deck Wrench
R57349-2e
Numbers in the circles refer to the Bill of Material (Subtopic 3.2.6). Numbers in the triangles refer to the System Data Sheet (Table 3-1).
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
directions. It is spring-centered, and the center is partially open. When this valve is in its centered position, pres-sure from the pump is blocked and the remaining ports are open to the tank.
CAUTIONDual counterbalance valve pressures are pre-set at the factory. Changing the settingscan cause equipment damage. Do not adjust counterbalance valve pressure settings. Ifadjustment becomes necessary, contact your local P&H MinePro Services.
A dual counterbalance valve is used in the cylinder circuit to prevent the wrenches from extending into the drill string when the control valve is in the spring-centered neutral position. It also provides a means to help hold the drill pipe when the pipe is uncoupled from the rotary carriage (the cylinder pressure is maintained by the counter-balance valve).
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
The dust curtain valve assembly controls the oil flow direction, rate of flow, and maximum operating pressure avail-able for operation of the dust curtain raising and lowering cylinder. It is a three-position, four way valve. The valve is solenoid actuated with manual override in both directions. It is spring-centered, and the center is partially open. When this valve is in its centered position, pressure from the pump is blocked. The remaining ports are open to the tank.
Cross port relief valves protect the dust curtain raising system from damage. Adjust the relief valve on the raise side of the circuit to 1000 psi and the lower side to 350 psi.
The pilot operated check valves in both raising and lowering circuits provide positive position locking for the dust curtain cylinders.
Adjust flow control valves to achieve a raising and lowering time between 4 and 5 seconds.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.2.3.7 Back Brace Lock
The back brace lock valve controls the direction of oil flow back brace lock cylinders. Each back brace has a lock that slides over the articulating joint; each lock is controlled by three cylinders.
Figure 3-24: Back Brace Lock Valve
R57349-2g
Numbers in the circles refer to the Bill of Material (Subtopic 3.2.6). Numbers in the triangles refer to the System Data Sheet (Table 3-1).
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
3.2.4 Valve Bank 2 36R199D7
Valve Bank 2 is mounted between the two mast hoist cylinders inside the machinery house (see Figure 2-3). The hydraulic circuits that are controlled by the valve assemblies mounted on valve bank 2 are the two pipe racks, the deck hatch and the breakout wrench. The availability of high pressure oil to operate these circuits is dependent upon the position of the relief unload/oil diverter valve on valve bank 1, as described under Subtopic 3.2.3.1. Refer to Figure 3-26.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
The pipe rack valve assembly controls the direction and flow rate of oil to and from the pipe rack cylinder. It is a three-position, four way valve. The valve is solenoid actuated with manual override in both directions. It is spring-centered, and the center is partially open. When this valve is in its centered position, pressure from the pump is blocked; the remaining ports are open back to the tank.
Flow control valves in both the extend (“over hole”) and retract (“store”) circuit control the speed of cylinder move-ment. Flow Control for the extend circuit is set for 12.5 GPM; Flow Control for the retract circuit is set for 15.5 GPM.
CAUTIONCounterbalance valve pressures are pre-set at the factory. Changing the settings cancause severe equipment damage. Do not adjust counterbalance valve pressure settings.
The pipe rack cylinder circuit is equipped with a dual counterbalance valve to prevent uncontrolled movement in either the centering or storing direction should a malfunction disrupt oil flow. Dual counterbalance valve pressures are pre-set at the factory and are not to be adjusted.
When the operator places the pipe rack button in the OVER HOLE position, the PLC causes solenoid B to ener-gize. The valve spool shifts so that oil from the P port of the valve flows to the B port of the valve and out of the valve bank. Oil flows through the 12.5 GPM flow control valve and over the check valve portion of the directional flow control valve into the head end of the hydraulic cylinder. As pressure increases, the crossover port on counter-balance valve causes the valve port on the opposite line to open. Oil from the rod end of the cylinders is then able to flow through the counterbalance valve, over the directional flow control valve and back to tank.
When the operator places the pipe rack button in the STORE position, the PLC causes solenoid A to energize. The valve spool shifts so that oil from the P port of the valve flows to the A port of the valve and out the A1 or A2 port of the valve bank (depending on which rack is active). Oil flows through the 15.5 GPM flow control valve and over the check valve portion of the directional flow control valve into the rod end of the hydraulic cylinder. As pressure increases, the crossover port on counterbalance valve causes the valve port on the opposite line to open. Oil from the head end of the cylinders is then able to flow through the counterbalance valve, over the directional flow control valve and back to tank.
When the pipe rack is in the stowed position, a limit switch will cause indication on the operator’s console.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
spring return. It is mounted on the bulkhead to the right of valve bank 2 and above valve bank 3.
Oil to operate the pipe rack gate is provided by the low-volume side of the auxiliary hydraulic pump. The line pro-viding oil to the pipe rack gate valve connects to the line between Valve Bank 1 and Valve Bank 2. See Figure 3-1.
WARNING!
When short pipes are used in the drill string, the shorter sections may not reach up tothe point where the pipe rack gate will hold them in the rack. The short pipe could fall outand cause severe personal injury or death. Always be sure that the length of pipe in thepipe rack is sufficient to allow the pipe rack gate to hold the pipe in the rack.
The pipe rack gate is located at the top of the pipe rack. It consists of a curved rod, or gate arm, that rotates down and in front of the drill pipe when it is stored in the pipe rack, protecting the drill pipe from falling out of the pipe rack.
When a loaded pipe rack is moved into the OVER HOLE position and the pipe is lifted from the rack by the rotary carriage machinery, the pipe rack gate arm rotates up and out of the way. This permits rack to return to the STORE position.
When the pipe rack is back in the STORE position, the gate arm rotates back down.
When the empty pipe rack moves out of the STORE position, the gate arm rotates up, allowing the rack to be placed in position to receive the pipe. When the pipe is placed into the pipe rack, the gate arm rotates back down and prevents the pipe from falling out.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
3.2.4.3 Pipe Rack Holdback
When the drill is started, the head brake motor and pump turn on. At the same time, the pipe rack holdback sole-noid energized. Oil pressure is provided to the pipe rack circuit, and acts to maintain the pipe rack cylinder in the retracted position. This is to prevent the pipe rack from drifting into the drill string during normal drilling operations.
When the operator energizes the pipe rack solenoid, the pipe rack holdback solenoid is de-energized and the pipe rack circuit can cause the pipe rack cylinder to extend or retract as required.
Figure 3-30: Pipe Rack Holdback Circuit
To PipeRack Valves
R57349-3d
Numbers in the circles refer to the Bill of Material (Subtopic 3.2.6). Num-bers in the triangles refer to the System Data Sheet (Table 3-1).
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
The deck hatch valve assembly controls the oil flow direction, rate of flow, and maximum operating pressure avail-able for operation of the deck hatch raising and lowering cylinder. It is a three-position, four way valve. The valve is solenoid actuated with manual override in both directions. It is spring-centered, and the center is partially open. When this valve is in its centered position, pressure from the pump is blocked; the remaining ports are open back to the tank.
A pair of connected pilot-to-open check valves maintain the deck hatch in the desired position.
Adjustable flow control valves determine raising and lowering speed for the deck hatch.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.2.4.5 Breakout Wrench Engage/Disengage
The Breakout Wrench Engage/Disengage Valve is used after the breakout wrench has been moved out to the drill pipe. It is a three-position, four way valve. The valve is solenoid actuated with manual override in both directions. It is spring-centered, and the center is closed. When this valve is in its centered position, all ports are blocked.
Figure 3-32: Breakout Wrench Engage / Disengage
R57349-3f
Numbers in the circles refer to the Bill of Material (Subtopic 3.2.6). Num-bers in the triangles refer to the System Data Sheet (Table 3-1).
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
When the operator places the breakout wrench control button in the ENGAGE position, the PLC causes the A sole-noid to energize and the valve spool shifts. Oil from the P port passes through the A port on the valve, out the A7 port on the valve bank and to the head end of the jaw cylinder. When the jaw cylinder extends, the jaws of the brea-kout wrench close around the pipe. Oil from the rod end of the cylinder returns unrestricted to the valve (port B to port T) and back to tank.
Once the jaws are in contact with the pipe and cannot move anymore, hydraulic pressure builds. When hydraulic pressure reaches the setting of the sequencing valve (2400 psi), the sequencing valve opens. Oil flows to the head end of the break cylinder, causing the cylinder to extend. As the cylinder extends, the breakout wrench jaws rotate anticlockwise to break the pipe joint. Oil from the rod end of the cylinder passes through the check valve on the sequencing valve to the low pressure line, from there to the valve (port B to port T) and back to tank.
When the operator places the breakout wrench control button in the DISENGAGE position, the PLC causes the B solenoid to energize and the valve spool shifts. Oil from the P port passes through the B port on the valve, out the B7 port on the valve bank and to the rod end of the jaw cylinder. When the jaw cylinder retracts, the jaws of the breakout wrench open. Oil from the head end of the cylinder returns unrestricted to the valve (port B to port T) and back to tank.
Once the jaws are completely open and cannot move anymore, hydraulic pressure builds. When hydraulic pres-sure reaches the setting of the sequencing valve (2400 psi), the sequencing valve opens. Oil flows to the rod end of the break cylinder. When the cylinder retracts, the breakout wrench jaws rotate back to their original position. Oil from the head end of the cylinder passes through the check valve on the sequencing valve to the low pressure line, from there to the valve (port B to port T) and back to tank.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
The Breakout Wrench In/Out Valve causes the breakout wrench to move to and away from the drill pipe.
When the operator places the breakout wrench control button in the OUT position, the PLC causes the A solenoid to energize and the valve spool shifts. Oil from the P port passes through the A port on the valve, out the A8 port on the valve bank, over the directional flow control valve and to the head end of the cylinder. When the cylinder extends, the breakout wrench moves outward toward the pipe. Oil from the rod end of the cylinder returns through the flow control valve. The oil then travels to the valve (port B to port T) and back to tank. Set the flow control valve so that the time to fully extend is between 5 and 6 seconds.
When the operator places the breakout wrench control button in the IN position, the PLC causes the B solenoid to energize and the valve spool shifts. Oil from the P port passes through the B port on the valve, out the B8 port on the valve bank, over the directional flow control valve and to the rod end of the cylinder. When the cylinder retracts, the breakout wrench moves back inward to the stowed position. Oil from the head end of the cylinder returns through the flow control valve. Set the flow control valve so that the time to fully retract is between 4 and 5 seconds. The oil then travels to the valve (port A to port T) and back to tank.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.2.5 Valve Bank 3
Valve Bank 3 is mounted between the two mast hoist cylinders inside the machinery house (see Figure 2-3). All of the leveling jack circuits are controlled by the valve assemblies mounted on valve bank 3, as well as the auxiliary winch.
Oil to operate these circuits is provided by the 37GPM cartridge of the auxiliary hydraulic pump (see Figure 3-1) during normal operation. When the drill is in Auto Level mode, or when the operator is manually operating all four leveling jacks simultaneously, oil from the 20 GPM cartridge is diverted from Valve Bank 1 and is also provided to Valve Bank 3.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
The function of the solenoid relief/unloading valve is to reduce system pressure during periods when high volume portion of the auxiliary pump is not needed to support operation. This function conserves energy and prevents overloading of the high volume pump.
This is a four-position, four way valve. It is solenoid actuated with a manual override. The valve is spring centered, and the center is open. When in the spring-centered open position, this valve allows oil from the high volume sec-tion of the auxiliary pump to bypass the high flow relief valve, flowing directly back to the tank without building pres-sure. This is the energy-saving provision for periods when the auxiliary hydraulic circuits are at rest.
Whenever the operator initiates movement for any of the devices controlled by the valves on Valve Bank 3, the PLC causes the solenoid relief/unloader valve A solenoid to energize. This causes the valve to shift so that oil from the P port of the valve flows to the A port, which is blocked. Oil flow backs up against the pressure relief valve and system pressure builds to the maximum setting of the relief valve (2850 psi (169 bar)). This establishes the maxi-mum pressure available to the equipment.
When the operator activates the Auto Level System, or when all four leveling jacks are manually operated simulta-neously, the PLC causes the B solenoid to energize. Oil flow from the P port of the valve flows to the B port, which is blocked. Oil flow backs up against the pressure relief valve and system pressure builds to the maximum setting of the relief valve (2850 psi (169 bar)).
The difference between the A solenoid position and the B solenoid position is that in B position, oil returning from the leveling jacks is ported to the A port of the unloading valve, which causes the oil to go through a .040" orifice before returning to tank.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
The auxiliary winch valve controls the direction and maximum pressure of the oil flow to the auxiliary winch hydrau-lic motor. This is a proportional, three-position, four way valve.The valve is spring centered, and the center is open. When in the spring-centered open position, this valve blocks pressure from the pump. All other circuits are open back to the tank.
An adjustable, pressure-compensated flow control valve in the valve bank manifold controls the flow rate of oil through the winch motor, thereby controlling the maximum speed of the winch. Set the flow control valve at 17 gal-lons per minute (64 lpm), which should provide a maximum drum rotation speed of 8.5 rpm.
Two pressure relief valves determine the maximum pressure in the circuit. One is active in the hoisting direction, and the other is active in the lowering direction. Set both relief valves for 2200 psi. A setting of 2200 psi on the relief valves results in a 12,000 pound (9,072 kg) line pull.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.2.5.3 Front Jack Valve
The front jack valve controls the direction of oil flow to the front jacks. This is a four-position, four way valve. It is solenoid actuated with a manual override. The valve is spring centered, and the center is open.
The jacks are hydraulically connected in parallel so that the pressure will tend to equalize between the cylinders during the machinery leveling procedure, and also while drilling. The flow rate is determined by a fixed flow control valve which allows a flow of 27 gallons per minute (102 lpm). The circuit includes regeneration and dual counter-balance valves, described in the following paragraphs.
Figure 3-20: Front Jack Valve Assembly
R57349-4d
Numbers in the circles refer to the Bill of Material (Subtopic 3.2.6). Num-bers in the triangles refer to the System Data Sheet (Table 3-1).
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
1. The front jacks are joined hydraulically, whereas the two rear jacks are controlled independently. Each of the rear jacks has its own valve and associated circuit components.
2. There is only one pressure switch on each of the circuits. This is the pressure switch that determines that the jack pads have come in contact with the ground. Adjust these pressure switches (one on each jack) to 950 psi ± 50 psi.
3. The flow control valves are fixed at 15 gallons per minute (57 lpm).
For more detailed information on the jack operation, refer to Subtopic 3.2.5.3. For a representation of the circuit schematic, refer to Figure 3-21.
A valve block is mounted on the jack housing. This block contains the regeneration valve and the dual counterbal-ance valve.
Regeneration Valve
The regeneration circuit is used to permit fast cylinder movement when the jacks are being lowered. The regenera-tion circuit is actuated when the jack is being extended, but not yet lifting the weight of the drill. It functions by circu-lating the oil being displaced from the rod end of the jack cylinder back into the head end of the cylinder (hence “regeneration”). This causes the jack to extend at a faster rate than it would if the oil from the cylinder rod end were directed back to the tank.
Figure 3-22: Regeneration and Dual Counterbalance Valves
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
Since the regeneration has only about one-half the force necessary to lift the drill, the regeneration circuit must turn off once the jacks begin to lift the drill. A Pressure Switch in each circuit detects when the jack pads have reached the ground, and have started to pick up the weight of the drill. Once the pressure switch is actuated, the regenera-tion circuit is shut off.
Dual Counterbalance Valve
The dual counterbalance valve prevents the jack cylinder from drifting, either under load or from the retracted posi-tion, when the control valve is in the neutral position.
CAUTIONDual counterbalance valve pressures are pre-set at the factory. Changing the settingsincorrectly can cause severe equipment damage. Follow correct procedures.
Refer to Figure 3-20. When the operator places the levelling jack button in the RAISE DRILL position (or during Auto Level operation), the PLC causes solenoid A to energize. The valve spool shifts so that oil from the P port of the valve flows to the A port of the valve and out the A2 port of the valve bank. Oil flows over the counterbalance valve check valve into the head end of the hydraulic cylinders. As pressure increases, pressure through the cross-over ports on the head end counterbalance valve causes the valve port on the rod side of the cylinder to open. Oil from the rod end of the cylinders is then able to flow through the counterbalance valve, and either regenerates (if the jacks are not both on the ground) or returns to the B port to tank.
When the operator places the levelling jack button in the LOWER DRILL position (or during Auto Level operation), the PLC causes solenoid B to energize. The valve spool shifts so that oil from the P port of the valve flows to the B port of the valve and out the B2 port of the valve bank. Oil flows through the regeneration valve, over the counter-balance valve check valve, and into the rod end of the hydraulic cylinders. As pressure increases, the crossover pressure through the ports on the rod side of the counterbalance valve causes the valve ports on the head end to open. Oil from the head end of the cylinders is then able to flow through the counterbalance valve and back to tank.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.2.5.5 Pressure Switch
The front jack circuit features two pressure switches.
The Front Pressure Switch detects when the jacks are on the ground so that the regeneration circuit can be turned off. Adjust the Front Pressure Switch to 950 psi ± 50 psi.
The Front Over Pressure Switch will cause an immediate shutdown of the drill when it is activated. To adjust, attach a 3000 psi gauge to port GA2 on the front regeneration valve and record the pressure required to support the front of the machine on jacks (mast down with cable reel is worst case). Adjust the Front Over Pressure Switch to 1750 psi ± 50 psi.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.2.5.7 Hydraulic Oil Cooler R6907D1.
The cooler for the hydraulic oil is mounted on the forward wall of the lubrication room on the front right area of the machinery deck. The two electric fans, controlled through the PLC by the temperature probe in the hydraulic tank, draw air from the outside over the cooler fins.
Only oil from the auxiliary hydraulic circuit is routed through the cooler. The main hydraulic system oil from the main pumps uses the cool oil from the tank but is not a part of the cooler circuit.
The cooler has a rated operating pressure of 300 psi with built-in 60 psi relief bypass.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
3.2.5.8 Return Filters 46Z529
The two return line filters for the hydraulic systems are flange-mounted on top of the hydraulic tank. The two filters are identical, and can be serviced without removal from the tank.
These by-pass type filters are rated at 80 gpm (303 lpm) and contain two 3-micron filter elements, mounted in tan-dem. The bypass opens at 25 psig (1.7 bar). A visual-type dirt gauge is mounted to the body of each filter to indi-cate the operating condition of the filter elements. The gauge faces are marked with red and green areas. Red indicates the need to replace the filter elements. Oil returns to the tank via the return filters mounted on top of the tank.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.2.6 Bill of Material
On the engineering drawings, numbers in circles refer to the Bill of Material, which provides component name, part number, and quantity. The list below, extracted from the Bill of Material, identifies components by name.
1. Double vane pump2. Pressure Switch3. Pressure Transducer4. Pressure Switch5. Oil Cooler6. Return Filter7. Valve Bank #18. Cylinder9. Cylinder10.Dual Counterbalance Valve11.Cylinder12.Cylinder13.Cylinder14.Cylinder15.Cylinder16.Valve Bank #217.Cylinder18.Cylinder19.20.Directional Valve21.Cylinder22.Valve Bank #323.Winch24.Regeneration Valve25.Cylinder26.Dual Sequence Valve27.Proportional Valve28.Tapping Plate29.Cylinder30.Manifold Pressure Tap31.Manifold Pilot Operated Check Valve32.Manifold Transition33.Manifold Pressure Tap34.Manifold Pressure Reducing valve35.Solenoid Valve36.Pressure Compensated Flow Control Valve37.Pressure Compensated Flow Control Valve38.Cylinder
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
3.2.7 System Data Sheet
On the engineering drawings, numbers in triangles refer to the System Data Sheet, which provides expanded or clarifying information regarding the item or function to which it applies.
Set relief pressure switch to 2825 psi. Used in auto-level program to detect full cylinder extension.
Item #4:
Hydraulic Pressure Switch
Set hydraulic pressure switch to 100 psi. Used to detect hydraulic back pressure. No hydraulic controls will operate unless switch has been tripped.
Mast HoistWith rotary head in lowered position, verify raising and lowering times of 2.5 to 3 minutes. Adjust flow controls on Valve Bank One accordingly.
Items #8, 10, 17 and 24:
Cylinders, Dual Counterbalance Valves, and Regen-eration Valves
FACTORY SET: DO NOT ADJUST!
Limit Switch Mast Anchor Pin limit switch indicates mast is pinned or unpinned
Table 3-1: System Data Sheet, Auxiliary Hydraulic System
Solenoid A is activated for auto-level or when all three jack controls are manually operated.
Solenoid B is activated for manual operation of the winch or manual operation of individual jacks.
Solenoid Relief/ Unloading Valve
Verify high flow relief pressure setting to be 2850 psi. Adjust relief valve accordingly.
Item #24:Regeneration Valve
Solenoid controlled by auto-level program.
Limit SwitchPressure switch and limit switch produce feedback signals for auto-level program sequence.
Item #4:Front Overpressure Switch
Attach 3000 psi gauge to port GA on front regen valve (Item #24) and record pressure required to support front of machine on jacks. Adjust front over pressure switch to trip at approximately 150% of recorded pressure.
Item #4:Front Pressure Switch
Adjust pressure switch to trip when jack pad comes in contact with the ground.
TEST POINT
ITEM/FUNCTION CHECKED SETTING
Table 3-1: System Data Sheet, Auxiliary Hydraulic System
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
3.3 Auxiliary Hydraulic System Maintenance
3.3.1 General
P&H recommended general maintenance practices can be found in Appendix A P&H recommended maintenance practices for hydraulic systems can be found in Appendix B. The paragraphs that follow provide information regard-ing installation, adjustment, lubrication, periodic maintenance, repair and replacement that are appropriate for gen-eral field maintenance of the auxiliary hydraulic system for this drill. For information on repair procedures not covered in this manual, contact your local P&H MinePro Services representative.
The inspections that follow are not intended to dictate constant and tedious inspection of every component on the drill on a daily basis; however, when appropriate, these are areas that should not be overlooked when other main-tenance services are being performed. In other words, whenever the opportunity arises, check the items indicated.
CAUTION!
Pressurized fluid escaping from a hydraulic system can penetrate the skin causing seri-ous injury. Always relieve pressure by connecting a microbore hose from the appropri-ate test port to the tank test port before disconnecting hydraulic lines. Tighten allconnections before reapplying pressure. Keep hands and body away from pinholes andnozzles which eject fluid under high pressure. Use a piece of paper to search for leaks.Do not use your hands. If any fluid is injected into the skin, it must be surgically removedwithin a few hours by a medical doctor or gangrene can result.
3.3.1.1 lnspect Hoses And Hydraulic Lines
Visually inspect hydraulic and lubrication hoses and tubing for abrasion, damage, kinks, or other signs of wear or decay. Report any problems that are found. Damaged hoses and piping must be replaced prior to continued oper-ation of the drill.
Technician Tip
The types of hoses and associated fittings and adapters specified for use on P&H drills providethe best performance to withstand the high pressures of the hydraulic system. Always replacehoses, fittings and adapters in accordance with P&H specifications.
Breakout WrenchVerify work port pressure relief setting to be 1500 psi. Adjust accord-ingly.
Breakout WrenchVerify extend time of 5 to 6 seconds, and 4 to 5 seconds to retract. Adjust flow control accordingly.
TEST POINT
ITEM/FUNCTION CHECKED SETTING
Table 3-1: System Data Sheet, Auxiliary Hydraulic System
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.3.1.2 lnspect Hydraulic Fittings For Leaks
Inspect hydraulic and lubrication connections, and use the appropriate tightening sequence to secure the connec-tion if necessary. Refer to Appendix B for further guidance if these appropriate tightening procedures are unfamiliar to you.
3.3.1.3 lnspect Hydraulic System Components
Visually inspect each hydraulic component for damage and leaks. Operate control valves and solenoids to check for correct component operation. Repair or replace damaged or malfunctioning hydraulic components. Inspections should include, but not be limited to, the following components:
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
3.3.2 Hydraulic Tank R6908D1
3.3.2.1 Installation
The hydraulic tank is located in the lubrication room on the front right portion of the drill. It is bolted to the machin-ery deck, with the drain tube extending downward to the underside of the deck.
3.3.2.2 Services
Daily or 8 hours
Check hydraulic fluid level. Check the sight glass daily and/or at the beginning of each shift. The placard next to the sight glass provides minimum and maximum oil levels depending on the physical condition of the drill (mast up or down, jacks up or down). Replenish the oil level using supplemental oil tank mounted near the air compressor. The hydraulic tank holds approximately 64 gallons (242 liters) of Dexron ATF.
Two weeks or 250 hours
P&H Mining Equipment recommends that a sample of oil be drawn from the hydraulic tank during every PM inspection. This sample should be about two quarts and should be taken when the oil is warmed through normal operation. The sample should be analyzed by a qualified lubrication specialist to deter-
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
mine whether it is suitable for continued use. The interval between oil changes as defined below may be extended based upon the operating conditions and on the care used in the handling oils and keeping them clean during the handling process.
Annually or 2000 hours
• Drain the hydraulic system.
• Remove the top cover and observe the condition of the inside of the tank. If there is a heavy deposit of debris, flush the tank.
• Refill the hydraulic system with approximately 64 US gallons (242 liters) of Dexron ATF.
3.3.2.3 Repair
WARNING!
Hydraulic oil is flammable and could explode if exposed to welding heat and/or sparks,resulting in serious injury or death. Always be certain that the tank is properly cleaned ofany flammable material before welding.
The hydraulic tank is made of mild steel. Any repairs can be accomplished by draining the tank and welding in accordance with accepted welding practices.
3.3.3 Suction Filters R16280D1
3.3.3.1 Installation
Two suction filters are flange-mounted at the rearward end of the hydraulic oil tank.
3.3.3.2 Service
It is normally unnecessary to remove the filter assembly from the pump suction line to service the filter unit. To replace the filter element, refer to Figure 3-28 and proceed as follows:
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
Step 1: Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activ-ities.
Step 2: Close the Handwell Valve to shut off the suction line valve by turning the knob anticlockwise.
Step 3: Remove the six capscrews and lockwashers from the filter cover, then remove the cover assembly from the filter body.
Step 4: Inspect the seal and O-ring between the cover and the body. Replace as required.
Step 5: Remove and discard the filter element. Replace with a new element.
Step 6: Install the cover assembly on the filter body. Confirm the correct arrangement of seals and be certain that the seals are properly seated.
Step 7: Install the six capscrews and lockwashers to secure the filter cover.
Step 8: Open the Handwell Valve and remove locks and tags from the operator controls.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.3.3.3 Cleaning, Inspection, and Repair
1. Check the filter weekly, or every 50 hours of operation, for visible damage, leaking seals, and leaking connec-tions.
2. Clean and inspect all auxiliary hydraulic pump suction filter components in accordance with the general clean-ing and inspection procedures described in Appendix A of this manual. Replace any worn or damaged compo-nents. See the LinkOne electronic parts manual for component identification.
3.3.4 Temperature Probe 89Z724D2
3.3.4.1 Installation
The probe threads into the side of the hydraulic tank. When installing the probe, pack the well with grease. The grease will act as a thermal conductor.
3.3.4.2 Service and Repair
No service is required, and the temperature probe is not repairable. If the unit fails, it must be replaced.
3.3.4.3 Replacement
WARNING!
Electric current can cause burns, injury, or even death. Disconnect, lock open, and tagthe power source which feeds this device to prevent power from being applied whileinspection and repairs are being performed. Before beginning repairs, try the operationalcontrols to verify that the intended power source is disconnected.
Step 1: Lock out and tag out the controls to the hydraulic pumps to prevent activation while the temperature probe is being serviced.
Step 2: Tag and disconnect the electrical wiring to the temperature probe, if not already disconnected.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
Step 3: Remove the temperature probe from the hydraulic tank.
NOTICE
The temperature probe assembly is not repairable, and must be replaced if damaged or inoper-able. Refer to the LinkOne electronic parts manual for temperature probe identification.
Step 4: Pack the well with grease. The grease will act as a thermal conductor. Thread the probe into the well.
Step 5: Install the electrical wiring to the probe in accordance with the identification tags placed during removal.
3.3.5 Low Level Switch R16982D1
The oil level switch is threaded into a fitting on the top of the hydraulic tank.
3.3.5.1 Testing the Switch
NOTICE
Thoroughly clean the top of the hydraulic tank before disconnecting or removing any of thehydraulic components.
To check the function of the switch, unthread the float switch assembly from the tank and pull the float rod about 2 feet (½ meter) out of the tank. The GUI should register a fault. If it does not register a fault, replace the float.
3.3.5.2 Service and Repair
No service is required, and the low level switch is not repairable. If the unit fails, it must be replaced.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.3.5.3 Replacement
WARNING!
Electric current can cause burns, injury, or even death. Disconnect, lock open, and tagthe power source which feeds this device to prevent power from being applied whileinspection and repairs are being performed. Before beginning repairs, try the operationalcontrols to verify that the intended power source is disconnected.
Step 1: Lock out and tag out the controls to the hydraulic pumps and the level switch to prevent activation while the level switch is being serviced.
Step 2: Tag and disconnect the electrical wiring to the level switch, if not already disconnected.
Step 3: Remove the level switch from the hydraulic tank.
NOTICE
The level switch assembly is not repairable, and must be replaced if damaged or inoperable.See the LinkOne electronic parts manual for switch identification.
Step 4: Apply a thin film of pipe sealant to the male pipe threads on the level switch, then install the switch in the tank.
Step 5: Install the electrical wiring to the switch in accordance with the identification tags placed during removal.
Add oil as necessary to attain the correct operating level.
3.3.6 Hydraulic Tank Breather 1046Z994
3.3.6.1 Installation
The hydraulic tank breather is threaded onto a stud mounted at the top of the tank.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
3.3.6.2 Service
Replace the breather at every PM.
3.3.6.3 Replacement
Remove the old breather by spinning it off the stud. Coat the new gasket (O-ring) with oil and install the new gasket into the new breather. Install the new breather onto the stud until the gasket makes contact, then turn the breather another 1/4 turn.
3.3.7 Magnetic Rod
3.3.7.1 Installation
The magnetic rod is threaded into a fitting in the top of the tank. The rod extends into the tank and attracts metal contaminants.
3.3.7.2 Service
Each PM, remove the magnetic rod and inspect it. Determine the source and severity of the contaminants captured by the rod. Record these findings for follow-up analysis. Wipe the rod clean and reinstall it into the fitting in the top of the tank.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.3.8 Return Filters 46Z529
3.3.8.1 Installation
The two return line filters for the hydraulic systems are flange-mounted on top of the hydraulic tank. The two filters are identical, and can be serviced without removal from the tank.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
3.3.8.2 Inspection, Service and Repair
1. Check the filter indicators weekly to ensure that the filters are still operating in the green zone of the indicator. Also check filter status at the GUI.
2. Check the filters for visible damage, leaking seals, and leaking connections.
3. If the filter indicators are in the red zone, or after six months or 2000 hours of operation the filter elements must be replaced.
Replace the hydraulic return line filter elements as follows:
DISASSEMBLY. Disassemble the return line filters for replacement of filter elements as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Follow lockoutand tagout procedures to prevent inadvertent machine startup during maintenance.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
1. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
2. Clean all dirt from the filter housings and fittings.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
3. Be sure that no pressure exists in any of the hydraulic system circuits before opening the filter assembly.
4. Remove the four capscrews from the filter cap, then remove the cap assembly and O-ring from the filter body.
5. Remove the two filter elements and the intermediate connector from the bowl.
6. Inspect the filter element for signs of damage or heavy buildup of debris collected on the inside of the element. Note the type of debris found; debris can be a clue to potential component failures.
7. Inspect the element for damage. Damage can warn that there is or has been a high pressure spike, or a surge of return oil. Spikes would indicate a potential problem with a pump or hydraulic motor.
8. Inspect the filter bowl. Note any damage as well as the presence and type of debris buildup.
9. Discard the filter elements, but do not discard the element connector.
10. Cover the opening of the filter body to prevent dirt or other small items from inadvertently falling into the bowl or tank.
CLEANING AND INSPECTION. Clean and inspect all of the return filter components in accordance with the gen-eral cleaning and inspection procedures described in Appendix A of this manual. Replace any worn or damaged components. The cap assembly including the spring and element retainer must be replaced as a unit. See the LinkOne electronic parts manual for component identification.
ASSEMBLY. Assemble the new filter elements in the return filter assembly as follows (refer to Figure 3-34):
1. Install the two new filter elements and element connector in the filter bowl.
2. Lightly oil the O-ring, then position it with the cover assembly on the filter head. Be certain that the spring-loaded element retainer is correctly positioned on the top filter element, and the O-ring is accurately positioned under the filter cap to prevent leakage during operation.
3. Install the four capscrews and lockwashers into the cap assembly, and torque them securely.
3.3.8.3 Service
Replace the filter elements when:
• indicators are in the red zone and/or the GUI is registering a fault
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
• after 6 months or 1000 hours of operation
• when the hydraulic oil is changed
Refer to Figure 3-34 and replace the filter elements as follows:
Step 1: Lock out and tag out the operator controls to prevent inadvertent machine startup during maintenance activities.
Step 2: Clean all dirt from the filter housings and fittings.
CAUTION!
Hot hydraulic oil can burn. Use lockout and tagout procedures to guard against inadvert-ent hydraulic system or machine startup during service or maintenance. Allow thehydraulic system to cool before maintenance or repair. Wear appropriate face and bodyprotective devices while changing filter elements.
Step 3: Remove the four capscrews from the filter cap, then remove the cap assembly and O-ring from the filter body.
Step 4: Remove the two filter elements and the intermediate connector from the bowl. Discard the filter elements, but do not discard the element connector.
Step 5: Cover the opening of the filter body to prevent dirt or other small items from inadvertently falling into the bowl or tank.
Step 6: Clean and inspect all of the return filter components in accordance with the general cleaning and inspec-tion procedures described in Appendix Z of this manual. Replace any worn or damaged components. The cap assembly including the spring and element retainer must be replaced as a unit. See the LinkOne electronic parts manual for component identification.
Step 7: Install the two new filter elements and element connector in the filter bowl.
Step 8: Lightly oil the O-ring, then position it with the cover assembly on the filter body. Confirm that the spring-loaded element retainer is correctly positioned on the top filter element, and the O-ring is accurately posi-tioned under the cover to prevent leakage during operation.
Step 9: Install the four capscrews and lockwashers into the cap assembly, and torque them securely.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.3.9 Auxiliary Hydraulic Pump 37U153D1
3.3.9.1 Location
The auxiliary hydraulic pump is flange-mounted to the back side of the PDT.
3.3.9.2 Maintenance and Repairs
No periodic maintenance is required. Repairs in the field are not recommended. If the pump requires service, remove it and send it to a qualified repair facility.
3.3.9.3 Removal
Remove the pump from the system as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
2. Clean all dirt away from the pump, hose assemblies, and fittings.
3. Turn the Handwell valve on the tank suction filter assembly fully counterclockwise to the closed position.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
WARNING!
Hot hydraulic oil can spray, causing injury or death. Use lockout and tagout proceduresto guard against inadvertent hydraulic system or machine start up during service ormaintenance. Allow the hydraulic system to cool before maintenance or repair. Slowlyrelease pressure or vent circuits before disconnecting hydraulic lines. Wear appropriateface and body protective devices while carefully loosening any connection or fitting.
4. Check to be certain that the hydraulic pressure is completely vented from the high-pressure and control pres-sure circuits.To vent system pressure, attach a Microbore hose from the hydraulic test kit between the appro-priate test port and the test port that is open to the tank.
5. Tag and remove the hydraulic hoses from the pump. Cap plug all hose fittings and pump ports to prevent the entry of foreign material into the pump or hydraulic system.
6. Support the pump (pump weighs approximately 30 lbs (14 kg)) so that its entire weight will not be supported by the shaft when the mounting capscrews are removed. Remove the two capscrews and lockwashers that secure the pump to the pump drive transmission. Slide the pump back from the pump drive until the driveshaft is clear of the pump drive, and remove the pump.
3.3.9.4 Installation
CAUTIONExercise care when installing the pump on the pump drive transmission to prevent mis-alignment, which can lead to premature pump failure.
Install the pump on the pump drive as follows:
1. Check the mounting flange on the pump drive, the pilot diameter on the pump, and the splined shaft and bore for burrs and imperfections that would prevent the pump from seating correctly on the pump drive. Carefully remove any imperfections by lapping.
2. Apply a light coat of grease to the pilot diameter and driveshaft splines. Position the gasket on the pump.
3. Carefully install the pump on the drive, and install the mounting capscrews and lockwashers. Be careful to pre-vent misalignment when tightening the capscrews.
4. Install the suction and outlet lines, then turn the suction line valve to the open position.
5. Start the pump drive with no load applied to the pump to prime the pump. Operate the system at moderate loading (such as the deck wrenches or the deck hatch) for a short period of time.
6. Check the reservoir oil level, and add oil if required.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.3.10 Valve Banks
3.3.10.1 General
Valve banks 1, 2 and 3 control the operation of the auxiliary hydraulic system. They are located at the rear of the machinery house, between the mast hoist cylinders. Refer to Figure 2-3.
Figure 3-36: Valve Bank 1
0102030405060708
BD0380a01LEGEND01. Relief Unload/Oil Diverter consists of four stacked valves. The top valve is a double solenoid, spring centered, 3
position/4 way directional valve with manual override. The second valve down is a single check valve that pre-vents backflow from the low pressure discharge of the auxiliary hydraulic pump.The third valve down is a shut-tle valve that connects externally to the auxiliary hydraulic system pressure transducer and two of the auto level pressure switches.The bottom valve is a single, adjustable pressure relief valve.
02. Mast Hoist. Top valve is a double solenoid, spring centered, 3 position/4 way directional valve with manual over-ride. Bottom valve contains a pair of one-way flow control valves.
03. Mast Anchor Pins. A double solenoid, spring centered, 3 position/4 way directional valve with manual override.04. Deck Wrench. Top valve is a double solenoid, spring centered, directional valve with manual control. Bottom
valve is a double, adjustable pressure relief valve.05. Dust Curtain. Top valve is a double solenoid, spring centered, 3 position/4 way directional valve with manual
override. The second valve down contains two pilot check valves. The third valve down is a double, adjustable pressure relief valve. Bottom valve contains a pair of one-way flow control valves.
06. Back Brace Lock. A double solenoid, spring centered, 3position/4 way directional valve with manual override.07. Spare08. Spare
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
Figure 3-38: Valve Bank 2
0102030405060708
BD0397a01
LEGEND01. Pipe Rack. Top valve is a double solenoid, spring centered, 3 position/4 way directional valve with manual
override.The bottom valve contains a pair of one-way flow control valves. Set the flow control valves to achieve a travel time in both directions of 8.0 - 12.0 seconds (typically 12.5 - 15.5 gpm).
02. Pipe Rack. Top valve is a double solenoid, spring centered, 3 position/4 way directional valve with manual override.The bottom valve contains a pair of one-way flow control valves. Set the flow control valves to achieve a travel time in both directions of 8.0 - 12.0 seconds (typically 12.5 - 15.5 gpm)
03. Pipe Rack Holdback. Top valve is a single solenoid, spring return, 2 position/4 way directional valve with manual override.The second valve contains a pressure relief valve. Set the pressure relief valve to 400 psi (27.6 bar)
04. Spare05. Spare06. Deck Hatch. Top valve is a double solenoid, spring centered, 3 position/4 way directional valve with manual
override.The second valve down is a dual pilot-to-open check valve with a 15 psi crack pressure.The third valve down is a dual relief valve. Each relief valve is to be set at 150 psi (10.35 bar).The bottom valve is a dual flow control valve. Outflow is metered to 3 GPM on the A side and 4 GPM on the B side.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
Figure 3-40: Valve Bank 3
01
02
03 04 05 06
BD0382a01
LEGEND01. Solenoid Relief Unloading Valve. Top valve is double solenoid, spring centered, 3 position/4 way
directional valve with a manual override. The second component down is a special porting block to provide a means to install pilot line between the solenoid relief unloading valve and the three jack control valves, also on valve bank #3. The third valve down contains a single adjustable, pilot oper-ated pressure relief valve, which function as a pilot stage relief valve. Bottom valve is a pressure relief valve, which operates as the main stage relief valve for the valve bank #3 circuits.
02. Auxiliary Winch. Top valve is a double solenoid, spring centered, 3 position/4 way proportional directional valve with manual override. Bottom valve is a double counterbalance valve. A flow con-trol valve installed in the valve bank manifold regulates the inflow rate to the directional valve.
03. Right Rear Jack. A double solenoid, spring centered, directional valve with manual control. A flow control valve installed in the valve bank manifold regulates the inflow rate to the directional valve.
04. Left Rear Jack. Valve configuration is identical to the right rear jack valve.05. Front Jacks. Valve configuration is identical to the right rear jack valve.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
3.3.10.2 Removal
Under normal circumstances, it is unnecessary to replace an entire valve bank assembly for maintenance or repair of its control circuits. Each individual control valve block can be removed from its position in a stacked valve assembly without need for removal of the manifold, hydraulic hoses, or fittings.
NOTICE
The following contains procedures for replacement of the hydraulic valve assembly compo-nents mounted on manifolds. These procedures are typical, and apply to all of the hydraulicsystem valve banks.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.3.10.3 Solenoid Replacement
Figure 3-42 illustrates the components of a typical solenoid-operated directional valve. It is unnecessary either to remove the valve from the manifold or to disassemble its hydraulic components in order to replace a valve solenoid coil.
1. Remove the solenoid from the directional valve as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
A. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activi-ties.
B. Tag the electrical connector(s) on the solenoid, or solenoids, to be removed.
Figure 3-42: Solenoid Operated Directional Valve
01 0203
0506
07
08
0911
04 04
10
LEGEND01. Name Plate Screw02. Valve Body Capsrew (under body)03. Connector Screw04. Seal05. Name Plate
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
C. Loosen the retainer screw on the electrical connector, then remove the connector from the solenoid. Be cer-tain to remove the seal as well.
D. Unthread the solenoid cap, then remove the cap and O-ring from the solenoid core. Save the O-ring for re-assembly.
E. Slide the solenoid assembly from the end of the solenoid core.
2. Clean and inspect the exterior of the directional valve and the solenoid in accordance with the general proce-dures provided in Appendix A.
3. Install the solenoid on the directional valve as follows:
A. Position a solenoid assembly over the end of the core, and locate it against the directional valve body.B. Lightly lubricate the O-ring, and install it over the core and against the end of the solenoid housing.
B. Install the solenoid cap, and tighten it firmly by hand.
C. Install the electrical connector and seal onto the solenoid in accordance with the identification tag, and fas-ten securely with the retaining screw.
3.3.10.4 Directional Valve Replacement
Depending on the specific circuit configuration, the solenoid-operated directional valves are mounted either as a single unit assembly on the manifold, or as the top valve in a stacked valve assembly. Refer to Figure 3-42 and proceed as follows:
1. Prepare the drill for hydraulic system maintenance as follows:
A. Move the drill to firm level ground.
B. If not already in position, lower the drill until it is supported completely by the crawler tracks.
C. Position the leveling jacks until the jack pads are resting on the ground without pressure.
D. Be certain that the mast is either fully up and locked in position, or that it is in the down position and resting completely on its supports.
E. Have adequate lighting available.
F. Have tools and replacement parts with you before starting the job.
CAUTION!
Hydraulic fluid can enter water supplies and cause illness. Never drain hydraulic fluidonto the ground.
G. Since some minor leakage of hydraulic fluid is unavoidable, keep a good supply of cleaning materials on hand.
H. Be sure that the auxiliary winch is not supporting any load, and that its hook is secured to the mast.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
2. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
3. Tag, loosen and remove the electrical connector(s) from the valve solenoid(s). It is not necessary to remove the solenoid(s) from the valve at this time.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
4. Make certain that no control pressure exists in any of the auxiliary hydraulic system circuits.
5. Remove the four round head machine screws from the valve identification plate on top of the valve body, then remove the plate.
6. Remove the four valve body capscrews, previously hidden by the identification plate, and carefully remove the valve from the manifold or intermediate valve (if part of a stacked valve subassembly). The valve is located on its mounting surface by a pair of dowel pins. Use care to avoid scratching or nicking the mounting surfaces dur-ing the removal process.
7. Remove and discard the used O-rings from the valve body.
8. Clean and inspect the exterior of the directional valve in accordance with the general procedures for cleaning and inspection in Appendix A. Replace any faulty valve, and all O-rings.
9. Install the directional valve as follows:
CAUTIONAlways use O-rings specified by P&H Mining Equipment. Using the wrong material orsize of O-ring may cause the O-ring to fail under high pressure.
A. Lubricate the new O-rings with hydraulic oil and insert them into the seats in the valve body.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
B. Make sure that the locating pins are correctly seated, then carefully position the valve body on the manifold mounting surface, or on top of the intermediate valve in the valve assembly.
C. Insert the pins into the pin holes to correctly align the valve. Install the four body retaining capscrews to fas-ten the valve body to the manifold. Torque the capscrews uniformly using a crosswise pattern.
D. Position the identification plate on top of the directional valve and fasten securely with four round head machine screws.
E. Install the electrical connector(s) and seal(s) onto the valve solenoid(s) in accordance with the identification tags, and fasten securely with the retaining screw.
F. Start the power unit, and bleed all air from the auxiliary hydraulic system.
3.3.10.5 Intermediate Stacked Valve Replacement
All valve bodies that are sandwiched between the solenoid-operated directional valves and the manifold are replaced using the following typical procedure.
1. Remove the solenoid-operated valve from the valve assembly as described above.
2. Loosen the four body retaining capscrews that fasten the valve body to the adjacent valve or manifold, and carefully remove the valve body. The valve body is located on its mounting surface by a pair of dowel pins. Use care to avoid scratching or nicking the mounting surfaces during the removal process.
3. Remove and discard the used O-rings from the valve body.
4. Clean and inspect the exterior of the directional valve in accordance with the general procedures provided in Appendix A. Replace any faulty valves, and all O-rings. See the LinkOne electronic parts manual for valve and seal kit information.
5. Lubricate the new O-rings with hydraulic oil and insert them into the seats in the valve body.
6. Make sure that the locating pins are correctly seated, then carefully position the valve body on the manifold mounting surface. Insert the pins into the pin holes to correctly align the valve.
7. Install four special capscrews to fasten the valve body to the manifold. Torque the capscrews uniformly using a crosswise pattern.
8. Install the solenoid-operated valve from the valve assembly as described under Subtopic 3.3.10.4.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
9. Start the power unit, and bleed all air from the auxiliary hydraulic system.
3.3.11 Dual Counterbalance Valves R6268D1
3.3.11.1 Theory of Operation
Dual counterbalance valves are used in several auxiliary hydraulic system branch circuits. Figure 3-44 illustrates a typical application on one of the jack cylinders. The function of dual counterbalance valves is to prevent the flow of fluid in a hydraulic circuit when the circuit is not sufficiently pressurized. This function prevents components, such as jack cylinders, from drifting under load when the hydraulic systems have been turned off or there is an unex-pected loss of hydraulic pressure.
All dual counterbalance valves on this drill are cartridge type, which means that the valve bodies do not need to be removed from the circuits to enable replacement of the working components of the valve. The circuits using dual counterbalance valves as shown in Table 3-2.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
Cartridge type counterbalance valve assemblies consist of a valve body that is drilled, tapped, and counter-bored to accept one or more valve cartridges, the valve cartridge assemblies, and the O-rings and back-up rings that seal the land areas of the valve cartridge.
3.3.11.2 Service
Counterbalance valves should not be serviced, except for two conditions:
Valve Leakage. Remove the cartridge and replace the O-ring seals.
Valve Malfunction. Replace the cartridge as a unit.
3.3.11.3 Cartridge Removal
To remove a counterbalance valve cartridge from a valve body, proceed as follows:
Step 1: Position the drill in a flat, level area. The ground must be stable and the area must be safe from hazards.
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
Step 2: Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activ-ities.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
Step 3: Be sure that no pressure exists in any of the auxiliary hydraulic system circuits.
A. Position the components so that there is no load being held by the cylinder.
B. If test ports directly into the cylinder are available, connect a microbore hose to both sides of the cylinder. If no ports are available, proceed slowly and with caution.
NOTICE
Clean any dirt away from the valve assembly and hydraulic hose fittings before loosening any ofthe hydraulic components.
Step 4: Cover the cartridge with a shop rag. With a wrench, use the wrench flats provided for removal. Do not attempt to loosen the cartridge by turning on the pressure adjustment assembly. Loosen and slowly unscrew the cartridge; any trapped pressure will be released before the cartridge is fully unscrewed. Plug the hole in the valve body to prevent entry of loose or airborne dirt.
3.3.11.4 Cleaning, Inspection, and Repair
Clean and inspect the valve assembly in accordance with the general procedures for cleaning and inspection in Appendix A.
Repair is limited to replacing O-rings and back-up rings. The cartridge valves are not field repairable. Replace any faulty valve cartridges.
Replace O-rings and back-up rings as follows:
Step 1: Remove and discard the O-rings and back-up rings from the O-ring grooves on the outside diameter of the valve cartridge.
Step 2: Replace all O-rings and back-up rings in the order indicated in Figure 3-45. Refer to the LinkOne elec-tronic parts manual for cartridge and seal kit information.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
Figure 3-45: Cartridge Service
F7357
03
040504060706080908
02
01
10
1314
1315
1617
1817
1817
1314
1315
1617
1817
1817
1112
12
11
10
2122
2324
252019
26
LEGEND01. Directional Valve02. Seal Kit03. O-Ring04. Backup Ring05. O-Ring06. Backup Ring07. O-Ring08 Backup Ring09. O-Ring10. Test Port Connector11. Counterbalance Valve12. Seal Kit13. Backup Ring
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.3.11.5 Cartridge Installation
To install the counterbalance valve cartridge into the valve body, proceed as follows:
Step 1: Lightly lubricate the O-rings and back-up rings for the cartridge valve, and install them in the grooves on the outside diameter of the valve cartridge.
Step 2: Carefully install the valve cartridge into its seat in the manifold. Avoid displacement or cutting of the O-ring seals during installation. Torque the valve 150-160 ft-lbs (203 - 217 Nm).
3.3.12 Main Hydraulic Pressure Transducer 36Q549
3.3.12.1 Location
One pressure transducer is used in the auxiliary hydraulic system. It is mounted on the wall behind and below valve bank 2 (refer to Figure 3-46), and is connected to a shuttle valve installed as part of the relief/unload oil diverter valve assembly on valve bank 1. The pressure transducer has a 1/4" NPT female pipe thread for connec-tion to the hydraulic circuit. It is connected to the electrical system with a four prong DIN electrical connector.
3.3.12.2 Removal
To remove the pressure transducer from the system, proceed as follows:
Step 1: Position the drill in a flat, level area. The ground must be stable and the area must be safe from hazards.
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out and
Figure 3-46: Auxiliary Hydraulic System Pressure Components
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
tag the operator controls to prevent inadvertent machine start-up during maintenancework.
Step 2: Lock out and tag out the operator controls to prevent inadvertent machine start-up during maintenance activities.
Step 3: Clean all dirt away from the pressure transducer and pipe fittings before loosening any components.
Step 4: Remove the signal wire connector from the connector on the transducer.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
Step 5: Confirm that hydraulic pressure is completely vented before loosening the pressure transducer.
Step 6: Unthread and remove the transducer from the 1/4" high pressure pipe fitting.
3.3.12.3 Cleaning, Inspection, and Repair
Clean and inspect the pressure transducer in accordance with the general procedures for cleaning and inspection in Appendix A. The pressure transducer is non-repairable, and therefore must be replaced with a new unit if dam-aged. See the LinkOne electronic parts manual for pressure transducer information.
3.3.12.4 Installation
Install the pressure transducer as follows:
Step 1: Apply a coating of pipe thread sealant to the 1/4" male pipe threads, and install the transducer in the shut-tle valve circuit.
Step 2: Install the signal wire connector and seal to the connector on the transducer.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.3.13 Hydraulic Pressure Switch R24844D1
3.3.13.1 Location
The hydraulic pressure switch (Item 02, Figure 3-46) is mounted on the wall behind and below valve bank 2, and is connected to a shuttle valve installed as part of the relief/unload oil diverter valve assembly on valve bank 1. The pressure transducer has a 1/4" NPT female pipe thread for connection to the hydraulic circuit. It is connected to the electrical system with a 1/2” NPT conduit connection.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
3.3.13.2 Adjustment
Adjust the hydraulic pressure for 100 psi as follows:
Step 1: Remove cover (01) to gain access to the self-locking adjustment screw (04).
Step 2: Use a screwdriver to adjust the setting on the pressure switch. Observe the indicator (02) to determine the switch is set to 100 psi (6.9 bar).
Step 3: Electrical testing can confirm that the switch closes when hydraulic pressure reaches 100 psi, and remains closed until pressure drops below 80-95 psi.
3.3.13.3 Maintenance and Repair
Clean and inspect the pressure switch in accordance with the general procedures for cleaning and inspection in Appendix A. The pressure switch is non-repairable, and therefore must be replaced with a new unit if damaged. See the LinkOne electronic parts manual for pressure switch information.
3.3.13.4 Removal
To remove the pressure switch from the system, proceed as follows:
Step 1: Position the drill in a flat, level area. The ground must be stable and the area must be safe from hazards.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
Step 2: Lock out and tag out the operator controls to prevent inadvertent machine start-up during maintenance activities.
Step 3: Clean all dirt away from the pressure switch and pipe fittings before loosening any components.
Step 4: Remove the wire connector from the switch.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
Step 5: Confirm that hydraulic pressure is completely vented before loosening the pressure switch.
Step 6: Unthread and remove the switch from the 1/4" high pressure pipe fitting.
3.3.13.5 Installation
Install the pressure switch as follows:
Step 1: Apply a coating of pipe thread sealant to the 1/4" male pipe threads, and install the transducer in the shut-tle valve circuit.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
3.3.14 Leveling System Pressure Switches 79Z2750D2
3.3.14.1 Location
The relief pressure switch (Item 03, Figure 3-46) is mounted on the wall behind and below valve bank 2, and is connected to a shuttle valve installed as part of the relief/unload oil diverter valve assembly on valve bank 1. The pressure transducer has a 3/8" SAE connector for connection to the hydraulic circuit. It is connected to the electri-cal system with a 1/2” NPT conduit connection.
Jack pressure switches are located on the upper jack housing. Pressure switches for the front jacks are mounted on the upper housing of the right front jack. Pressure switches for the rear jacks are mounted on each jack housing.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.3.14.2 Adjustment
Levelling system pressure switches and their settings are described in Table 3-3:
Relief Pressure Switch
The relief pressure switch indicates to the PLC that all of the leveling jacks have reached the ground. Refer to Fig-ure 3-49 and adjust the relief pressure switch for 2825 psi as follows:
Step 1: Loosen lock nut (02) to allow movement of the adjustment screw (01).
Step 2: Use a screwdriver to adjust the setting on the pressure switch. Observe the indicator (04) to determine the switch is set at 2825 psi (195 bar).
Step 3: Electrical testing can confirm that the switch closes when hydraulic pressure reaches 2825 psi.
Overpressure Switch
Step 1: Attach a 3000 psi gauge to Port GA on the front regeneration valve.
WARNING!
Contact with rotating machinery and live electrical circuits can cause personnel injury ordeath. Before starting the drill be sure all personnel are clear of drill mast, movingmachinery, rotating shafts, electrical cabinets and other areas that may be hazardous.
Step 2: Start the drill.
Step 3: Actuate the front jack raise sequence until the front jacks are supporting the weight of the drill.
Circuit Location Function Setting
Relief Pressure Switch Near Valve Bank 2
Indicates that all jacks are in contact with the ground and starting to lift the drill.
2825 psi
Overpressure Switch Right Front Jack HousingIndicates that pressure is significantly higher than normal.
150% of recorded lifting pressure (refer to Over-pressure Switch)
Front JackPressure Switch Right Front Jack Housing
Indicates that the front jacks are in contact with the ground.
Set to trip when jack pad comes in contact with the ground
Left Rear JackPressure Switch
Left Rear Jack HousingIndicates that the left rear jack is in contact with the ground.
Right Rear JackPressure Switch
Right Rear Jack HousingIndicates that the right rear jack is in contact with the ground.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
Step 4: Record the pressure required to support the front of the drill on jacks.
Step 5: Actuate the front jack lower sequence until the jacks are fully retracted.
Step 6: Turn off the drill.
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
Step 7: Lock out and tag out the operator controls to prevent inadvertent machine start-up during maintenance activities.
Step 8: Refer to Figure 3-49. Loosen lock nut (02) to allow movement of the adjustment screw (01).
Step 9: Use a screwdriver to adjust the setting on the pressure switch. Observe the indicator (04) to determine the switch is set to approximately 150% of the pressure recorded in Step 4 above.
Jack Pressure Switches
The jack pressure switches indicates to the PLC that the associated leveling jack(s) have reached the ground. Refer to Figure 3-49 and adjust all three jack pressure switches to close when the jack has reached the ground as follows:
Step 1: Loosen lock nut (02) to allow movement of the adjustment screw (01).
Step 2: Use a screwdriver while observing the indicator (04) to adjust the setting on the pressure switch to approximately 200 psi (13.8 bar).
WARNING!
Contact with rotating machinery and live electrical circuits can cause personnel injury ordeath. Before starting the drill be sure all personnel are clear of drill mast, movingmachinery, rotating shafts, electrical cabinets and other areas that may be hazardous.
Step 3: Start the drill.
Step 4: Actuate the jack raise sequence for the front jacks circuit until the jacks contact the ground.
Step 5: Confirm that the pressure switch closes when both jacks contact the ground. If it does not, note that the pressure setting must be decreased.
Step 6: Actuate the jack raise sequence for the left rear jack circuit until the jack contacts the ground.
Step 7: Confirm that the pressure switch closes when the jack contacts the ground. If it does not, note that the pressure setting must be decreased.
Step 8: Actuate the jack raise sequence for the right rear jack circuit until the jack contacts the ground.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
Step 9: Confirm that the pressure switch closes when the jack contacts the ground. If it does not, note that the pressure setting must be decreased.
Step 10: Turn off the drill.
Step 11: For any switch that did not close when the jack(s) came in contact with the ground, adjust the pressure switch to a lower pressure and re-test.
3.3.14.3 Maintenance and Repair
Inspect the pressure switch in accordance with the general procedures for cleaning and inspection in Appendix A. Test the switch for satisfactory hydraulic pressure and electrical function. The pressure switch is non-repairable, and therefore must be replaced with a new unit if damaged. Refer to Figure 3-50 and pre-adjust the replacement switch on a test bench to the pressure setting specified in Subtopic 3.3.14.2. See the LinkOne electronic parts manual for pressure switch information.
3.3.14.4 Removal
To remove the pressure switch from the system, proceed as follows:
Step 1: Position the drill in a flat, level area. The ground must be stable and the area must be safe from hazards.
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
Step 2: Lock out and tag out the operator controls to prevent inadvertent machine start-up during maintenance activities.
Step 3: Clean all dirt away from the pressure switch and pipe fittings before loosening any components.
Step 4: Remove the wire connector from the switch.
Figure 3-50: Bench Test Set-up
01 02 04 05 0603
BD0575a01
LEGEND01. Port-a-Power02. Gauge03. Tee Fitting04. Hose05. Adapter06. Pressure Switch
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
Step 5: Confirm that hydraulic pressure is completely vented before loosening the pressure switch.
Step 6: Uncouple the 3/8" SAE fitting and remove the switch.
3.3.14.5 Installation
Install the pressure switch as follows:
Step 1: Couple the 3/8" SAE fitting to install the transducer in the shuttle valve circuit.
Step 2: Attach the 1/2” wire connector to the switch.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
3.3.15 Regeneration Valve 36U437D1
3.3.15.1 Description
One regeneration valve is used in each of the three jack circuits. Figure 3-51 illustrates one of the valves installed on a jack housing. These valves are cartridge type valves, and, therefore, do not require removal from the piping to replace a cartridge or the seals.
3.3.15.2 Service
Remove a regeneration valve cartridge assembly as follows:
Step 1: Position the drill so that it is supported on the crawler tracks, and the jack pads are resting on firm ground with no applied load.
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
Step 2: Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activ-ities.
Step 3: Tag and disconnect the electrical connector from the solenoid valve operator.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
Step 4: Remove the nut that retains the solenoid coil, and remove the coil from the valve.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
Step 5: Confirm that no pressure exists in any of the auxiliary hydraulic system circuits.
CAUTIONClean any dirt away from the valve assembly and hydraulic hose fittings before loosen-ing any of the hydraulic components.
Step 6: With a wrench, loosen and remove the valve cartridge from the valve body. Be sure to use the wrench flats provided for removal. Do not attempt to loosen the cartridge by turning on the pressure adjustment assembly. Plug the hole in the valve body to prevent entry of loose or airborne dirt.
Step 7: Inspect the O-rings and back-up rings on the outside diameter of the valve cartridge. Remove and dis-card them if they are damaged.
3.3.15.3 Cleaning, Inspection, and Repair
Clean and inspect the valve assembly in accordance with the general procedures for cleaning and inspection in Appendix A. The cartridge valves are not field repairable. Replace any faulty valve cartridges, all O-rings. and back-up rings. See the LinkOne electronic parts manual for cartridge and seal kit information.
3.3.15.4 Cartridge Installation
To install the valve cartridge into the valve body, proceed as follows:
Step 1: Lightly lubricate the new O-rings and back-up rings for the cartridge valve, and install them in the grooves on the outside diameter of the valve cartridge.
Step 2: Carefully install the valve cartridge into its seat in the manifold. Avoid displacement or cutting of the seals during installation. Torque the valve to 225 ± 12 ft-lbs (305 ± 16 Nm).
Step 3: Install the solenoid coil on the valve with the solenoid nut.
Step 4: Connect the electrical connector to the valve solenoid.
Step 5: Start the hydraulic systems, bleed the air from the jack circuit, and test the function of the replaced regen-eration valve.
BD120149 Mechanical Systems Manual Main Hydraulic System
Section 4
Main Hydraulic System
4.1 General
The Main Hydraulic System provides fluid power to operate the propel function of the drill. Two main pumps supply hydraulic flow, one to each of the side frames. This section describes the theory of operation of the main hydraulic system and provides information for adjustment, removal, and installation of the major components.
4.2 Theory of Operation
The system consists of two independent closed loop hydrostatic drives, which provide the torque to operate the propel transmissions. The major components include: a hydraulic tank, two identical variable-displacement hydrau-lic pumps, two variable-displacement hydraulic motors, system control valves, and hydraulic oil filters. The propel motors and brakes are an integral part of the propel transmission.
Each of the propel circuits is an independent closed loop system. The system is pressurized by a small-volume charge pump, which is tandem mounted on the main piston pump drive shaft. In addition to maintaining the basic loop system pressure, the charging pump provides pressure for the pump servo controls, motor displacement con-trol, and the brake release circuits.
When the drill is operating in propel mode, and the operator moves the joystick controller away from the NEUTRAL position, the electro-hydraulic servo control on the pump is energized. Energizing the servo control causes the pump pistons to begin to stroke. The direction and amount of movement of the joystick away from NEUTRAL posi-tion determines the direction of oil flow from the pump main ports (through “A” or “B”) and establishes the volumet-ric displacement of the pump pistons. When the displacement of the pistons is increased, the flow rate of oil discharging from the pump into the motor circuit increases, causing the propel motor to turn faster.
Main Hydraulic System BD120149 Mechanical Systems Manual
The block diagram at Figure 4-1 demonstrates system operation.
4.2.1 Hydraulic Tank R6908D1
The oil for the main hydraulic system comes from the hydraulic tank. The main hydraulic system and the auxiliary hydraulic system share a common oil tank. The tank is located in the lubrication room on the forward right portion of the machinery deck.
For a detailed description of the hydraulic tank and its components, refer to Subtopic 3.2.1.
BD120149 Mechanical Systems Manual Main Hydraulic System
4.2.2 Main Hydraulic Pumps R51924D1
4.2.2.1 Description
The two main hydraulic pumps, mounted on the forward side of the pump drive transmission (PDT), are identical. They are axial piston pumps with a rotary servo, trimmer, adjustable volume stops, and a neutral bypass with detent (not spring or pressure centered). The pumps are configured to supply hydraulic fluid to the hydraulic motors and brakes for the propel system. The pumps also provide braking for the propel motors when the controls are placed in neutral position. Servo pressure from the right pump is used to release the hoist brake and to adjust the displacement of the propel motors.The pumps contain: an axial piston crossover-center variable pump which con-trols the speed and direction of the motor actuator; the auxiliary gerotor pump which supplies servo pressure (for controlling the displacement of the variable pump) and replenishment pressure; the servo pressure relief valve; the replenishment pressure relief valve; and the replenishment check valves for legs A & B.
4.2.2.2 Theory of Operation
When the main motor starts, the PDT causes the pump to turn; however, during normal start-up, the pump is in the neutral position and oil pressure does not develop in the main hydraulic circuit.
When the operator places the drill in PROPEL mode and moves the joystick, a signal is provided to the electrohy-draulic stroker. The stroker (or servo) causes the swash plate within the motor to rotate. The movement of the swash plate causes oil to move through the main hydraulic circuit. The movement of the servo determines the rate of oil flow through the circuit as well as the direction.
BD120149 Mechanical Systems Manual Main Hydraulic System
4.2.3 Propel Motors 41U100D2
Motors receive oil flow from the main pump. The variable displacement motors can be controlled for either high speed and low torque, or low speed and high torque, through the operator’s speed control.
The propel motors are integral components with the propel transmissions; brakes are internal to the component. Brakes are hydraulically released and spring set. In order for the brakes to release, the switch on the operator’s console must be in the RELEASE position, and the joystick must be moved off neutral. This permits oil to flow from the pilot control valve bank to cause the brakes to release.
BD120149 Mechanical Systems Manual Main Hydraulic System
4.2.4 Pilot Control Valve Bank 36U435D4
The pilot control valve bank is in the lubrication room, between the hydraulic tank and the low pressure valve stand. It contains three valves: the speed control valve, the left brake valve and the right brake valve.
4.2.4.1 Speed Valve
In its de-energized state, the speed valve directs oil from the pump’s H port to a blocked port on the pilot control valve bank. The motor then receives no pressure through its X port, and the motor is fully stroked (low speed, high torque).
When the operator places the speed switch in the high speed position, this causes the propel speed solenoid to energize. When the valve spool shifts, oil from port B of the speed valve enters the motor through port X and destrokes the motor’s swash plate, providing higher speed and lower torque.
Main Hydraulic System BD120149 Mechanical Systems Manual
4.2.4.2 Brake Valve
WARNING!
Uncontrolled drill movement can cause severe personal injury or death. Always confirmthat the tow bar is attached to both the drill and the tow vehicle before using the handpump to release the propel brakes.
The brake valve solenoids energize when the operator presses the brake release switch on the operator’s console. Oil is not provided to release the brakes, however, until the joystick is moved, which causes the pump’s internal porting to open and allows oil to flow through the Z port to the brake valve.
4.2.4.3 Towing System
CAUTION
Excessive speed can cause substantial damage to propel system components. Nevertow the drill faster than the drill can propel itself.
When the drill’s motor is not running, the pumps that supply the oil to release the propel brakes cannot perform that function. When it is necessary to tow the drill, the propel brakes must be released by hydraulic pressure provided by a hand pump located near the front right corner of the drill. The hand pump also includes an accumulator and a pressure gauge to assist with maintaining pressure to the brake during long moves. Spring-loaded breakaway valves are provided to allow the brakes to set if the tow vehicle should separate from the drill.
BD120149 Mechanical Systems Manual Main Hydraulic System
4.3 Main Hydraulic System Maintenance
4.3.1 Hydraulic Tank R6908D1
4.3.1.1 Description
The auxiliary hydraulic system and the main hydraulic system share a common oil tank. The tank is located in the lubrication room on the forward right portion of the machinery deck. For detailed description about maintaining the hydraulic tank and its components, refer to Subtopic 3.2.1.
Figure 4-8:
01
0304
06
0908
BD0361a01
02
05
07
10
11
LEGEND01. Suction Filters02. Temperature Probe03. Hydraulic Tank04. Low Level Switch
Main Hydraulic System BD120149 Mechanical Systems Manual
4.3.2 Main Hydraulic Pumps R51924D1
4.3.2.1 Pump Start-up, Adjustment and Functional Testing
This procedure is to be used for start-up and functional testing of the main hydraulic pumps and propel system after installation on the drill. The procedure is suitable for periodic testing of the pumps to confirm normal operation. On-the-drill testing of these pumps is limited to a few basic pressure measurements, observations and adjustments. However, more thorough testing can be done only by removing the pumps from the system, installing them on a hydraulic test stand, and implementing complete pressure, flow, and controls functional tests to rated design capacity.
Main Hydraulic System BD120149 Mechanical Systems Manual
Step 5: Disconnect the electrical connectors from the right and left propel brake solenoid valves on the Propel Control Valve Bank in the lubrication room. Refer to Figure 4-11.
NOTICE
With the electrical connectors disconnected from the brake valves, the propel brakes should notbe able to release and the propel drive should not be able to rotate.
Step 6: Install a 0 - 1500 psi (103.5 bar) gauge onto the pressure taps, one for each charge filter.
Step 7: Install a 5000 psi (345 bar) (minimum) pressure gauge on the A port of each pump.
CAUTIONOperating the pump with low charge pressure could cause substantial damage to thepump. If the gauge does not register specified pressure within a few seconds, shut downthe drill and determine the cause. Do not operate the drill if charge pressure is low.
BD120149 Mechanical Systems Manual Main Hydraulic System
Step 8: Start the main drive motor.
Step 9: Confirm the charge pressure reading on the 0 - 1500 psi gauges registers 250 - 350 psi (17.5 - 24 bar).
Step 10: Raise and level the drill on the jacks. The drill must be raised until the crawler belts are completely clear of the ground.
Step 11: Allow the hydraulic systems to operate until normal operating temperature is reached (usually about 15 minutes).
Step 12: Set the propel mode normal/maintenance switch to MAINTENANCE position.
WARNING!
Unexpected machine movement or operation can cause serious injury or death. Whennecessary to operate the drill to make an adjustment or perform a check on the propeldrive system, position a person to watch the crawler mechanism and to keep personnelat a safe distance from the drill. Always use the cab horn (in accordance with local pol-icy) to signal that the drill is about to move.
Step 13: Set the mode select propel/hoist/drill switch to PROPEL position.
Step 14: Assign someone to watch the crawler mechanism for motion, and to keep others away from the drill dur-ing the propel drive adjustment and testing.
Step 15: Have the operator move the propel joystick to the FORWARD position, and turn the compensator adjust-ment screw on the pump inward until the pump port “A” pressure reads 4200 psi (283 bar).
NOTICE
The indicator should remain on, or very near, the zero position.
Step 16: Confirm that there is no rotation of the crawler tumblers.
Step 17: Move the gauges to the B port of each pump.
Step 18: Move the propel joystick to the REVERSE position. Pressure in the pump port “B” circuit should now be 4200 psi (283 bar).
NOTICE
The indicator should remain on, or very near, the zero position.
Step 19: Confirm that there is no rotation of the crawler tumblers.
Step 20: Return the propel joystick to NEUTRAL position, and confirm that the pressures at ports “A” and “B” are equal. If they are not, adjust the NULL of the pump as follows:
a. Turn the spring stop adjustment in or out until it just contacts the spring and there is no free play. Lock in place. Then proceed with step 2 below.
Main Hydraulic System BD120149 Mechanical Systems Manual
b. Turn the trimmer screw to place the input shaft in the zero stroke position. Check for positive center-ing. Lock in place. For cross-center pumps, set maximum volume stops so that the servo shaft link touches stop pins when the handle is stroked each side of center. For one side of center pumps, set maximum stop so that the servo shaft link touches the stop pin. Set the minimum stop to prevent crossing over center. Lock the stops in place.
c. Apply signal current to one proportional valve. Adjust current from minimum to maximum. Note the pressure and current values at which the pump just starts to stroke and at which the pump reaches full stroke. These must be within the values shown in Table 4-1.
d. If control pressure is off the same amount at the start and end of the stroke, the control may be dis-assembled and the spring adjusted. One flat (1/6 of a turn) of adjustment will change the pressure by 4.6 psi (0.31 bar).
e. If the change in pressure from start to end of stroke is incorrect, the spring is incorrect and must be replaced.
f. If pressures are correct but current is incorrect, then either the coil is incorrect or the proportional valve is bad.
g. With minimum signal, the pump must return to zero stroke within 200 psi (13.8 bar) maximum.
h. For cross-center pumps, repeat the test on the opposite side of center.
i. Increase and decrease current between minimum and maximum several times. Pump stroke should follow control pressure smoothly and proportionally. Full stroke to zero or zero to full stroke should be achieved in no more than two seconds. Adjust stroke from zero stroke up to approximately 50% stroke and then adjust down from full stroke to the same current value. The flow at the two settings must not vary more than 25%.
Step 21: Check the propel brake set/release switch to be sure it is in the SET position.
Step 22: Connect the electrical connectors to the right and left brake solenoids Propel Control Valve Bank in the lubrication room.
Step 23: Move the propel brake set/release switch to RELEASE position.
Step 24: Check the hydraulic pressure on the gauges at pressure test points G1 and G2 on the Propel Control Valve Bank in the lubrication room.
BD120149 Mechanical Systems Manual Main Hydraulic System
NOTICE
Brake operating pressure must be at least 250 psi (18 bar) at pressure test points G1 and G2.
Step 25: Move the propel speed hi/low switch to the LOW position.
WARNING!
Unintentional machine movement or operation can cause serious injury or death. Whennecessary to operate the drill to make an adjustment or perform a check on the propeldrive system, position a person to watch the crawler mechanism and to keep personnelat a safe distance from the drill.
Step 26: Be sure that someone is still positioned to watch the crawler mechanism for motion, and to keep others away from the drill during the propel drive adjustment and testing.
Step 27: Move the propel joystick to the full FORWARD position and check the rotational speed and direction of the left and right crawler drive tumblers. Both should rotate at 4 rpm in the forward direction.
Step 28: Return the propel joystick to the NEUTRAL position. There should be no movement of the crawler drives.
Step 29: Move the propel joystick to the REVERSE position and check the rotational speed and direction of the left and right crawler drive tumblers. Both should rotate at 4 rpm in the reverse direction.
Step 30: Return the propel joystick to the NEUTRAL position. There should be no movement of the crawler drives.
Step 31: Move the propel speed hi/low switch to the HIGH position.
Step 32: Move the propel joystick to the full FORWARD position and check the rotational speed and direction of the left and right crawler drive tumblers. Both should rotate at 6.6 rpm in the forward direction.
Step 33: Return the propel joystick to the NEUTRAL position. There should be no movement of the crawler drives.
Step 34: Move the propel joystick to the REVERSE position and check the rotational speed and direction of the left and right crawler drive tumblers. Both should rotate at 6.6 rpm in the reverse direction.
Step 35: Return the propel joystick to the NEUTRAL position. There should be no movement of the crawler drives.
Step 36: Move the propel brake set/release switch to the SET position.
Step 37: Lower the drill off the jacks, and raise the jacks to fully stored position.
Step 38: Check the pump compensator adjustment to be certain the locknut is tight and the acorn nut is securely in place on the adjustment screw.
NOTICE
Over-tightening of the locknut can damage the compensator adjustment.
Step 39: Remove the test gauges from the pressure tap fittings, and check the entire system for leaks.
Main Hydraulic System BD120149 Mechanical Systems Manual
Technician Tip
When the main pumps and the propel motors are set up and functioning correctly, the appropri-ate speeds will be achieved in the propel system. If the crawlers still do not track straight afterthe pumps have been adjusted (and flow and pressure confirmed), refer to motor adjustmentprocedure in Subtopic 9.3.1.4.
4.3.3 Removal
To remove either of the hydrostatic pumps from the pump drive transmission, proceed as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
Step 1: Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activ-ities.
Step 2: Clean all dirt away from the pump, hose, and electrical fittings.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
Step 3: Check to be certain that the hydraulic pressure is completely vented from the high-pressure and control pressure circuits.
Step 4: Close the hydraulic tank Handwell valves.
Step 5: Tag and remove the hydraulic hoses from the pump. Cap or plug all hose fittings and pump ports.
Step 6: Tag and disconnect the electrical control wiring from the electrohydraulic stroker control on the pump.
Step 7: Attach a suitable hoist to the pump to prevent an overhung load on the shaft when the mounting bolts are loosened. Protect the external tubing on the pump from being bent or crushed.
Step 8: Mark the pump, if more than one is being removed, to assure that it is remounted at the same shaft posi-tion on the transmission.
BD120149 Mechanical Systems Manual Main Hydraulic System
Step 9: Remove the capscrews and lockwashers from the mounting flange of the pump, and pull the pump away from the pump drive transmission. Use care to prevent binding of the shaft or damage to the spline teeth when withdrawing the pump from its mounting.
Step 10: Inspect the pump and pump drive transmission splines for damage.
4.3.4 Installation
To install the pump on the pump drive transmission, proceed as follows:
CAUTION!
Disassembling heavy components with inadequate hoisting apparatus can injure per-sonnel and/or damage equipment. Use suitable rigging and hoisting equipment to stabi-lize and lift heavy objects.
Step 1: Using a suitable hoist, lift the pump into position at the rear of the pump drive transmission. Be careful to avoid bending or pinching the external tubing on the pump with the sling.
Step 2: Grease the female spline with lithium grease before inserting the splined pump shaft.
Step 3: Insert the shaft of the pump into the bore of the pump drive transmission. Be careful to avoid side loading and/or binding of the shaft as the pump is moved into position against the transmission.
Step 4: Coat the threads of two 5/8" capscrews with sealing grease (P&H Spec 499). Insert capscrews with lock-washers to fasten the pump to the pump drive transmission.
Step 5: Fill the pump case with clean oil, then install the hydraulic hose assemblies in accordance with the identi-fication tags placed during pump removal.
Step 6: Install the electrical wiring to the electrohydraulic stroker control in accordance with the identification tags placed during pump removal.
Step 7: Open the Handwell valve.
Step 8: Install a 0 - 1500 psi (103.5 bar) gauge into the charge pump circuit (atop the charge filter).
Step 9: Start the pump and monitor charge pressure. Refer to the start-up procedure in steps 6 through 9 in Sub-topic 4.3.2.1.
Main Hydraulic System BD120149 Mechanical Systems Manual
4.3.5 Pilot Control Valve Bank (Valve Bank 4) 36U445D4
The Pilot Control Valve Bank, also known as Valve Bank 4, contains three identical solenoid valves: Right Propel Brake, Left Propel Brake, and Propel Speed. It also includes two pilot valves for the tow circuit. Each valve is a two-position, four-way valve with solenoid and manual actuation with a spring return. Field repair of the valves is limited to the replacement of the solenoid coil and O-rings.
BD120149 Mechanical Systems Manual Main Hydraulic System
4.3.6 Charge Filter 46Z547
The charge filter assembly is mounted in-line between ports “G” and “H” on each of the two main hydraulic pumps, mounted on a bracket over the PDT. The function of these filters is to ensure the cleanliness of the pressurized oil stream from the control pressure (charge pressure) section of the main hydraulic pump, and to prevent fouling of the main pump control valves. These by-pass type filters are rated at 30 gpm (113.6 lpm) maximum flow, and 2500 psi (172.5 bars). The by-pass is set to open when flow pressure differential across the filter exceeds 30 psid (2.1 bars differential). A single 3-micron element is used for oil filtration. The filter assembly includes a by-pass indicator that sends a signal to the PLC, which will initiate a fault indicator on the GUI. It is not necessary to remove the filter assembly from the line to replace the element or seals.
Inspect the filter units during PM for visible damage, leaking seals, or leaking fittings. If the GUI indicates that the filter is bypassing, the element should be replaced. Replace the charge filter elements as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine startup during maintenance.
A. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system or
Main Hydraulic System BD120149 Mechanical Systems Manual
machine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
B. Be sure that no pressure exists in any of the main hydraulic system circuits.
C. Remove the bleed plug located on bottom of the filter. Drain oil from the filter into a pail before removing the filter element.
NOTICE
Clean dirt from the filter assembly before loosening the bleed plug and filter cap.
D. Loosen and remove the cap from the filter body.
E. Remove the old filter element and examine its condition for clues to potential problems. Discard the old filter element only after it has been examined.
F. Inspect the bottom of the filter bowl for debris. Look here as well for clues to potential problems. Clean the bowl if necessary.
G. Check the cap seal O-ring and back-up ring for nicks or damage. Replace these components as necessary.
H. install a new filter element into the body of the filter. Be sure the element is correctly located on the bottom seat.
I. Apply a coating of hydraulic oil to the O-ring and back-up ring, and install with the filter cap. Torque the cap securely.
J. Install the bleed plug securely in the filter.
Figure 4-14: Charge Filter Ports
01
02
03
BD0579a01
LEGEND01. Pressure Test Port02. Filter Cap03. Bleed Port
BD120149 Mechanical Systems Manual Main Hydraulic System
K. Start the hydraulic pumps, and bleed the trapped air from the main hydraulic system. This can be done using the Microbore hose in the hydraulic test kit. Attach to the pressure test port on the top of the charge fil-ter and allow the discharge to shoot into a pail.
4.4 . Troubleshooting
Component problems and circuit problems are often interrelated. An incorrect circuit may operate with apparent success, but will cause failure of a particular component within it. The component failure is the effect, not the cause of the problem.
Problem Possible Cause Remedy
Noisy Pump Air in fluid Repair leak in suction line
Repair leak at shaft seal
Fill tank to correct fluid level
Eliminate fluid turbulence in tank
Cavitation in pump or motor rotating group
Increase fluid temperature, but do not exceed 180°F (82°C)
Decrease fluid viscosity
Clean suction strainer
Misaligned shaft Check pump shaft for mis-alignment
Check and relieve any axial interference
Mechanical fault in pump Return the pump to P&H MinePro Services for repair, or replace the pump
The power unit provides a single source of torque with which to drive the main air compressor and the three pumps for the auxiliary and main hydraulic systems. Major components of the power unit include the electric main drive motor, the hydraulic pump transmission, and the main air compressor. These are mounted on a rigid base as a unitized assembly. The structural section of the base is sized to retain alignment of all components, regardless of the mounting support. Refer to Figure 5-1.
5.1.1 Power Unit Assembly Alignment
The power unit components -- that is, the main AC drive motor, the main air compressor and the pump drive trans-mission -- are mounted to a steel skid. This arrangement is intended to reduce the flexing between the motor and
Figure 5-1: Power Unit
06
05
07
040301
09
10
11
02
BD0398b01
08
LEGEND01. Charge Filter02. Auxiliary Pump03. Main Drive Motor04. Compressor Air Cleaner05. Main Air Compressor Inlet Valve
06. Main Air Compressor07. Compressor Coupling08. Base09. PDT Coupling10. Pump Drive Transmission (PDT)11. Main Hydraulic Pump
compressor and thus preventing premature failure of the coupling, and secondly to be used as a tool to keep re-alignment adjustments to a minimum in field installations.
If any of these components is replaced in the field, first check to ensure that:
• Shaft is concentric to the motor end cover pilot
• Both pilots and faces of adapter mounting are concentric and parallel
• Compressor input shaft is concentric to the bell housing pilot
The following steps needs to be carried out for either motor or compressor field installation:
1. Make sure the machine is level (use a spirit level).
2. Make sure that all mating surfaces and foot mounting pads are clean.
3. Remove adapter from motor or compressor.
4. Fit motor or compressor to respective mounting pads on the skid. Tighten mounting bolts. (Do not install cou-pling at this stage.)
5. Use a magnetic base dial indicator to determine height difference between compressor and motor shaft. Add shims to foot mountings on the lowest component. Max .015" (.381mm) TIR. If motor is lower than compressor, motor base bolts must be loosened and shimmed accordingly. (If motor is lower, pump drive transmission will have to be re-aligned.)
6. Loosen compressor foot mounting bolts and remove compressor.
7. Slide coupling hubs onto their respective shafts. Do not tighten.
8. Re-install adapter to motor. Install and tighten bolts. Torque to 266 ft-lbs (360 Nm) dry. Remove inspection cov-ers.
9. Re-install compressor using shims as established in step 5. Install base mounting bolts, do not tighten.
10. Fasten adapter to compressor/motor foot mounting bolts and torque compressor bolt's 266ft-lbs (360Nm) dry, motor bolt's 650 ft-lbs. (880 Nm) dry.
11. Remove adapter inspection cover to gain access to coupling.
12. Slide coupling hubs together. Inside gap should be a nominal 1/8" (3.175mm). Install flexible inserts into either coupling half. Slide flexible insert retainer cover onto hub and fasten.
13. Insure that equal length of shaft extends into each hub, secure both hubs with set screws provided and torque to 110 in-lbs. (12Nm)
14. Insert dowels on either end of mounting adapter.
If new or different compressor/motor is installed, new holes are to be drilled and reamed fordowels in new locations. Do not use existing holes. Holes are to be drilled 29/64" (11.508mm)then reamed with number 8 taper pin reamer.
15. Dowel both compressor and motor feet to base. If either the compressor or the motor is a new or service exchange unit, new dowel holes are to be drilled in different locations. Holes are to be drilled .500" (12.7mm) and reamed with a number 9 tapered pin reamer.
If pump drive transmission coupling has to be re-aligned then the following steps should be followed.
16. Loosen bolts on the PDT mounting plate. Do not remove.
17. Remove dowel pins from mount to skid and dowel pins from mount to PDT. Remove coupling guard.
18. Check and align coupling. Max TIR .008" (2.03mm)
19. Fasten bolts mounted to PDT and mount to skid. Torque to 266 ft-lbs (360Nm).
20. Confirm alignment within .008" (2.03mm). If alignment is within tolerance, lubricate the spacer with grease and install the spacer between the coupling halves.
21. Drill one pilot hole, 15/32" (11.907mm) diameter, through the mounting plate and into PDT. Do not drill deeper than 1" (25mm) into PDT. Drill one hole, 15/32" (11.907mm) in diameter, through the mounting plate into the skid. Ream hole to .4996" (12.67mm) and install dowels. Do not use old holes.
22. 22. Install coupling guards.
5.2 Theory of Operation
5.2.1 Main Drive Motor 5100A1368F12
‘The drill is powered by a double-shafted, high-voltage AC electric motor. The motor is sized, at 700 HP (at 60 Hz), to provide the total torque needed to operate the main air compressor and the pumps for both the main and auxil-iary hydraulic systems.
5.2.2 Air Compressor 51U165D4
The air compressor is coupled to the motor drive shaft at one end of the motor. Compression of the air is accom-plished by the main and secondary rotors synchronously meshing in a one-piece cylinder. The main rotor has four helical lobes spaced 90° apart. The secondary rotor has five matching helical grooves 72° apart to allow meshing with the main rotor lobes.
NOTICE
The Air Compressor is covered in Section 6, Bailing Air System.
The hydraulic pump drive transmission is coupled to the motor shaft at the other end of the motor. The power unit is mounted to the machinery house deck with four isolator mounts to minimize the effects of machinery vibration. All four hydraulic pumps are flange-mounted to the output shafts of the pump drive transmission.
5.3 Main Hydraulic System Components
5.3.1 Main Drive Motor
5.3.1.1 General
The power unit is driven by a double-shafted, high-voltage AC electric motor. The motor operates the main air com-pressor and the pumps for the main and auxiliary hydraulic systems. The motor is direct coupled to the compressor and pump drive transmission with flexible couplings.
5.3.1.2 Removal
Remove the main drive motor from the power unit base as follows:
WARNING!
Hazardous voltage can cause burns, injury, or death. Disconnect, lock open, and tag thepower source which feeds the main drive motor to prevent power from being appliedwhile inspection and repairs are being performed. Before beginning repairs, try the oper-ational controls to verify that the intended power source is disconnected.
1. Disconnect, lock out, and tag the power source to the main drive motor to prevent power from being applied while service being performed.
2. Clean all dirt from the pumps, hoses, and electrical fittings.
3. Tag and disconnect the electrical wiring and conduit from the main drive motor.
4. Tag and disconnect the electrical control wiring from the electrohydraulic stroker controls on the main hydraulic pumps.
6. Remove the nuts, lockwashers, and capscrews from the motor and adapter flanges.
7. Remove the four dowel pins, nuts, lockwashers, and capscrews from the motor feet.
8. Open roof (if mast is vertical) to lift motor out.
CAUTION!
Disassembling heavy components with inadequate hoisting apparatus can injure per-sonnel and/or damage equipment. Use suitable rigging and hoisting equipment to stabi-lize and lift heavy objects.
9. Attach a suitable lifting device to the motor, and lift enough of the motor weight to enable sliding it away from the compressor-motor adapter. Do not lift the motor off the base until the flexible coupling halves are sepa-rated. Retain the coupling insert with to the compressor half of the coupling.
10. Lift the motor away from the power unit base and set it on wooden blocking to protect the mounting foot sur-faces. Keep the motor shim set for re-use.
11. Clean and inspect the motor and power unit base components in accordance with the cleaning and inspection procedures described in Appendix A of this manual.
5.3.1.3 Installation
12. Install the main drive motor as follows (refer to Figure 5-2):
A. Position the motor shim set on the power unit base.
Figure 5-3: Legend for Figure 5-2
LEGEND01. Nut02. Band03. Capscrew04. Air Cleaner05. Service Indicator06. Bracket07. Hose Clamp08. HoseO9. tube10. Capscrew11. Lockwasher12. Inlet Manifold13. Gasket14. Inlet Manifold15. Capscrew16. Lockwasher17. Oil Filter18. Filter Gasket19. Nut20. Capscrew21. Shim Set
Assembling heavy components with inadequate hoisting apparatus can injure personneland/or damage equipment. Use suitable rigging and hoisting equipment to stabilize andlift heavy objects.
B. Attach a suitable lifting device to the motor, and position the motor on top of the shims. Continue to support most of the motor weight with the lifting device until the motor is in final position.
C. Carefully slide the motor into position against the compressor-motor mounting adapter. Rotate the motor shaft as necessary so the coupling halves mate correctly. Be certain that the flexible insert is installed in the coupling. If the compressor has not been moved, the motor and compressor shafts should be correctly aligned by the mounting adapter.
D. Position the shims as necessary under the motor feet, then install the dowel pins, capscrews, lockwashers, and nuts. Torque the nuts securely.
E. Install the covers on the compressor-motor adapter with capscrews and lockwashers.
F. Install the hydraulic pump drive transmission on the gear box mounts, as described under Subtopic 5.3.2.6.
G. Install the electrical wiring to the main drive motor.
H. Confirm alignment in accordance with Subtopic 5.1.1.
5.3.2 Hydraulic Pump Drive Transmission GH5429879
5.3.2.1 Description
The pump drive transmission (PDT) is a multi-shafted gear reducer that distributes torque from the electric main drive motor to the three attached hydraulic pumps. The output shafts to the pumps all rotate at the same speed. The input shaft of the hydraulic pump drive is connected to the main drive motor shaft by means of a flexible cou-pling. The hydraulic pumps are flange-mounted to the hydraulic pump drive transmission housing. A single pump on the forward side of the pump drive provides flow and pressure to the auxiliary hydraulic system. The two hydro-static pumps for the main hydraulic system are located on the rear side of the pump drive.
The pump drive transmission has a ventilated gear case. The gears are lubricated by a splash-type oil bath.
5.3.2.2 Removal
Removal. Remove the PDT as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent operation of the machine during maintenance work.
2. Open the drain cock located on the bottom front side of the pump drive housing and drain the lubricating oil into a suitable container. The housing contains approximately 2 gallons (7.6 liters) of oil.
3. Remove the guard which encloses the flexible coupling between the main drive motor and the pump drive transmission.
4. Disconnect the pump drive from the main drive motor at the flexible coupling by removing the capscrews, washers, and locknuts which secure the pump drive to the coupling flange extension. Do not remove the attaching capscrews, washers, or nuts from the motor end of the flexible coupling at this time. The hydraulic pump drive can be removed from the power unit assembly with all pumps installed. The following procedure, however, assumes that all of the hydraulic pumps have been removed from the pump drive as described under the topics, Auxiliary Hydraulic Pump, Removal, and Main Hydraulic Pump.
CAUTION!
Disassembling heavy components with inadequate hoisting apparatus can injure per-sonnel and/or damage equipment. Use suitable rigging and hoisting equipment to stabi-lize and lift heavy objects.
5. Attach a suitable lifting device to stabilize the pump drive transmission.
6. Remove the pipe nipple, oil drain cock, hex nipple, and pipe elbow from beneath the pump drive housing.
7. Remove the four locating dowel pins from mount and the pump drive housing. Two dowel pins are on each side of the pump drive housing.
8. Remove the four capscrews and lockwashers which secure the pump drive housing to mount.
9. Open roof (mast vertical only) to access pump drive with a crane.
10. Remove the pump drive from the power unit assembly.
5.3.2.3 Disassembly
Disassemble the hydraulic pump drive transmission as follows:
1. Remove the coupling hub and sleeve from the pump drive input shaft as follows (refer to Figure 5-4):
NOTICE
The following equipment is required: A suitable hydraulic puller with an adjusting assembly anda crosshead leg assembly having SAE Grade 8 studs, two rosebud torches, heat resistantgloves and a fire extinguisher.
A. Thoroughly clean the coupling hub to be removed to avoid combustion when heat is applied.
B. Place the pump drive housing on a support with the input shaft facing up.
C. Drill and tap the face of the coupling hub for the appropriate puller leg thread size, as shown in Figure 5-5.
D. Assemble the puller as illustrated in Figure 5-5. Check to be sure the puller has enough stroke to pull the hub off the input shaft.
SAFETY FIRST
Surfaces will be extremely hot. Be certain to wear all appropriate personal protective equipment(PPE).
E. Heat the hub evenly with a rosebud torch to approximately 300 - 500°F (150-260°C) while applying pressure with the puller. The temperature of the hub may be measured with a heat sensitive crayon.
CAUTIONExcessive heat can damage hub teeth. Avoid placing the heat directly on the hub teeth.Apply the heat as shown in Figure 5-5.
F. Apply puller pressure until the hub clears the shaft.
2. Refer to Figure 4-5 and disassemble the pump drive housing as follows:
A. Thoroughly clean the split housing exterior using a suitable solvent. Make sure the disassembly area is clean. Place the assembled pump drive so the oil drain side of the housing is facing down on the work sup-port, and the input shaft facing up.
B. Remove the dowel pins which align the two housing halves.
C. Separate the housing halves using bolts as jacking screws in the tapped holes provided in the housing flanges.
CAUTION!
Disassembling heavy components with inadequate hoisting apparatus can injure per-sonnel and/or damage equipment. Use suitable hoisting equipment to stabilize and liftheavy objects.
D. Using a suitable lifting device, remove the upper housing half. Bearings will remain on the input shaft and pump drive (output) shafts in the lower housing half. The bearing/seal carrier will remain with the upper housing half along with seal, O-ring and snap ring.
E. Note the orientation of the seal lip and bearing seal carrier to ensure proper reassembly. Then, remove all necessary parts from the upper housing. It is normally unnecessary to remove the pump adapters (14) from the housings in order to disassemble the pump drive transmission.
NOTICE
The disassembly method for each pump drive (output) shaft is identical. The following proce-dure will apply equally to each.
F. Remove snap ring and the splined adapter from each end of output shaft.
G. Press against the lower end of the output shaft and remove the shaft with bearings in place on the shaft.
H. Remove the bearings from the shaft using a puller which contacts only the inner race of the bearings.
I. Remove the gear spacers and the gear from the shaft.
5.3.2.4 Repair
Clean and inspect all of the pump drive transmission components in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. Replace all worn or damaged parts. Replace all gaskets.
5.3.2.5 Assembly
Assemble the pump drive transmission as follows:
1. Reinstall the bearings on their respective shafts, being careful to press only on the inner race. Be sure the bearings are pressed fully onto the shaft.
2. Lubricate bearings with light oil and install seal using Loctite Plastic Gasket 54931 on the outer diameter. Assemble seal carrier with Loctite 609. Grease the seal surface before installing.
3. Install all pump drive shafts in the lower housing half and secure with snap rings.
4. Install all splined adapters and secure with snap rings.
5. Use SAF-T-LOK Silicone Sealant No. 732 to seal the pump drive housing halves and install the upper housing half on the lower half.
6. Install the locating dowel pins in the housings.
7. Tighten bolts and nuts to 60 ft-lbs (81 Nm), following the bolting sequence illustrated in Figure 5-6.
8. Reinstall the coupling hub and coupling half on the input shaft as follows:
A. Place the sleeve on the input shaft with the flange facing away from the pump drive transmission housing.
B. Heat the hub to 275°T (135°C) using one of the following methods:
1). For oven heating, set the oven thermostat to 275°F (135°C) and heat the hub at least one hour for each inch of wall thickness. Do not allow the hub teeth to come into contact with the heat source.
WARNING!
Use of an open flame in a combustible atmosphere can ignite the atmosphere or causean explosion resulting in the injury or death of personnel and damage to equipment. Donot use an open flame in a combustible atmosphere or near combustible materials.
2). For oxy-acetylene or blow torch heating, mark the hub with a 275°T temperature sensitive crayon in several places near the teeth. Direct the flame toward the hub bore and keep it in motion while heating to avoid overheating an area. Do not apply heat directly to the hub teeth. When using an oxy-acetylene torch, use an excess acetylene mixture.
C. Mount the hub on the shaft as quickly as possible to avoid heat loss. Make certain that the position of the hub teeth relative to the shaft end is correct before assembling. Line up the bore with the shaft and slide the hub onto the shaft until the hub face is flush with the end of the shaft.
NOTICE
If it is necessary to drive the hub into position, tap lightly with a soft brass or lead hammer. Donot strike the hub teeth or pound hard enough to damage bearings.
Install the pump drive transmission as follows (refer to Figure 5-2):
1. Using a suitable lifting sling, position the pump drive housing in mount on the power unit base, and secure it lightly with the mounting capscrews and lockwashers. Do not tighten fully at this time.
2. Install the four dowel pins which accurately position the pump drive housing relative to the two gear box mounts, then complete tightening of the mounting capscrews.
3. Using a dial indicator, check the alignment of the coupling hubs on the motor shaft and pump drive shaft. Align-ment must be parallel within 0.002" TIR. Always rotate the hub on which the dial indicator is mounted and mount the dial indicator on the most easily rotated hub.
NOTICE
The coupling extension will need to be removed from the coupling assembly to enable checkingoverall hub-to-hub alignment.
4. Install the coupling extension with two new gaskets, capscrews, lockwashers and locknuts.
5. Lubricate the coupling using the lubricant specified in the Lubrication Chart. To do so, fill the front section with lubricant until an excess appears at an open hole. Plug that hole. Continue with the rear section until lubricant appears out the rear hole. Plug that hole.
6. Install the coupling guard between the motor and the pump drive housing with capscrews and lockwashers.
7. Install the pipe elbow, hex nipple, drain cock, and pipe nipple beneath the pump drive housing.
8. Confirm alignment in accordance with Subtopic 5.1.1.
9. Install the hydraulic pumps. Refer to Subtopic 4.3.4.
10. Fill the pump drive with 2 gallons (7.6 liters) of gear oil. Refer to Subtopic 17.3.2.
BD120149 Mechanical Systems Manual Main Air System
Section 6
Main Air System
6.1 General
In order to drill most effectively, the rock chips and dust generated by the drill bit at the bottom of the blasthole must be removed. The main air system provides a large volume of air under pressure to blow these particles out of the hole. An additional benefit to providing air through the drill bit is that it helps keep the drill bit cool.
Main Air System BD120149 Mechanical Systems Manual
6.2 Theory of Operation
6.2.1 Main Air Compressor 51U165D4
The main air compressor (Figure 6-2) is a single-stage, positive-displacement oil-flooded rotary screw compressor using two meshing helical rotors to effect compression. The compressor is protected against dust contamination by a pair of two-stage air filters, which are attached to the air inlet valves. The compressor is ported to accept an external, re-circulating supply of oil for cooling and lubrication. Oil is supplied at the compressor inlet, and mixes directly with the air being compressed. The compressed air-oil mixture flows from the compressor into the T tank (a combination oil reservoir and air-oil separator) where the majority of oil separates from the air stream. The sepa-rated oil, retained temporarily in the enlarged bottom of the T tank, is circulated through the oil temperature control and filter circuit, then back to the inlet of the compressor.
Figure 6-2: Main Air Compressor and Main Motor
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LEGEND01. Compressor Base02. Isolation Mounts03. Main Air Compressor04. Main Air Compressor Oil Filter05. Inlet Valve Manifold
06. Inlet Valves07. Air Cleaner Support Bracket08. Air Cleaner Filters09. Bearing Oil Filter10. Main Motor
BD120149 Mechanical Systems Manual Main Air System
6.2.1.1 Compression Principle
The Compression Principle is demonstrated in Figure 6-3:
Compression of the air is accomplished by the main and secondary rotors synchronously meshing in a one-piece cylinder. The main rotor has four helical lobes spaced 90° apart. The secondary rotor has five matching helical grooves 72° apart to allow meshing with the main rotor lobes.
The air inlet port is located on top of the compressor near the center. The discharge port is near the bottom at the opposite end of the compressor cylinder.
The compression cycle begins as the rotors unmesh at the inlet port and air is drawn into the cavity between the main rotor lobes and the secondary rotor grooves (A, Figure 6-3). When the rotors pass the inlet port cutoff, air is trapped in the interlobe cavity and flows axially with the meshing rotors (B). As meshing continues, more of the main rotor lobe enters the secondary rotor groove, normal volume is reduced, and pressure increases.Volume reduction and pressure increase continues until the air/oil mixture trapped in the inter-lobe cavity by the rotors passes the discharge port and is released to the oil reservoir (C).
Each rotor cavity follows the same “fill-compress-discharge” cycle in rapid succession to produce a continuous, smooth, and shock-free discharge air flow.
6.2.1.2 Air Flow
Air enters the compressor after first passing through the main compressor air cleaner and the inlet valves (refer to Figure 6-2). After compression, the air/oil mixture passes into the oil reservoir in the bottom of the T-Tank, where most of the entrained oil is removed by velocity change and impingement. The air and any remaining oil -- now a mist -- then pass through the oil separator in the upper leg of the T-Tank; the separated oil is returned to the system through tubing connecting the separator to the compressor. The air passes through the T-Tank discharge manifold, discharge minimum pressure relief valve, and bailing air control (butterfly) valve.
6.2.1.3 Lubrication, Cooling, And Sealing
An oil circulation pump draws oil from the oil reservoir. Oil is pumped through the oil cooler, thermal control (ther-mostatic mixing) valve, main oil filter, and bearing oil filter, and discharges into the main oil gallery of the compres-sor. A portion of the oil flow is directed through internal passages to the bearings, gears, and shaft oil seal. The
Main Air System BD120149 Mechanical Systems Manual
balance of the oil is injected directly into the compression chamber to remove heat of compression, seal internal clearances, and to lubricate the rotors.
6.2.1.4 Turn Valve
The turn valve is a rotary helical valve located near the discharge port. The turn valve is locked in place at the fac-tory to produce maximum output. The turn valve can be unlocked via a set screw, enabling the turn valve to be turned to open and close cylinder ports that communicate with the inlet passage. This varies the compressor rotor volume to match the demand for air required for drilling.
Main Air System BD120149 Mechanical Systems Manual
6.2.3 Air Intake
6.2.3.1 General
Air from atmosphere is filtered through a pair of dual-stage air cleaners and a pair of inlet valves prior to entering the compressor. The inlet valves are closed at main motor start and modulated during operation by the subtractive pilot valve.
Refer to Figure 6-6 as the functions of the components are described in the following subsections.
BD120149 Mechanical Systems Manual Main Air System
6.2.3.2 Main Compressor Air Cleaner 46Z534D1
Two double-element filters are installed, one in each air intake line. These filter the air going to the compressor.
6.2.3.3 Vacuum Switches R15628D1
A vacuum switch is plumbed between the air cleaner and the inlet valve in each of the two air intake lines. The vac-uum switch indicates to the PLC when a filter needs to be changed.
Main Air System BD120149 Mechanical Systems Manual
6.2.3.4 Inlet Valves
The inlet valves are piston-actuated devices. They close when the system is operating at full pressure, and the degree of opening changes as the system pressure changes. Refer to Figure 6-10, views A, B, C, D and E, which illustrate how the inlet valve assemblies operate
BD120149 Mechanical Systems Manual Main Air System
.
Inlet
Figure 6-10: Inlet Valve Modulation Operation
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BD0527a01
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LEGEND01. Adjusting Screw02. Subtractive Pilot
Valve03. Spring04. Poppet05. Diaphragm06. From Air Valve07. Inlet Pressure Gauge08. To Inlet Valve09. From Low Pressure
Hydraulic System10. Control Piston11. Piston12. Piston Spring13. Inlet Valve Stem14. Inlet Valve Spring15. Inlet Valve16. Air from Filters17. Air to Compressor
Main Air System BD120149 Mechanical Systems Manual
A. COMPRESSOR IS OFF. Air pressure in line from air valve is zero. The subtractive pilot valve is closed, and pressure on the inlet pressure gauge is zero. No air pressure is acting on the cylinder cap, and no hydraulic pressure is acting on the cylinder cap. The piston spring holds the piston in the open position; however, the small, weak valve spring is strong enough to keep the valve over the opening so that dust and other contam-inants do not enter the compressor.
B. MAIN MOTOR STARTS. Air pressure in line from air valve is zero. The subtractive pilot valve is closed, and pressure on the inlet pressure gauge is zero. No air pressure is acting on the cylinder cap. Until the motor is running at normal speed, pilot hydraulic pressure from the low pressure hydraulic system moves the control piston in the cylinder. The main piston compresses the piston spring and pushes against the inlet valve stem, closing the valve.
C. NORMAL OPERATION, FULLY UNLOADED. When pressure at the air valve is between 0 and 58 psi, the subtractive pilot valve is closed, and pressure on the inlet pressure gauge is zero. No air pressure is acting on the cylinder cap, and no hydraulic pressure is acting on the cylinder cap. The piston spring holds the pis-ton in the open position. As the compressor lobes turn, sufficient vacuum is created to pull the inlet valve open against the small, weak inlet spring. Full air volume is available for compression.
D. NORMAL OPERATION, MODULATING. When pressure at the air valve is between 58 and 65 psi, the sub-tractive pilot valve is partially open. Pressure on the inlet pressure gauge is between 0 and 21 psi.Air pres-sure working on the piston causes the piston to move in the cylinder. This causes the inlet valve to partially close off the flow of air through the inlet valve.
E. NORMAL OPERATION, FULLY LOADED. When pressure at the air valve is over 65 psi, the subtractive pilot valve is fully open. Pressure on the inlet pressure gauge is 21 psi. Air pressure working on the piston causes the piston to move to the fully closed position, causing the inlet valve to completely close off the flow of air through the inlet valve.
In this way, the inlet valves control air going to the air compressor based on demand. The condition of the inlet valves at various stages is recapped in Table 6-1
The compressor inlet pressure switch is mounted on the air control panel in the machinery house. It indicates to the PLC that the low pressure hydraulic system is sending hydraulic fluid to the intake valves to keep the intake valves closed during start-up. When the CIPS closes, it sends a signal to the PLC that pressure in the low pressure hydraulic line reaches 275 psi, and the main motor can start.
Main Air System BD120149 Mechanical Systems Manual
6.2.3.6 Pilot Air Pressure
The pilot air pressure gauge is mounted on the air control panel, above the subtractive pilot valve. The pilot air pressure is a function of main air pressure acting through the subtractive pilot valve. Refer to Table 6-2.
Figure 6-12: Pilot Air Pressure Gauge and Subtractive Pilot Valve
Inlet Valve State Main Air Pressure Pilot Pressure Gauge Reading
Shut down: closed 0 psi 0 psi
Startup (15 seconds): closed 0 psi 0 psi
Open: fully unloaded 0-58 psi 0 psi
Modulating: partially unloaded
58-65 psi 0-21 psi
Closed: fully loaded over 65 psi 21 psi
Table 6-2: Inlet Pressure Gauge Readings
LEGEND01. Inlet Pressure Gauge02. Subtractive Pilot Valve
BD120149 Mechanical Systems Manual Main Air System
6.2.3.7 Check Valve 36Z1245D1
When system air pressure is at or above 65 psi, inlet valves are closed and no air is allowed into the system; how-ever, the compressor continues to turn. If a vacuum develops between the inlet valve and the air compressor, noisy operation results. To avoid this undesired operation, a line with a check valve has been installed between the main compressor air cleaner and the compressor that bypasses the inlet valve on the left side and permits a small amount of air to enter the system. The check valve works in conjunction with the Air Pilot Valve to move some air through the compressor, which also serves to keep the screws lubricated. Quiet, smooth operation results.
Main Air System BD120149 Mechanical Systems Manual
Figure 6-14: Inlet Valve Lines
LEGEND01. Oil line from low pressure hydraulic system (only functions at startup)02. Air line from subtractive pilot valve03. Oil return line from T-Tank oil separator (scavenger line)04. Bypass air line (from check valve)
BD120149 Mechanical Systems Manual Main Air System
6.2.4 Oil Circulation
6.2.4.1 General
Oil is induced into the air compressor to lubricate the lobes and to act as an air seal. As the air moves through the compressor, the oil is entrained with it. This oil is removed from the air before the air is sent out to the bit. The oil is then cooled and filtered and returned to the compressor.
Refer to Figure 6-15 as the functions of the components are described in the following subsections.
Figure 6-15: Oil Circulation
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LEGEND01. Inlet Valve02. Main Air Compressor03. Main Motor04. Compressor Air Temperature Gauge05. Compressor Air Temperature Probe06. Compressor Oil Temperature Probe07. T-Tank08. Main Air Pressure Differential Gauge09. Main Air Pressure Differential Switch
Main Air System BD120149 Mechanical Systems Manual
6.2.4.2 Compressor Air Temp Gauge 5826907
The Compressor Air Temperature Gauge is located on the discharge pipe exiting on the right side of the compres-sor. It indicates the current temperature of the discharge air/oil mixture. During operation, the compressor should maintain a normal operating temperature of 180°-185°F (82°-85°C).
6.2.4.3 Compressor Air Temp Probe 89Q136D1
The Compressor Air Temperature Probe is located on the discharge pipe exiting on the right side of the compres-sor. It sends a signal to the PLC indicating the current temperature of the air discharge.
Figure 6-16: Compressor Air Temperature Probe and Gauge
BD120149 Mechanical Systems Manual Main Air System
6.2.4.4 T-Tank R55420F1
T-Tank is the common name for the oil separator/reservoir. It is mounted on the When the oil and air mixture enters from the compressor, the majority of the oil falls out of the air by gravity and impaction. The oil is recirculated through the cooler and the filter, then returned to the air compressor.
6.2.4.5 Compressor Oil Temp Probe 89Q136D1
The Compressor Oil Temperature Probe is inside the T-Tank, and sends a signal to the PLC indicating the current temperature of the oil inside the T-Tank.
6.2.4.6 Oil Separator Elements 5010587, 5010588
Part of the T-Tank, the two oil separator filter sections extend upward from the main reservoir. Each contains a two-stage oil remover, which removes oil that is still entrained as a mist in the main air flow. The oil removed by the sep-arators returns by a different path from the path of the majority of the oil in the T-Tank. It returns to the compressor through the scavenger lines, filtered but without going through the oil cooler.
Main Air System BD120149 Mechanical Systems Manual
6.2.4.7 Main Air Pressure Differential Switch 5000261 and Gauge 89Z559
This two-position manual switch is mounted on the air control panel. Changing the position of the knob causes the associated gauge to read the air pressure either before the oil separators or after the oil separators, depending on its position. Decisions regarding changing or cleaning the oil separator filter elements can be based on the differen-tial between the two readings.
6.2.4.8 Shutoff Valve R6902D4
The shutoff valve is located on the underside of the T-tank. It is used to isolate system components during mainte-nance.
6.2.4.9 Circulation Pump R56963D1
An oil circulation draws oil from the oil reservoir. Oil is pumped through the oil cooler, thermal control (thermostatic mixing) valve, main oil filter, and bearing oil filter, and discharges into the main oil gallery of the compressor. A por-tion of the oil flow is directed through internal passages to the bearings, gears, and shaft oil seal. The balance of the oil is injected directly into the compression chamber to remove heat of compression, seal internal clearances, and to lubricate the rotors.
Figure 6-18: Main Air Pressure Differential Switch and Gauge
BD120149 Mechanical Systems Manual Main Air System
The oil circulation pump is a self-contained assembly that incorporates a mounting frame, a 20 horsepower motor, coupling and gear pump rated at 150GPM. The assembly mounts horizontally between the T-tank and the house wall on the left hand platform next to the T-tank. Refer to Figure 6-20.
Pump discharge piping includes an in-line check valve to provide pump relief. A second in-line oil check valve is included to limit T-tank back-pressure. These components are positioned below the left hand platform near the pump package. Pump discharge piping parallels the outside of the house, then enters the cooler room and termi-nates at the compressor cooler inlet. A bypass line plumbs off a tee connection to the check valve located inside the cooler room. The cooler discharge piping re-enters the house and joins into the compressor oil filter.
Main Air System BD120149 Mechanical Systems Manual
6.2.4.10 Thermostatic Mixing Valve R38039D2
The thermostatic mixing valve is mounted in the fan room at the front left corner of the drill. Access to the fan room is only from the left-hand platform.
The thermostatic mixing valve has a 130°F (54°C) element. Oil moves through the valve and bypasses the cooler until the fluid temperature reaches approximately 120°F (49°C). As the temperature of the oil continues to rise, the valve slides farther open until it is fully open, porting all oil through the cooler, when oil temperature is 140°F (60°C).
BD120149 Mechanical Systems Manual Main Air System
6.2.4.11 Compressor Oil Cooler R56899F1
The compressor oil cooler is mounted on the left front of the drill. Oil from the compressor is cooled by a fan draw-ing air through cooling fins on the cooler. The fan is driven by an electric motor.
Main Air System BD120149 Mechanical Systems Manual
6.2.4.12 Compressor Oil Flow Switch COFS R29648D1
The compressor oil flow switch is mounted in the oil line just before the main compressor oil filter, to the right of the compressor. Its primary function is to indicate to the PLC that oil is flowing through the lines. During the main motor start-up sequence, the circulation pump is started. To confirm that the pump is on, the PLC monitors the flow switch. Once the flow switch closes, the PLC issues a 2-seconds delay to allow time for the oil to build pressure within the compressor. Then the main motor starts. The PLC continues to monitor the flow switch.
The compressor oil pressure switch is mounted on the air control panel. It indicates to the PLC that sufficient oil pressure exists to ensure proper compressor operation. The switch is set at 15 psi with a 7 psi differential; that is, the switch closes when oil pressure reaches 15 psi and stays closed until pressure drops below 8 psi (8 psi is the minimum operating pressure). The pressure switch is not recognized during the initial start of the main motor; how-
BD120149 Mechanical Systems Manual Main Air System
ever, during the first 5 seconds of motor operation, the PLC monitors oil flow. If the initial 5 seconds has elapsed and the pressure switch is not closed, the main motor will shut down and the GUI will register a fault.
6.2.4.14 Compressor Oil Filter R51071F1
The compressor oil filter, mounted to the right of the air compressor, removes contaminates from the recirculated oil as it returns to the compressor.
6.2.4.15 Scavenger Oil Return Filter 5000348
Oil recovered from the T-Tank oil separator returns to the compressor through the scavenger lines. Scavenger oil is filtered by a spin-on filter at the air control panel.
Main Air System BD120149 Mechanical Systems Manual
6.2.4.16 Compressor Oil Pressure Differential Switch 5000261 and Gauge 89Z559
A two-position manual switch mounted on the air control panel causes the associated gauge to read the air pres-sure either before the oil separators or after the oil separators, depending on its position. Decisions regarding changing or cleaning the oil separator filter elements can be based on the differential between the two readings.
Figure 6-27: Compressor Oil Pressure Differential Switch and Gauge
Main Air System BD120149 Mechanical Systems Manual
6.2.5.1 General
Bailing air provides sufficient quantity of air at sufficient pressure to remove rock chips and dust from the blasthole. Although the compressor is functioning the entire time the main motor is running, the air needs to be controllable so that compressed air is permitted to flow through the drill string only when required.
Refer to Figure 6-28 as the functions of the components are described in the following subsections.
6.2.5.2 Subtractive Pilot Valve 36Q577D1
After the main motor has been running for six seconds, the air compressor inlet valves open and air is compressed until a pressure of the subtractive pilot valve setting (typically 65 psig) is achieved. At that point, the subtractive pilot valve will cause the inlet valves to close again. The subtractive pilot valve continues to react to system pres-sure, and the compressor will compress air when and only when it is needed.
The function of the subtractive pilot valve is described in greater detail in Subtopic 6.2.3.4.
BD120149 Mechanical Systems Manual Main Air System
6.2.5.3 Main Air Pressure Transducer MAPT 44Q1536
The Main Air Pressure Transducer is mounted on the air control panel. Sensing before the butterfly valve, it indi-cates to the PLC that sufficient air pressure exists and the bailing air system can be used.
6.2.5.4 Bailing Air Pressure Transducer BAPT 44Q1536
The Bailing Air Transducer is mounted on the air control panel. Sensing after the butterfly valve, it indicates to the PLC the pressure of air going to the bit.
Main Air System BD120149 Mechanical Systems Manual
6.2.5.5 Main Air Pressure Switch MAPS R7090D1
The main air pressure switch is mounted on the air control panel. It closes when main air is 40 psi or greater, and opens when air pressure is 34 psi or less. When closed, it allows the butterfly valve motor control to energize.
6.2.5.6 Air Pilot Valve R56220D1
The air pilot valve is mounted on the bailing air pipe after the T-Tank. When the butterfly valve opens, pressure from the main line is piloted to the air pilot valve, which blocks the path to the muffler. When the butterfly valve closes, the pilot valve opens, allowing approximately 350 CFM of air to pass through. This valve is required to allow the compressor to still produce air flow, which is necessary to prevent the rotors inside the compressor from rum-bling. The pilot valve works in conjunction with the bypass line and Check Valve to move some air through the com-pressor.
BD120149 Mechanical Systems Manual Main Air System
6.2.5.7 Muffler 27U762D1
The muffler is clamped to the back brace support between the T-Tank and the machinery house. When the main air compressor is running and the bailing air is turned off, approximately 350 CFM exhausts to atmosphere through the muffler.
6.2.5.8 Relief Valve R6902D4
The relief valve is mounted in the T-Tank. The setting for the relief valve is calibrated at the factory. At that time, the valve is preset and a tag is attached to the valve that contains the calibration numbers. No field adjustment is required.
Main Air System BD120149 Mechanical Systems Manual
6.2.5.9 Butterfly Valve R51305D1
The butterfly valve is mounted in the bailing air pipe between the relief valve and the dump valve. It features an electric actuator that is controlled through the PLC by a switch on the operator’s console. In order for the switch signal to be active, the Main Air Pressure Switch must be closed (i.e., main air pressure must be at least 40 psi).
Figure 6-36: Butterfly Valve with Electric Actuator
BD120149 Mechanical Systems Manual Main Air System
6.2.5.10 Dump Valve GH5000369
This is a normally open, pressurize to close check valve. When pressure from the main air system acts on the valve, the valve closes. When the pressure is removed, the valve opens to allow air to exhaust without going through the drill string.
6.2.5.11 Water Injection
Water is injected into the air stream when the operator turns on the function on the operator’s console. The amount of water varies from 0 to 5 GPM. Refer to Section 16, Water Injection System for a detailed description.
Main Air System BD120149 Mechanical Systems Manual
6.3 Main Air System Components
6.3.1 Main Compressor Air Cleaner 46Z534
Service the main compressor air cleaner when necessary, as follows:
1. Shut down the main motor.
2. Remove primary element by removing attaching hardware.
3. Check the status of the safety element restriction indicator, which is part of the safety element retaining nut. Replace the safety element only if the indicator on the wing nut shows red. Reset the wing nut indicator by applying suction in accordance with the instructions on the wing nut.
BD120149 Mechanical Systems Manual Main Air System
CAUTIONFilter damage will result if the air pressure is too high or if the air nozzle is held too closeto the filter. Follow instructions to avoid damage to the filter element. Clean the elementsaway from the compressor, such as outside the machinery house or in a shop, to avoidcontaminating the safety element (or the compressor inlet, if the safety element hasbeen removed).
5. Clean primary element using compressed air on the pleated paper inside the element. Keep the air nozzle at least one inch from the pleated paper while rotating the element. Air pressure must not exceed 100 psi (6.9 bar).
6. Inspect the cleaned element by holding a light bulb inside it. Rotate the element slowly and inspect for damage. If the element is ruptured or has holes or gasket damage, replace it. Primary element can be cleaned up to six times if care is used. However, inner (safety) element should never be cleaned. Replace the safety element instead of cleaning it. Always replace safety element after three cleanings of primary element, more often if necessary.
7. Remove the primary body and clean either by using compressed air or by washing the tubes out with water.
8. Check the condition of the wing nut indicator. If the center has changed
9. Install parts in reverse order of removal, start the motor and see that the vacuum switches do not actuate.
Main Air System BD120149 Mechanical Systems Manual
6.3.2 Main Air Compressor 51U165D4
The main air compressor (Figure 6-39) is a single-stage, positive-displacement rotary machine using two meshing helical rotors to effect compression. The compressor is protected against dust contamination by a pair of two-stage air filters, which are attached to the air inlet valves. The compressor is ported to accept an external, re-circulating supply of oil for cooling and lubrication.
Figure 6-39: Main Air Compressor
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06. Inlet Valves07. Air Cleaner Support Bracket08. Air Cleaner Filters09. Bearing Oil Filter10. Main Motor
Main Air System BD120149 Mechanical Systems Manual
WARNING!
Working on or near rotating machinery while in operation is hazardous and can result inthe injury or death of personnel. Shut down the main air compressor, and use lockout/tagout procedures prior to starting any service on the machinery.
1. Lock out and tag the high-voltage main circuit breaker switch to prevent operation of the main drive motor dur-ing disassembly.
CAUTION!
Pressurized oil will spray with extreme force from oil line fittings when being loosened,and can cause severe injury. Slowly release air pressure or vent the T-Tank before loos-ening any oil line fittings. Wear appropriate face, ear, and body protective devices whileopening pressurized systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will self-vent through the pilot air valve and out the main air system muffler in approximately 2 minutes when the main air compressor is not operating and all con-trols are in the OFF position.
3. Tag and disconnect the oil pressure hose that is connected to the main oil filter flanged connection port on the compressor housing. This hose leads from the main oil filter element differential pressure test valve, which is mounted on the air control panel.
4. Disconnect the wires from the oil filter indicator, air filter indictors, and temperature probe.
Figure 6-41: Legend for Figure 6-40
LEGEND01. Nut02. Band03. Capscrew04. Air Cleaner05. Service Indicator06. Bracket07. Hose Clamp08. Hose09. Tube10. Capscrew11. Lockwasher12. Inlet Manifold13. Gasket14. Inlet Manifold15. Capscrew16. Lockwasher17. Oil Filter18. Filter Gasket19. Nut20. Capscrew21. Shim Set
BD120149 Mechanical Systems Manual Main Air System
5. Disconnect the compressor oil filter from the compressor housing by removing the capscrews, lockwashers, and gasket. Discard the used gasket.
CAUTIONCap or plug all open oil lines to prevent entry of contaminants and dirt, and also to pre-vent spillage of oil.
6. Tag and remove the oil return line from the air-oil separator to the housing of the compressor air inlet valve(s).
7. Tag and remove the two hydraulic hoses attached to each compressor inlet valve from the low pressure hydraulic system.
8. Tag and remove the air pilot piping from the subtractive pilot valve and low-torque start-up circuits to the two inlet air valves.
9. Disconnect the air discharge pipe from the compressor by removing the eight bolts holding the compressor and pipe flanges together. Discard the used flange gasket.
10. Remove the two air inlet tubes that connect the air cleaner filters with the compressor inlet valves. Loosen hose clamps and slide hose sections onto the air inlet tubes.
11. Open house roof (if the mast is vertical) to allow components to be hoisted in and out.
12. Attach suitable hoisting equipment to the air cleaner support bracket during its removal from the compressor assembly. Unbolt and remove the bracket from the motor mount adapter flange and the inlet valve manifold flange. The two air cleaner filters can remain assembled to the bracket.
13. Attach suitable hoisting equipment to the inlet valve manifold, remove the 12 capscrews and lockwashers from the inlet manifold/compressor mounting flange, then remove the inlet manifold and manifold gasket from the top of the compressor. The two inlet valves need not be disassembled from the manifold.
14. Remove the adapter cover from each side of the compressor motor adapter to expose the drive coupling.
15. Disconnect adapter from the compressor by removing the eight capscrews, nuts, lockwashers, and the two taper pins from the compressor-side flange.
16. Disconnect the compressor from the power unit base by removing the four cap screws and lockwashers that fasten the compressor feet and shims to the base. Match mark the shims for later re-assembly.
CAUTION!
Incorrect lifting of the compressor can cause serious injury or property damage. Be cer-tain lifting rigging is secure and the hoist is of sufficient capacity before attempting thelift. (Weight of the bare compressor is approximately 4,000 pounds (1814 kg).
17. Using a suitable lifting device, lift the compressor enough to take most of the weight off the feet. Carefully slide the compressor axially away from compressor motor adapter to disengage the two halves of motor drive cou-pling.
18. Remove the flexible insert from motor drive coupling.
Main Air System BD120149 Mechanical Systems Manual
19. Lift the bare compressor from the power unit base, and place it on secure wooden supports.
20. Loosen the motor drive coupling set screw, and use a suitable gear puller to remove the coupling from the compressor input shaft.
21. Remove the coupling key from the compressor input shaft with a soft drive plug.
6.3.2.2 Repair
Repair of the main air compressor requires special tools, test equipment, and experience to be performed correctly. Whenever the main air compressor requires repair or overhaul, contact your P&H MinePro Services representa-tive.
6.3.2.3 Installation
Install the compressor on the compressor base and interconnect it into the system as described below. Refer to Figure 6-40 for identification and location of components.
1. Remove any nicks or burrs from the compressor input shaft keyway and drive coupling key, then install the key into the keyway. Be certain that the key is firmly seated on the bottom of the keyway, and that the key fits snugly in the keyway.
2. Heat the compressor half of drive coupling (refer to Figure 6-42) in oil, or an electric oven, to 350°F (177°C). Allow sufficient time for the heat to thoroughly penetrate the half-coupling, then install it on the compressor input shaft.
3. Position the end of the compressor input shaft even with the bottom of the counterbore in the half-coupling, then tighten the set screw onto the key, and allow the half-coupling to cool.
4. When the half-coupling has cooled, remove the set screw, apply a coating of Loctite to the threads, then install and tighten the set screw securely.
5. Install the flexible insert for drive coupling onto the motor half of the coupling.
6. Position the four shims on the power unit base where the compressor feet are to be located.
BD120149 Mechanical Systems Manual Main Air System
WARNING!
Incorrect lifting of the compressor can cause serious injury or property damage. Be cer-tain that lifting rigging is secure and the hoist is of sufficient capacity before attemptingthe lift. Weight of the bare compressor is approximately 4,000 pounds (1850 kg).
7. Attach a suitable lifting device, and move the compressor into approximate mounting position over the power unit base.
8. Lower the compressor until it almost touches the shims, then push the compressor axially toward the motor until the drive coupling halves engage.
NOTICE
The motor shaft may need to be rotated and the elevation of the compressor may need to beadjusted with the hoist to accomplish engagement of the coupling halves.
9. Push the compressor mounting flange and compressor adapter flange together and fasten loosely with eight capscrews, lockwashers, and nuts.
10. Install two taper pins in the compressor mounting/motor adapter flanges, then torque the capscrews and nuts securely.
11. Install four capscrews and lockwashers through the compressor mounting feet and shims, then tighten securely.
12. Working through the access openings in compressor motor adapter, check the axial position of the drive cou-pling halves with a feeler gauge to confirm the 0.13" (3.302 mm) gap between faces (refer to Figure 6-42). If the gap is not within 0.020" (0.508 mm) of 0.13" (3.302 mm), the compressor must be removed from the base, and the half coupling position on the compressor input shaft must be adjusted accordingly. Then re-install the compressor in accordance with Steps 7 through 12.
13. Install the two adapter covers on the compressor motor adapter with cap screws and lockwashers.
14. Attach suitable hoisting equipment to the inlet valve manifold, and install the compressor inlet valve manifold and two inlet valves, as a subassembly, onto the top of the compressor. Install with a new flange gasket and torque the 12 mounting bolts and lockwashers securely.
15. Attach suitable hoisting equipment to the air cleaner support bracket, including the two air cleaner filters, and hoist the subassembly into place for installation. Install the bracket by bolting it to the compressor-side flange of the compressor motor adapter and the inlet valve manifold flange on the compressor.
16. Close the roof after the last heavy piece has been placed.
17. Position one of the air inlet tubes between an inlet valve and an air cleaner filter and slide a hose onto the inlet manifold. Slide the opposite hose onto the air filter. Adjust the engagement of hoses on the tube, manifold, and air filter so there is sufficient overlap for clamping; Fasten hoses in position with hose clamps. Repeat this step for the other tubing assembly.
18. Install main oil filter assembly to the mounting flange of the compressor with four capscrews and lockwashers. Install the filter assembly with a new gasket.
Main Air System BD120149 Mechanical Systems Manual
19. Install the compressor air discharge pipe to the compressor with eight bolts, lockwashers, and nuts. Install a new gasket in the flange assembly.
20. Install the air piping from the subtractive pilot valve and low-torque start-up circuits to the two inlet air valves.
21. Install the two hydraulic hoses from the low pressure hydraulic system to each compressor inlet air valve.
22. Install the oil return line from the air-oil separator to the housing of the compressor air inlet valve(s).
23. Install the oil pressure hose assembly from the main oil filter element differential pressure test valve onto the flanged main oil filter connection port of the compressor.
24. Connect wires that were removed earlier.
CAUTIONCheck that the oil level in the compressor T-Tank reservoir is at the correct fill level priorto starting the main air compressor.
BD120149 Mechanical Systems Manual Main Air System
6.3.3 Compressor Inlet Valves
6.3.3.1 Removal
In most cases, it is possible to service the inlet valve assemblies without removing them from the compressor. If it is desirable or necessary, either inlet valve assembly can be removed from the compressor as follows (refer to Fig-ure 6-43):
Figure 6-43: Compressor Inlet Valve Assembly
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Main Air System BD120149 Mechanical Systems Manual
WARNING!
Working on or near rotating machinery while in operation is hazardous and can result inthe injury or death of personnel. Shut down the main air compressor, and use lockout/tagout procedures prior to starting any service on the machinery.
1. Lock out and tag the high-voltage main circuit breaker switch to prevent operation of the main air compressor drive motor during service on the machinery.
2. Remove the air inlet tube, which connects the air filter with the compressor inlet valve, and the other hose assemblies connected to the inlet valves. Refer to Subtopic 6.3.3.1, for procedures.
CAUTION!
Incorrect lifting of the valve assembly can cause serious injury or property damage. Becertain lifting rigging is secure and the hoist is of sufficient capacity before attemptingthe lift.
3. Attach a suitable hoist to the inlet valve assembly to be removed, then remove the capscrews, lockwashers, and nuts holding the valve assembly onto the inlet valve manifold, and lift the valve assembly away from the compressor.
6.3.3.2 Disassembly
Refer to Figure 6-43 and disassemble the inlet valve assembly as follows:
1. If the valve assembly has been removed from the compressor, position and clamp the assembly, with the outlet flange side down, on sturdy blocking.
CAUTION!
Removal of the cylinder cap bolts without using spring retainers will enable the cap torapidly release resulting in the injury of personnel and damage to equipment. Attachsuitable spring retainers before removing all of the cylinder cap bolts.
2. Remove the spring loaded cylinder cap as follows:
A. Remove two cylinder cap bolts located 180" apart, and install two studs in the threaded bolt holes.
B. Install two nuts on the studs, and position the, finger tight, against the cylinder cap.
C. Remove the remaining cylinder cap bolts.
D. Loosen the nuts on the studs uniformly until the spring compression is completely released, then remove the studs.
3. Remove the cylinder cap and cylinder cap gasket. Discard the gasket.
4. Pull the piston and piston spring from the bore of the cylinder.
BD120149 Mechanical Systems Manual Main Air System
Technician Tip
If the piston is seized or stuck inside the cylinder, it will be necessary to remove the cylinderfrom the inlet housing. This will enable application of force from the back side to move the pis-ton out of the bore.
5. Remove the eight capscrews and lockwashers that retain the cylinder to the housing, then pull the cylinder and cylinder gasket from the housing. Discard the cylinder gasket.
6. Remove the inlet valve assembly and the valve spring from inside the inlet valve housing.
6.3.3.3 Repair
Clean the components of the inlet valve assembly thoroughly. See Appendix A of this manual for general instruc-tions and precautions regarding the cleaning of components.
Inspect the components of the inlet valve assembly as follows:
1. Inspect the housing and cylinder bores for nicks, burrs, scratches or cracks.
2. Inspect the piston and inlet valve for nicks, burrs, scratches or cracks. Also check for broken piston ring land areas.
3. Inspect the piston rings for wear, cracks and loss of spring compression.
4. Inspect the springs for worn or broken coils and loss of compression force.
5. Inspect the cylinder cap for nicks, burrs, scratches and distortion.
6. Inspect the pipe and straight threads on all parts for cleanliness and damage.Replace all defective parts if sig-nificant damage or wear is found. Dress down all burrs, nicks and scratches with a fine file or emery cloth. All gaskets should be replaced.
6.3.3.4 Assembly
Refer to Figure 6-43 and assemble the components of the inlet valve assembly as follows:
1. Insert the shaft of the inlet valve into the small bore end of the cylinder, and position the cylinder flange-end up on top of the inlet valve disc.
2. Install the valve spring into the counterbore of the inlet valve shaft.
3. Position the piston spring over the spring guide in the bottom of the cylinder.
4. Install the piston rings in the grooves of the piston. Position the ring gaps so that they are approximately 180° apart.
5. Lubricate the bore and OD of the piston and rings with compressor oil, then install the piston into the cylinder with the valve spring guide entering first. Assure that the spring guide enters the valve spring.
Main Air System BD120149 Mechanical Systems Manual
Technician Tip
Use a piston ring compressor to insert the piston into the bore. Do not use sharp objects suchas screwdrivers to aid in compressing the piston rings. Do not use excessive force to insert thepiston rings into the cylinder bore. Compress each ring as it enters the lead-in taper at the top ofthe cylinder.
6. Place a new flange gasket on the cylinder, and install the cylinder in the inlet valve housing. Torque the eight capscrews and lockwashers evenly to uniformly compress the gasket.
7. Install the cylinder cap with a new gasket as follows:
A. Install two temporary studs, positioned 180° apart, in the cylinder cap bolt holes.
B. Install the cylinder cap and new gasket over the studs, and position them against the piston.
C. Install a nut on each stud and position them against the cylinder cap.
D. Tighten the nuts uniformly until the cap and gasket are in position against the cylinder flange, then install four cylinder cap bolts finger tight.
E. Remove the two temporary studs and nuts and install the remaining cylinder cap bolts finger tight.
F. Torque the cylinder cap bolts uniformly to avoid distorting the cap and to uniformly compress the gasket.
8. Confirm that the valve spring will freely move the inlet valve disc to its seat in the housing when the inlet valve is in normal operating position. It is important that the disc seats completely, because it is the only device to prevent back-flow of oil from the compressor into the inlet filters.
6.3.3.5 Installation
Install the inlet valve assemblies as follows:
CAUTION!
Incorrect lifting of the valve assembly can cause serious injury or property damage. Becertain lifting rigging is secure and the hoist is of sufficient capacity before attemptingthe lift.
1. Attach a suitable hoist to the inlet valve assembly, lift it from the work area, and position it for installation over the inlet valve manifold.
2. Place a new gasket in the correct position on top of the inlet manifold, and slowly lower the valve assembly onto the top of the gasket.
3. Secure the inlet valve assembly to the manifold with capscrews, lockwashers, and nuts. Torque the bolts evenly with a crosswise pattern to uniformly compress the gasket.
4. Install the air inlet tube, and the other hose assemblies that attach to the air inlet valves, in accordance with Subtopic 6.3.2.3.
BD120149 Mechanical Systems Manual Main Air System
6.3.4 T-Tank R55420F1
The T-Tank is a pressure vessel that serves two functions within the main air system. Its first function is to provide reservoir space for oil that is circulated through the compressor. The second function is to contain the air-oil sepa-rator which removes the oil mist that remains entrained in the air flow after passing through the reservoir section of the T-Tank.
The T-Tank is mounted on a platform on the left side of the drill, outside the machinery house (Figure 6-44). It is located directly behind the main power transformer. Two oil separators extend vertically from the horizontal lower part of the T-Tank.
A flanged port located near the bottom of the T-Tank is used to connect piping for circulating oil from the T-Tank, through the cooler and main oil filter, then into the compressor. The air-oil separators (Figure 6-45) each have two filter elements that remove the remaining oil mist from the air stream. Oil that is stripped by the outer oil separator element drains by gravity into the T-Tank. The oil that becomes trapped between the outer and the inner element,
Figure 6-44: T-Tank (on Left Hand Platform)
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LEGEND01. Sight Tube02. Fill Plug03. Oil Separators04. Main Air Pipe05. Sling Lift Point
06. Union07. Safety Relief Valve08. Air Pilot Valve09. Air/Oil Reservoir10. Compressor Oil Temperature Probe11. Shutoff (Drain) Valve
Main Air System BD120149 Mechanical Systems Manual
and also at the center of the inner element, is forced by air pressure into oil pickup scavenger tubes and is circu-lated directly back to the compressor.
An outlet in the separator cover is connected to the main air delivery and control piping. Other fittings on the T-Tank include an oil fill port, a tank drain and thermocouple port, pilot air pressure port, oil level sight tube, and a tank inspection port.
The T-Tank does not need to be removed from the drill for service of its components. The only components requir-ing periodic maintenance and/or replacement are the oil level sight-tube and the two filter elements in each of the oil separators. These components are not repairable and should be replaced if they show signs of failure. Proce-dures for replacement of these components follow:
6.3.4.1 Replace Oil Separator Elements GH5010587, GH5010588
Refer to Figure 6-44 and replace the filter elements inside the oil separator as follows:
BD120149 Mechanical Systems Manual Main Air System
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
CAUTION!
High pressure hydraulic or air systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits beforeloosening fittings or connections. Wear appropriate face, ear, and body protectivedevices while venting air or hydraulic systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will vent through the main air system muffler when the main air compressor is not running and the controls are de-energized.
3. Thoroughly clean the air-oil separator flange and fittings to remove any dirt that could fall into the T-Tank when the separator cover and other fittings are opened.
4. Tag and remove the hose assembly on top of the oil separator cover that connects to the scavenger tubes.
Technician Tip
It is not necessary to remove the fittings or interconnecting tubing from the oil separator cover.
5. Tag and remove the upstream pressure tap hose assembly on top of the oil separator cover.
6. Remove hose from the safety relief valve.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can injure personnel and/or damage equipment. Use suitable slings and hoisting equipment to stabilize and liftheavy objects.
7. Attach suitable hoisting equipment to the main air pipe assembly, and carefully take up the slack.
8. Remove nuts, lockwashers, and capscrews that attach main air pipe flange to the oil separator cover, and lift the main air pipe assembly from the T-Tank.
9. Remove and discard gasket.
10. Attach a suitable hoist to oil separator cover, remove capscrews and lockwashers from the separator cover, then lift the separator cover and attached inner separator element from the T-Tank. Lift the cover straight up when removing it from the T-Tank to avoid damaging the separator element.
Main Air System BD120149 Mechanical Systems Manual
11. Remove outer separator element from the T-Tank. Discard the element in a suitable container, and cover the T-Tank opening to prevent entry of dirt.
12. Remove capscrews, lockwashers, retainer, and inner separator element from oil separator cover. Discard the element in a suitable container.
13. Clean away any deposits from inside the T-Tank and from the mounting surfaces of oil separator cover.
14. Inspect scavenger tubes for signs of deterioration or plugging. Replace as necessary.
15. Inspect the insert (Item 10, Figure 6-45) to be sure it is positioned correctly. The cut-out at the bottom must face the front of the drill away from the 6" inlet pipe.
CAUTION!
Staples on the element gaskets eliminate static electricity, which could cause the oil toflash, resulting in personal injury and/or property damage. Do not remove the staplesfrom the element gaskets.
16. Inspect the element gasket to ensure that the staples are in place.
17. Install new inner separator element to oil separator cover assembly with retainer, capscrews, and lockwashers. Position inner scavenger tube so that it rests on the bottom plate of the inner element.Install a new outer sepa-rator element into the top of the T-Tank. Align the holes in the element cover with those of the T-Tank flange.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can injure personnel and/or damage equipment. Use suitable slings and hoisting equipment to stabilize and liftheavy objects.
18. Attach suitable lifting equipment to separator cover assembly, and position on top of outer element flange on the T-Tank. Be sure outer scavenger tube is correctly positioned at the bottom of the outer element. Position the holes in the separator cover to align with the holes in the outer element flange.
19. Install oil separator cover to the T-Tank flange with capscrews and lockwashers. Torque the capscrews evenly in a crisscross pattern to uniformly compress the outer element flange.
20. Attach suitable lifting equipment to air inlet nozzle, and position the flange above the mating flange on top of separator cover assembly.
21. Install main air pipe to separator cover assembly with capscrews, lockwashers, nuts, and a new gasket. Do not tighten the nuts at this time.
22. Align the opposite end of air pipe with manifold and couple with union. Tighten the union securely, then uni-formly tighten the nuts at the flange end of the air inlet nozzle.
23. Install the hose assembly to the scavenger tube fitting on top of oil separator cover.
24. Install the upstream pressure tap hose assembly on top of oil separator cover.
BD120149 Mechanical Systems Manual Main Air System
25. Check the level of compressor oil in the T-Tank, and fill as necessary.
26. Ensure the T-Tank shut-off valve is open and there are no leaks. Refer to Figure 6-46.
27. Start the main air system and check the T-Tank for leaks.
6.3.4.2 Oil Level Sight Tube R25778D1
The oil level sight-tube is installed on the side of the T-Tank. Replace the sight-tube assembly as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
CAUTION!
High pressure hydraulic or air systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits beforeloosening fittings or connections. Wear appropriate face, ear, and body protectivedevices while venting air or hydraulic systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will vent through the main air system muffler when the main air compressor is not running and the controls are de-energized.
Main Air System BD120149 Mechanical Systems Manual
CAUTIONBe sure to thoroughly clean the areas around the tank drain cock and the oil level sight-tube before draining down the T-Tank. Close clearances between running components inthe compressor will not survive abrasive dirt in the oil.
3. Drain the oil in the reservoir so that the level of the remaining oil is below the lowest part of the sight tube assembly. Drain the oil into a suitable, clean container so that the oil can be salvaged and re-used.
4. Loosen the compression nuts on the top and bottom 90 degree tube fittings, then bend the plastic sight-tube enough to remove the tube from the compression fittings.
5. Coat the male pipe threads on the fittings with pipe thread sealant before installation.
6. Position compression nuts and new ferrules on each end of the replacement sight tube, and insert the tube ends into the 90 degree tube fittings. Use care when bending the tube for insertion that the tube does not become creased.
7. Tighten the compression nuts to seal and retain the tube.
8. Fill the reservoir with compressor oil to the correct level for operation.
6.3.5 Circulation Pump R56963D1
The circulation pump is used to ensure a flow of oil through the main air compressor during start-up, as well as when the compressor is running and the bit air flow is turned off. The pump system is connected in the compressor oil circulation circuit. In addition to the low pressure pump and electric motor, the system includes a pressure relief which is an integral part of the pump assembly.
The circulation pump is mounted on the left hand platform between the T-Tank and the machinery house wall.
6.3.5.1 Removal
Remove the pump from the oil circulation circuit as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operators controls. Lock out andtag the operators control to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during pump removal.
CAUTION!
High pressure hydraulic or air systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits before
BD120149 Mechanical Systems Manual Main Air System
loosening fittings or connections. Wear appropriate face, ear and body protectivedevices while venting air or hydraulic systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will vent through the main air system muffler when the main air compressor is not running and the controls are de-energized.
3. Close the shutoff valve, located in the oil discharge piping below the T-Tank.
4. Clean all dirt from the area around the pump and hoses.
5. Tag and disconnect the suction and pressure hoses from the circulation pump. Cap or plug the hose fittings and pump ports to prevent the entry of contaminants.
6. Remove wires from the motor junction box.
7. Remove the four capscrews and lockwashers from the pump feet and use a suitable lifting device to remove the pump.
8. Tag and remove the hose adapters and pipe fittings from the pump ports.
6.3.5.2 Cleaning, Inspection And Repair
Clean and inspect the oil circulation pump in accordance with the general cleaning and inspection procedures described in Appendix A of this manual.
Inspect the pump for wear, housing cracks and leaks. If any leaks or cracks are found, replace the pump; it is not field repairable.
6.3.5.3 Installation
Install the oil circulation pump as follows:
1. Coat the male pipe threads with pipe thread sealant and install the pipe fittings and hose adapters in the suc-tion and pressure ports of the pump. Position the fittings for ease of connection to the hoses.
2. Install the pump assembly with four capscrews and lockwashers.
3. Connect the suction and pressure hoses to the pump fittings.
4. Connect wires.
5. Open the shut-off valve located in the oil discharge piping below the T-Tank.
6. Check the oil level in the T-Tank. Add oil as necessary.
7. Operate the system and check for leaks. Also check pump rotation (the pump must turn clockwise when viewed from the motor fan). The circulation pump is non-adjustable.
Main Air System BD120149 Mechanical Systems Manual
6.3.6 Compressor Oil Cooler R56568D1
6.3.6.1 Removal
Remove the compressor oil cooler from the system as follows (refer to Figure 6-47):
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent start-up of the hydraulic systems and air systems during maintenance activities.
CAUTION!
High pressure hydraulic or air systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits beforeloosening fittings or connections. Wear appropriate face, ear, and body protectivedevices while venting air or hydraulic systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will vent through the main air system muffler when the main air compressor is not running and the controls are de-energized.
3. Turn the shut-off valve located at the bottom of the T-Tank to closed position
BD120149 Mechanical Systems Manual Main Air System
Technician Tip
.Detach the cable reel support bar and lower the reel to provide some working room.
CAUTION!
Disassembling heavy components with inadequate hoisting apparatus can injure per-sonnel and/or damage equipment. Use suitable slings and hoisting equipment to stabi-lize and lift heavy objects.
4. Attach suitable hoisting equipment to the cooling air louver and take up the slack in the slings.
5. Tag and disconnect the hose assemblies from the hydraulic oil cooler assembly. Collect any fluid that leaks from the hoses and fittings in a suitable container. Cap or plug the open end of the hose and the cooler ports to prevent entry of dirt.
6. Loosen and remove the pipe cap on top of the compressor oil cooler assembly.
7. Loosen and remove the drain plug at the bottom of the compressor oil cooler, and drain all of the oil into a suit-able container for disposal.
8. Tag and disconnect the hose assemblies from the compressor oil cooler assembly. Collect any fluid that leaks from the hoses and fittings in a suitable container. Cap or plug the open end of the hose and the cooler ports to prevent entry of dirt.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can injure personnel and/or damage equipment. Use suitable slings and hoisting equipment to stabilize and liftheavy objects.
9. Attach a suitable hoist to the cooler to provide support while the fasteners are removed.
10. Remove the capscrews, washers, and nuts which fasten the cooler to the shroud assembly, then lift the cooler away from the shroud.
11. Disassemble the hose fittings from the cooler.
Main Air System BD120149 Mechanical Systems Manual
6.3.6.2 Cleaning, Inspection, and Repair
Clean and inspect the compressor oil cooler in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. Inspect the cooler for cracks, leaks, and/or damaged fins. The cooler assembly is not field repairable, and therefore must be replaced with a new or reconditioned cooler if it is damaged or leaking.
6.3.6.3 Installation
Install the compressor oil cooler as follows:
1. Apply pipe thread sealant to the pipe threads of the hose adapters, and install the adapters in the inlet and out-let ports of the cooler. Tighten the adapters so the hose connection ends will couple easily with the hoses when the cooler is installed.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can injure personnel and/or damage equipment. Use suitable rigging and hoisting equipment to stabilize and liftheavy objects.
2. Attach a suitable hoist to the compressor oil cooler assembly, and lift the cooler to its mounting position. Leave the hoist in place until the fasteners have been installed.
3. Install the compressor oil cooler to the cooler shroud with capscrews, washers, and nuts. Torque the nuts securely.
4. Install the inlet and outlet oil hoses to the bottom of the cooler.
5. Be sure the drain plug at the bottom of the cooler is sealed and tightened.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can injure personnel and/or damage equipment. Use suitable slings and hoisting equipment to stabilize and liftheavy objects.
6. Attach suitable hoisting equipment to the cooling air louver and install the louver on the oil cooler shroud with capscrews, lockwasher and nuts.
7. Add compressor oil to the T-Tank reservoir as necessary to replace the oil lost during cooler replacement.
8. Return the cable reel to its operating position (if it was lowered) and secure.
9. Confirm that the T-Tank shut-off valve is in the open position.
BD120149 Mechanical Systems Manual Main Air System
6.3.7 Thermostatic Mixing Valve R38039D2
The thermal mixing valve is used to control temperature of the compressor oil in the oil cooling system. The ele-ments are so designed that a portion of the oil is flowing through the oil cooler at all times. On start-up with the unit cold, the elements are open to the by-pass, allowing oil to pass directly from the T-Tank to the compressor during warm-up. As the oil warms, the elements gradually close the bypass flow, causing more oil to flow through the cooler. After the main air system is at normal operating temperature, the mixing valve maintains compressor dis-charge temperature.
Figure 6-48: Themostatic Mixing Valve
LEGEND01. O-ring02. Capscrew03. Lock Washer
04. Sleeve05. Bolt-in Seat06. Flange Gasket07. Element
Main Air System BD120149 Mechanical Systems Manual
6.3.7.1 Removal
Refer to Figure 6-49 and remove the thermal mixing valve from the oil cooling circuit as follows):
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
BD120149 Mechanical Systems Manual Main Air System
CAUTION!
High pressure hydraulic or air systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits beforeloosening fittings or connections. Wear appropriate face, ear, and body protectivedevices while venting air or hydraulic systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will vent through the main air system muffler when the main air compressor is not running and the controls are de-energized.
3. Match mark the three flanges that mate with the flanges on the thermal mixing valve for subsequent assembly.
4. Close the shut-off valve at the bottom of the T-Tank to prevent oil drainage from the tank while the system is open.
5. Slowly loosen and remove the capscrews, lockwashers, and nuts from the mixing valve flanges. Separate the flanges, then remove and discard the flange gaskets. Collect any oil leaking from the open flanges in a suitable container for disposal.
6. Plug the open fittings to prevent entry of dirt.
7. Lift the thermal mixing valve out of the valve support.
6.3.7.2 Disassembly
Refer to Figure 6-50 and disassemble the thermostatic mixing valve as follows:
1. Remove the four capscrews that retain the housing cover to the valve housing, then remove the cover and hous-ing gasket. Discard the used gasket.
Main Air System BD120149 Mechanical Systems Manual
2. Remove the two thermostatic elements with the element O-rings and O-ring sleeves.
6.3.7.3 Cleaning, Inspection, And Repair
Clean and inspect the compressor oil cooler in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. Check the elements for correct operation by heating them in oil. They should be fully open at 10°F above their rating.
None of the thermal mixing valve components are repairable. See the LinkOne electronic parts manual for compo-nent identification. Provide the following new components for assembly:
• Two thermostatic elements.
• Two element O-rings.
• Two O-ring sleeves.
• One housing O-ring.
6.3.7.4 Assembly
Refer to Figure 6-50 and assemble the thermostatic mixing valve as follows:
1. Install the two sets of O-rings and O-ring sleeves on the two thermostatic elements.
2. Install the elements in the valve housing. Make sure that the elements are correctly seated.
3. Position the new housing O-ring on the cover flange, then install the housing cover with four capscrews. Torque the capscrews evenly to obtain uniform compression of the gasket.
6.3.7.5 Installation
Install the thermostatic mixing valve in the cooler circuit as follows:
1. Position the thermal mixing valve in the valve support bracket. Be sure to match the flange locations with the assembly match marks on the mating pipe flanges.
2. Install new flange gaskets, and install the three pipe flanges to the thermal mixing valve with capscrews, lock-washers, and nuts. Torque the capscrews evenly to obtain uniform compression of the gaskets.
3. Open the shut-off valve at the bottom of the T-Tank.
4. Add oil to the T-Tank to make up for the oil lost during disassembly.
BD120149 Mechanical Systems Manual Main Air System
6.3.8 Compressor Oil Filter, R51071F1
The main compressor oil filter is located to the right of the main air compressor. It has several indicators to help determine when the filter needs to be changed.
• For element changes based on time, refer to Section 17, Preventive Maintenance.
• Refer to Figure 6-52. Change the element in the main compressor oil filter when the filter indicator indicates in the CHANGE FILTER area.
• A pressure differential valve on the Main Air Control Panel allows monitoring of the condition of the filter ele-ment. Change the filter if the pressure differential exceeds 8 psi.
• The GUI will register a fault if the filter element needs to be changed.
Main Air System BD120149 Mechanical Systems Manual
The element should be changed when indicated by any of the above monitoring systems. To change the main com-pressor oil filter element, refer to Figure 6-53 and proceed as follows:
WARNING!
Inadvertent machine movement can cause injury or death. Do not perform maintenancework on a machine without first disabling the operator controls. Lock out and tag theoperator controls to prevent inadvertent machine operation while performing manuallubrication tasks.
Figure 6-53: Changing Main Compressor Oil Filter
LEGEND01. Visual Indicator02. Seal Kit03. Bleed Valve04. Nut Kit05. Nut Retainer Kit06. Electric Indicator07. Sending Unit08. Fill Plug and O-ring09. Head O-ring10. Baffle11. Cup Seal12. Bypass Valve13. Bypass Indicator O-ring14. Filter Element15. Bypass Spring16. Drain Plug
BD120149 Mechanical Systems Manual Main Air System
1. Lock out and tag out the operators controls to prevent inadvertent drill operation.
2. If the filter indicator is in the red CHANGE FILTER position or if it has been more than 160 hours of operation since the last filter element change, change the element as follows:
CAUTION!
Pressurized oil will spray with extreme force from the compressor main oil filter whenbeing loosened, and can cause severe injury. Slowly release air pressure or vent the T-Tank before loosening the filter canister. Wear appropriate face, ear, and body protectivedevices while opening the canister.
A. Vent any residual air from the T-tank.
B. Remove the drain plug and drain the oil into a pail.
CAUTIONDo not remove the filter element from the housing until all the oil has drained to preventunfiltered oil from contaminating the filtered compressor oil
C. Remove filter head by rotating handle counterclockwise until the head is free of housing. Carefully place the filter head to the side to avoid damaging the sensor.
D. Hold baffle down and push down on indicator assembly to be sure it moves freely up and down within the baffle.
E. Remove baffle and check the bore for nicks. Smooth the bore if necessary and replace seal if it is damaged.
F. Remove element from housing. Remove indicator assembly from the element using a screwdriver between the indicator assembly and the element cap and carefully prying downward. Inspect O-ring and replace it with a new, oiled O-ring if necessary.
G. Remove O-ring from head and replace it if necessary. Clean the O-ring area of the head, lubricate a new O-ring with oil and reinstall the O-ring in the head.
H. Install indicator assembly into new element. Place the element into housing being sure the large diameter of spring contacts the new element. Install baffle.
I. Place head on housing and turn handle clockwise until it is hand tight. Do not exceed 20 ft-lb (26 Nm).
J. If leakage appears around handle, remove snap ring and remove the handle from the head. Discard O-ring. Coat a new O-ring with oil and reassemble the unit with the new O-ring.
To ensure unrestricted flow of oil to the main compressor, the oil filter assembly must be serviced at regular inter-vals. To determine when the filter media needs replacing, an indicator has been built into the body of the main com-pressor oil filter assembly. Change the filter before the indicator reads “CHANGE FILTER”.
The main compressor oil filter is flange mounted to the oil return port on the main compressor. Check this indicator once each week or every 40 hours of operation.
The element must be replaced when the top of the indicator on the filter is in the red “Change Filter” half of the win-dow (refer to Figure 6-52). The compressor must be running and the oil at operating temperature for the indicator
Main Air System BD120149 Mechanical Systems Manual
to read accurately. Check the indicator with a bright light to be certain of the indicator position. Some lubricants will obscure the indicator.
If the filter indicator is in the red “Change Filter” zone, or if there are filter faults on the GUI, the filter element must be replaced.
6.3.9 Subtractive Pilot Valve, 36Q577D1
6.3.9.1 Description
The subtractive pilot is a spring-loaded diaphragm pressure regulator, which is used to control operation of the compressor inlet valve, after the compressor has achieved normal operating rpm (refer to Figure 6-54). The dia-phragm cavity receives pressure from the oil separator. At the pilot setting, the diaphragm begins to unseat (open) a poppet to admit pressure to the compressor inlet unloading valve piston. This pressure begins to stroke the pis-ton that closes the inlet valve, thereby restricting the inlet and partially unloading the compressor.
As pressure in the oil separator rises, the subtractive pilot admits higher pressure to the unloader piston to further restrict the inlet, until the inlet is fully closed at the subtractive pilot valve's highest setting.
6.3.9.2 Adjustment
In order to obtain full compressor capacity at the maximum operating pressure, the subtractive pilot valve (refer to Figure 6-54) should be set to unload with the inlet valve fully closed at approximately 10 psig (0.7 bar) above the maximum operating pressure. Adjustment is accomplished by loosening the pressure screw locknut, then turning the screw in or out to achieve the desired pressure setting. The farther the pressure screw is turned clockwise, the higher the set pressure will be. After the desired setting has been achieved, tighten the pressure screw locknut securely.
BD120149 Mechanical Systems Manual Main Air System
6.3.9.3 Removal
Remove the subtractive pilot valve from the system as follows:
CAUTION!
Compressed air will exit from air line fittings with extreme force when being loosened,and can cause severe injury. Slowly release air pressure or vent the T-Tank before loos-ening any air line fittings. Wear appropriate face, ear, and body protective devices whileopening pressurized systems.
1. Vent any residual air pressure from the T-Tank. The T-Tank will vent through the main air system muffler when the main air compressor is not running and all controls are in the OFF position.
2. The subtractive pilot valve is located on the main air system control panel. To remove the valve from the sys-tem, remove the inlet and outlet pipe fittings from the body of the valve.
6.3.9.4 Disassembly
Technician Tip
In determining whether to rebuild or replace the subtractive pilot valve, consider that a simplerepair error could result in significant system malfunctions. It may be more economical to dis-card the faulty subtractive pilot valve and replace it with a new one.
Disassemble the subtractive pilot valve as follows (refer to Figure 6-54 for identification and location of compo-nents):
1. Loosen the locknut and pressure screw to remove spring pressure from the diaphragm and valve cover.
2. Clamp the valve body in soft jaws in a vise, and unscrew the valve cover, and remove it from the valve body.
3. Remove the spring button, pressure spring, and damper from the assembly.
4. Lift the diaphragm stop out of the valve body.
5. Remove the pressure plate nut and lockwasher from the seat disc stem, then remove the pressure plate, dia-phragm, diaphragm gasket, and the seat gasket from the seat disc.
6. Lift the seat ring out of the valve body.
6.3.9.5 Repair
None of the components from the subtractive pilot valve are repairable. Replace all defective parts. It is necessary to replace some components in groups to ensure satisfactory repair. When replacing the diaphragm, also replace both diaphragm and seat gaskets. When replacing the seat disc at seat ring, also replace the mating seat ring of disc and the seat disc gasket.
6.3.9.6 Assembly
Assemble the subtractive pilot valve as follows (refer to Figure 6-54 for component identification and location):
Main Air System BD120149 Mechanical Systems Manual
1. Install the seat ring in the counterbore in the valve body.
2. Assemble the diaphragm assembly by installing the following components over the stem of the seat disc in this order: seat gasket; diaphragm gasket, diaphragm, and pressure plate; then install and tighten the lock washer and pressure plate nut.
3. Install the diaphragm assembly in the valve body so that the seat disc mates with the seat ring.
4. Install the diaphragm stop in the valve body with the flange seated on top of the diaphragm.
5. Insert the damper inside of the pressure spring, then install the pressure spring and damper on top of the dia-phragm assembly.
6. Position the spring button on top of the pressure spring with the pilot diameter inside the top coil of the spring.
7. Make sure that the pressure screw is only minimally engaged in the valve cover, then screw the cover on to the valve body and tighten securely.
6.3.9.7 Installation
Install the subtractive pilot valve in the main air system as follows:
1. Spread a thin film of pipe compound on the male pipe threads of the connecting fittings, and install them securely into the body of the valve.
2. Check the adjoining fittings and clamps to confirm that they are connected securely.
3. Adjust the pressure setting of the subtractive pilot valve in accordance with the procedure described in Sub-topic 6.3.9.2.
6.3.9.8 Pilot Pressure Gauge
The pilot pressure gauge registers pressure from the subtractive pilot to the compressor inlet unloader piston. The gauge is installed in the air line between the subtractive pilot valve and the inlet valve assembly. The gauge pres-sure reading varies with pressure in the T-Tank, from a range of 0 psi to 21 psi.
The pilot pressure gauge is not repairable and must be replaced if it fails.
NOTICE
The gauge is installed into a ¼" pipe fitting. Wrap the male pipe threads with Teflon pipe threadtape before installation into the pipe fitting.
BD120149 Mechanical Systems Manual Main Air System
6.3.10 Main Air Control Panel
Figure 6-55: Main Air Control Panel
CIPS MAPS
SUB PILOT
VALVE OPENS
AT 58 PSI
TANK FILTER
COMP. FILTER
COPS
BAPT
BACS
01
02
03
04
05
06 07
08
09
101112A
B
C
E
D
G
F
H
MAPT
BD0509a01
LEGEND01. Bit Air Pressure Transducer02. Check Valve*03. Bit Air Control Solenoid*04. Main Air Pressure Transducer05. Electrical Panel06. Compressor Inlet Pressure Switch07. Main Air Pressure Switch
08. Subtractive Pilot Valve09. T-Tank Oil Separator Pressure
PIPING LEGENDA. From Bit AirB. To Air Pilot ValveC. From Compressor Filter (inlet side)D. From Compressor Filter (outlet side)
E. From Separator (outlet side)F. From Separator (inlet side)G. From T TankH. To Compressor
* The check valve and the bit air control solenoid are for drills with pneumatic but-terfly valves. They are not used on drills with electrically-operated butterfly valves.
Main Air System BD120149 Mechanical Systems Manual
The main air control panel is mounted inside the machinery house, at the left side of the main air compressor. This panel contains many of the control components required for operation and control of the main air compressor. It also supports the transducer for bit air pressure control. Figure 6-55 identifies the specific components mounted on the panel.
The individual control components can be serviced without need to remove the entire panel from its location.
6.3.11 Bit Air Pressure Transducer (BAPT), 44Q1536
6.3.11.1 Removal
The bit air pressure transducer can be removed from the panel without disconnecting any other components. Remove the pressure transducer as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
CAUTION!
High pressure hydraulic or air systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits beforeloosening fittings or connections. Wear appropriate face, ear, and body protectivedevices while venting air or hydraulic systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will vent through the main air system muffler when the main air compressor is not running and the controls are de-energized.
3. Tag and disconnect the signal wiring from pressure transducer.
4. Turn the pressure transducer in a counter-clockwise direction to remove it from the pipe fitting.
6.3.11.2 Cleaning, Inspection, And Repair
Clean and inspect the transducer in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. Check the transducer for correct operation by pressure testing on a test bench, if avail-able. The pressure transducer is not field repairable. See the LinkOne electronic parts manual for component iden-tification.
6.3.11.3 Installation
Install the pressure transducer on the panel as follows:
1. Apply pipe thread sealant to the male pipe threads, and install the transducer on the pipe fitting. Tighten securely to prevent leakage and loosening by vibration.
Remove and disassemble the low-oil pressure switch as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
CAUTION!
High pressure hydraulic or air systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits beforeloosening fittings or connections. Wear appropriate face, ear, and body protectivedevices while venting air or hydraulic systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will vent through the main air system muffler when the main air compressor is not running and the controls are de-energized.
3. Tag and disconnect the pressure tubing from the pressure switch assembly.
4. Tag and disconnect the signal wiring from the low-oil pressure switch.
5. Remove the mounting capscrews from the pressure switch, and remove the pressure switch assembly from the panel.
6. Remove the elbow tube fitting from the pressure port of the switch.
6.3.12.2 Cleaning, Inspection, And Repair.
Clean and inspect the pressure switch in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. Check the switch for correct operation by pressure testing on a test bench, if available. The pressure switch should be set to open at 8 psi (0.55 bar) and to close at 15 psi (1.0 bar). The pres-sure switch is not field repairable. See the LinkOne electronic parts manual for component identification.
6.3.12.3 Assembly And Installation
Assemble and install the low-oil pressure switch assembly as follows:
Main Air System BD120149 Mechanical Systems Manual
1. Coat the male pipe threads of the tubing elbow fitting with pipe thread sealant, and install in the pressure switch. Position the fitting as shown on Figure 6-55.
2. Position the pressure switch on the panel, and install with the mounting capscrews.
3. Connect the pressure tubing connector to the elbow fitting.
4. Install the signal wiring in the terminal box of the pressure switch.
5. Operate the main air system to test the repair.
6.3.13 Main Air Pressure Transducer (MAPT) 44Q1536
6.3.13.1 Removal
The main air pressure transducer can be removed from the panel without disconnecting any other components. Remove the pressure transducer as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
CAUTION!
High pressure hydraulic or air systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits beforeloosening fittings or connections. Wear appropriate face, ear, and body protectivedevices while venting air or hydraulic systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will vent through the main air system muffler when the main air compressor is not running and the controls are de-energized.
3. Tag and disconnect the signal wiring from pressure transducer.
4. Turn the pressure transducer in a counter-clockwise direction to remove it from the pipe fitting.
6.3.13.2 Cleaning, Inspection, And Repair
Clean and inspect the transducer in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. Check the transducer for correct operation by pressure testing on a test bench, if avail-able. The pressure transducer is not field repairable. See the LinkOne electronic parts manual for component iden-tification.
BD120149 Mechanical Systems Manual Main Air System
6.3.13.3 Installation
Install the pressure transducer on the panel as follows:
1. Apply pipe thread sealant to the male pipe threads, and install the transducer on the pipe fitting. Tighten securely to prevent leakage and loosening by vibration.
2. Install the signal wiring on top of pressure transducer.
3. Operate the main air system to test the repair.
6.3.14 Scavenger Oil Return Filter GH5000348
6.3.14.1 Removal
The scavenger oil return filter assembly can be serviced for normal maintenance without removing the entire unit from the air panel. Remove the filter unit assembly for replacement as follows (refer to Figure 6-55):
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
CAUTION!
High pressure hydraulic or air systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits beforeloosening fittings or connections. Wear appropriate face, ear, and body protectivedevices while venting air or hydraulic systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will vent through the main air system muffler when the main air compressor is not running and the controls are de-energized.
3. Spin the filter counterclockwise until the filter clears the stud threads. Discard the filter.
6.3.14.2 Installation
Coat the gasket on a new filter with a thin coat of oil. Spin the filter onto the stud threads clockwise until the gasket contacts the housing. Rotate the filter another ¼ turn.
6.3.15 Air Pilot Valve R56220D1
The function of the air pilot valve is to vent air pressure from the main air line and T-Tank when the bit air flow is turned off. When pilot air pressure is removed from the pilot air valve, the air pilot valve opens to discharge air from the main air line into the muffler. The air pilot valve is mounted to a pipe nipple in the discharge air line between the safety valve and the muffler.
Main Air System BD120149 Mechanical Systems Manual
6.3.15.1 Removal
Remove the air pilot valve as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
CAUTION!
High pressure hydraulic or air systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits beforeloosening fittings or connections. Wear appropriate face, ear, and body protectivedevices while venting air or hydraulic systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will vent through the main air system muffler when the main air compressor is not running and the controls are de-energized.
3. Tag and disconnect the pilot air and main air pressure hoses from the air pilot valve, and remove the hose adapters.
4. Remove the air pilot valve from the pipe nipple on which it is mounted.
6.3.15.2 Cleaning, Inspection, And Repair
Clean and inspect the air pilot valve in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. The valve unit is not field repairable. See the LinkOne electronic parts manual for component identification.
6.3.15.3 Installation
Install the air pilot valve as follows:
1. Apply pipe thread sealant to the male pipe nipple, and install the air pilot valve on the nipple. If a directional arrow is indicated on the valve body, the flow should be in the direction toward the muffler.
2. Install the pilot pressure and main air pressure hoses and adapters as previously tagged.
3. Start the main air system, and test the function of the air pilot valve.
6.3.16 Pressure Relief Valve R12262D4
The main air system pressure relief valve is factory adjusted to open if the pressure in the main air line exceeds 130 psi (9.0 bar). The valve is mounted in a coupling in the main air line near the T-Tank.
BD120149 Mechanical Systems Manual Main Air System
6.3.16.1 Removal
Remove the pressure relief valve as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
CAUTION!
High pressure hydraulic or air systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits beforeloosening fittings or connections. Wear appropriate face, ear, and body protectivedevices while venting air or hydraulic systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will vent through the main air system muffler when the main air compressor is not running and the controls are de-energized.
3. Tag and disconnect the pilot air valve discharge hose from the pressure relief valve discharge piping.
4. Loosen the two upper hose clamps, and disconnect the air discharge hose from the pressure relief valve dis-charge pipe fittings.
5. Remove the pipe fittings, as a unit, from the discharge of the pressure relief valve.
6. Remove the pressure relief valve from the main air line.
6.3.16.2 Cleaning, Inspection, And Repair
Clean and inspect the pressure relief valve in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. This valve is not field repairable. See the LinkOne electronic parts manual for component identification.
6.3.16.3 Installation
Install the pressure relief valve as follows:
1. Apply pipe thread sealant to the male pipe threads on the pressure relief valve, and install the valve on the main air line. Align the valve discharge to match the position of the air discharge hose leading to the muffler.
2. Apply pipe thread sealant to the male pipe threads on the pipe fittings for the discharge port of the pressure relief valve, and install the fittings.
3. Install the pressure relief valve discharge hose with two hose clamps.
Main Air System BD120149 Mechanical Systems Manual
4. Apply pipe thread sealant to the male pipe threads, and connect the pilot air valve discharge hose to the pres-sure relief valve discharge piping.
5. Start the main air system, and check for air pressure leaks.
6.3.17 Butterfly Valve R51305D1
The butterfly valve is used to start and stop the flow of air to the drilling bit. It is a 4-inch flange-mounted valve, located immediately downstream of the pressure relief valve in the main air line. The butterfly valve is operated by an electric actuator, which controls the timing and the extent of opening and closing. There is also a manual over-ride in the event the actuator were to become inoperable.
6.3.17.1 Removal
Remove the butterfly valve from the main air piping as follows:
Figure 6-56: Butterfly Valve Electric Actuator and Valve Assembly
BD120149 Mechanical Systems Manual Main Air System
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
CAUTION!
High pressure hydraulic or air systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits beforeloosening fittings or connections. Wear appropriate face, ear, and body protectivedevices while venting air or hydraulic systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will vent through the main air system muffler when the main air compressor is not running and the controls are de-energized.
3. Tag and disconnect the electrical connections from the butterfly valve.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can injure personnel and/or damage equipment. Use suitable slings and hoisting equipment to stabilize and liftheavy objects.
4. Attach a suitable hoist to the butterfly valve, and remove all slack from the sling or cables.
5. Remove the capscrews, lockwashers, and nuts that hold the pipe flanges and valve body together, then remove the butterfly valve and gaskets from the main air piping. Discard the used gaskets.
NOTICE
It may be necessary to spread the pipe flanges slightly to remove the valve assembly.
6.3.17.2 Cleaning, Inspection, And Repair
Clean and inspect the butterfly valve and the main air pipe flanges in accordance with the general cleaning and inspection procedures described in Appendix A of this manual.
Repair is limited to the replacement of worn or damaged parts. Before repairing the valve for the first time, contact your local P&H MinePro Services representative for tool kit R51305D4. Refer to Figure 6-57.
BD120149 Mechanical Systems Manual Main Air System
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can injure personnel and/or damage equipment. Use suitable slings and hoisting equipment to stabilize and liftheavy objects.
1. Attach a suitable hoist to the butterfly valve, and lift the valve into position between the main air line pipe flanges.
2. Install two new gaskets between the valve body and the pipe flange faces, then install the mounting cap-screws, lockwashers, and nuts through the pipe flanges. Torque the capscrews uniformly using a crisscross tightening pattern.
3. Install the electrical wiring on the butterfly valve as tagged.
4. Start the main air system, check for air leaks, and test the operation of the butterfly valve.
6.3.18 Muffler 27Q762D1
The muffler is mounted on the left-hand catwalk, just behind the T-Tank. It is mounted vertically on a back brace.
The muffler is not field repairable. If it becomes unserviceable, it must be replaced.
6.3.19 Dump Valve GH5000369
This is a normally open, pressurize to close check valve. When pressure from the main air system acts on the valve, the valve closes. When the pressure is removed, the valve opens to allow air to exhaust without going through the drill string.
6.4 Troubleshooting
Table 6-3 identifies some potential compressor system problems and lists probable causes to be corrected:
BD120149 Mechanical Systems Manual Low Pressure Hydraulic System
Section 7
Low Pressure Hydraulic System
7.1 General
The low pressure hydraulic system consists of an electric-motor-driven pumping unit (refer to Figure 7-1), which supplies hydraulic flow to valves on the low pressure hydraulic stand and the lube pump in the lubrication room. The low pressure hydraulic valves (refer to Figure 7-2) direct flow to the boarding ladder and cab roof hatch cylin-ders. Other valves present on the valve block are not connected and are considered spares.
Figure 7-1: Low Pressure Motor/Pump Assemblies
Figure 7-2: Low Pressure Hydraulic Valve Bank (Valve Bank 4)
Low Pressure Hydraulic System BD120149 Mechanical Systems Manual
The pump-motor assembly is mounted inside the machinery house, forward and to the left of the main hydraulic pumps. The hydraulic valves are mounted on a valve stand in the lubrication room on the front right area of the drill frame.
Figure 7-3: Low Pressure Hydraulic Valve Stand
BD0723a01
02
01
03
04
LEGEND01. Low Pressure Hydraulic Valve Stand02. Low Pressure Hydraulic Valve Bank (Valve Bank 4)03. Pilot Control Valve Bank (Valve Bank 5)04. Hydraulic Tank
BD120149 Mechanical Systems Manual Low Pressure Hydraulic System
7.2 Theory of Operation
7.2.1 General
The pump and motor are mounted in a stand to the left of the main hydraulic system pumps. The pump and motor share the stand with a pump and motor that are used for the hoist brake system (the hoist brake system is dis-cussed at the back of this section). The following subsections will discuss each circuit of the low pressure hydraulic system.
Low Pressure Hydraulic System BD120149 Mechanical Systems Manual
7.2.2 Intake and Delivery
The low pressure hydraulic system motor becomes energized when the drill main motor starts. For diagnostic and maintenance purposes, it also becomes energized when there is power on the drill and the DC SYSTEM switch (Figure 7-6) on the operator’s console is switched to the ON position.
‘This system shares the same hydraulic reservoir as the main and auxiliary hydraulic systems. Hydraulic oil is drawn from the tank through a the Handwell valve suction filter. The system features a pump-motor package with a 460V electric motor driving a positive displacement hydraulic pump. A check valve internal to the 5-station manifold prevents back-flow of oil through the pump when the unit is not operating. An adjustable pressure relief valve,
BD120149 Mechanical Systems Manual Low Pressure Hydraulic System
located immediately downstream of the check valve, establishes the maximum output pressure from the hydraulic pump.
7.2.3 Cab Roof Hatch Circuit
The cab roof hatch circuit actuates a pair of single-acting hydraulic cylinders to open the roof hatch. Each cylinder is equipped with a breather plug on the vented side of the piston to keep the inside (rod end) of the cylinders clean. A solenoid-operated directional valve is used to control the pressurized oil flow for hatch opening, to hold the hatch in its open position, and to allow the hatch to close by gravity. The configuration of the directional valve also enables the roof hatch to be manually opened. A pressure relief valve located downstream of the directional valve limits the force at which the roof hatch can be opened with hydraulic power. Set the pressure relief valve to 250 psi.
Low Pressure Hydraulic System BD120149 Mechanical Systems Manual
7.2.4 Boarding Ladder Circuit
The boarding ladder circuit actuates a single-acting hydraulic cylinder to raise the boarding ladder. The cylinder is equipped with a breather plug on the vented side of the piston to keep the inside (rod end) of the cylinders clean. A solenoid-operated directional valve is used to control the pressurized oil flow for raising the ladder, to hold the lad-der in its raised position, and to allow the hatch to lower by gravity. The configuration of the directional valve also enables the deck hatch to be manually lowered. A pressure relief valve located downstream of the directional valve limits the force at which the ladder can be raised with hydraulic power. Set the pressure relief valve to 300 psi.
A limit switch senses when the ladder is fully raised. The drill cannot propel if the ladder is not fully raised.
BD120149 Mechanical Systems Manual Low Pressure Hydraulic System
7.2.5 Grease Pump Circuit
The grease pump is connected directly to the hydraulic pressure circuit with no intermediate control valves. An internal grease pump supply solenoid (GPSS) energizes when the PLC initiates a lubrication cycle. With the GPSS energized, oil flows through the grease pump supply valve, through a pressure reducing valve and to the grease pump cycle solenoid (GPCS) valve. The GPCS energizes for one second, then de-energizes for one second, as long as the GPSS is energized. This applies pressure alternately to the top and bottom of the pump piston, allow-ing lubricant to be drawn from the reservoir and pushed out through the vent valve to the automatic lubrication sys-tem components.
Low Pressure Hydraulic System BD120149 Mechanical Systems Manual
7.3 Low Pressure Hydraulic System Maintenance
7.3.1 Hydraulic Pump-Motor
Either of the hydraulic pump-motor packages can be removed and replaced using similar procedures, Replace a hydraulic pump-motor assembly as follows:
WARNING!
Inadvertent machine movement during service can cause serious injury, or death. Do notperform maintenance work on a machine without first disabling the operator controls.Lock out and tag the operator controls to prevent inadvertent machine startup duringmaintenance work.
1. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
2. Tag and disconnect the wiring from the pump motor electrical junction box.
WARNING!
Hot hydraulic oil can spray with extreme force and volume, causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
3. Be sure that no pressure exists in any of the low pressure hydraulic system circuits.
BD120149 Mechanical Systems Manual Low Pressure Hydraulic System
CAUTIONClean dirt from the pump-motor assembly and hydraulic hose fittings before looseningany of the hydraulic components.
4. Turn the Handwell valve off (fully counterclockwise).
NOTICE
Failure to execute step 4 will enable oil to siphon from the hydraulic oil tank during removal ofthe pump-motor assembly.
5. Tag and disconnect the pressure and suction hose assemblies and fittings from the pump. Cap and/or plug the hose fittings and pump ports to prevent contamination of the hydraulic system.
6. Remove the capscrews and lockwashers from the pump-motor mounting feet, and remove the pump-motor assembly from the low-pressure hydraulic system panel. The nuts are weld nuts and will remain attached below the panel floor.
7. Clean dirt and oil from the pump mounting surface of the low pressure hydraulic panel. Follow the cleaning pro-cedures in Appendix A.
8. Position the replacement pump-motor assembly on the low-pressure hydraulic panel, and install securely with capscrews and lockwashers.
9. Attach SAE fittings. If SAE fittings are not used, coat the male pipe threads of the hose fittings with pipe thread sealant, and install the fittings in the suction and pressure ports of the pump-motor assembly.
10. Install the suction and pressure hose assemblies.
11. Open the Handwell valve.
12. Connect the electrical wiring to the pump motor as tagged.
13. Jog the pump-motor until the system is fully primed, and bleed air from the low pressure hydraulic system, as necessary.
7.3.2 Check Valve Cartridge
Check valves consist of a valve body that is drilled, tapped, and counterbored to accept a check valve cartridge, the valve cartridge assembly, and the O-rings and back-up rings that seal the land areas of the valve cartridge. Cartridge-type valve bodies need not be removed from the system to replace the cartridge assemblies.
Check valves should not be serviced, except for two conditions:
• Valve Leakage. Remove the cartridge and replace the O-ring seals.
• Valve Malfunction. Replace the cartridge as a unit.
Low Pressure Hydraulic System BD120149 Mechanical Systems Manual
WARNING!
Inadvertent machine movement during service can cause serious injury, or death. Do notperform maintenance work on a machine without first disabling the operator controls.Lock out and tag the operator controls to prevent inadvertent machine startup duringmaintenance work.
1. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
2. Be sure that no pressure exists in any of the low pressure hydraulic system circuits.
CAUTION!
Clean dirt from the valve assembly and hydraulic hose fittings before loosening any ofthe hydraulic components.
3. Close the Handwell valve.
NOTICE
Failure to execute step 3 will enable oil to siphon from the hydraulic oil tank during removal ofthe check valve cartridge.
4. With a wrench, loosen and remove the check valve cartridge from the valve body. Be sure to use the wrench flats provided for removal. Plug the hole in the valve body to prevent contamination of the hydraulic system.
5. Remove and discard the O-rings and back-up rings from the O-ring grooves on the outside diameter of the valve cartridge.
6. Clean and inspect the valve assembly in accordance with the general procedures for cleaning and inspection in Appendix A. The cartridge valves are not field repairable. Replace any faulty valve cartridges, and all O-rings and back-up rings. Refer to the LinkOne electronic parts manual for cartridge and seal kit information.
7. Lightly lubricate the new O-rings and back-up rings for the cartridge valve, and install them in the grooves on the outside diameter of the valve cartridge.
8. Carefully install the valve cartridge into its seat in the manifold. Avoid displacement or cutting of the O-ring seals during installation. Torque the valve securely.
BD120149 Mechanical Systems Manual Low Pressure Hydraulic System
10. Jog the pump-motor until the system is fully primed. Bleed air from the low pressure hydraulic system, as nec-essary.
7.3.3 Low Pressure Hydraulic System Valve Bank
7.3.3.1 Cab Roof Hatch Relief Valve
The cab roof hatch pressure relief valve is a cartridge-type valve assembly. Cartridge-type pressure relief valve assemblies consist of a valve body that is drilled, tapped, and counterbored to accept a pressure relief valve car-
Figure 7-11: Low Pressure Hydraulic Valves
LEGEND01. Pressure Relief Valve02. Directional Control Valve03. Pressure Relief Valve04. Flow Control Valve05. Manifold
06. Test Port Connector07. Check Valve08. Pressure Reducing Valve09. Flow Control Valve10. Pilot Operated Check Valve11. Directional Control Valve
Low Pressure Hydraulic System BD120149 Mechanical Systems Manual
tridge, the valve cartridge assembly, and the O-rings and back-up rings that seal the land areas of the valve car-tridge. Cartridge-type valve bodies need not be removed from the system to replace the cartridge assemblies.
Replace the pressure relief valve cartridge as follows:
1. Lower the cab roof hatch to the closed position.
WARNING!
Inadvertent machine movement during service can cause serious injury, or death. Do notperform maintenance work on a machine without first disabling the operator controls.Lock out and tag the operator controls to prevent inadvertent machine startup duringmaintenance work.
2. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or refitting.
3. Be sure that no pressure exists in any of the low pressure hydraulic system circuits.
4. Turn the Handwell valve off.
CAUTIONClean dirt from the valve assembly and hydraulic hose fittings before loosening any ofthe hydraulic components.
5. With a wrench, loosen and remove the pressure relief valve cartridge from the valve body. Be sure to use the wrench flats provided for removal. Plug the hole in the valve body to prevent contamination of the hydraulic system.
6. Remove and discard the O-rings and back-up rings from the O-ring grooves on the outside diameter of the valve cartridge.
7. Clean and inspect the valve assembly in accordance with the general procedures for cleaning and inspection in Appendix A. The cartridge valves are not field repairable. Replace any faulty valve cartridges, and all O-rings and back-up rings. Refer to the LinkOne electronic parts manual for cartridge and seal kit information.
8. Lightly lubricate the new O-rings and back-up rings for the cartridge valve, and install them in the grooves on the outside diameter of the valve cartridge.
9. Carefully install the valve cartridge into its seat in the valve body. Avoid displacement or cutting of the O-ring seals during installation. Torque the valve securely.
BD120149 Mechanical Systems Manual Low Pressure Hydraulic System
10. Open the Handwell valve.
11. Operate the pump-motor and cab roof hatch circuit to fill the circuit with hydraulic oil. Bleed all trapped air from the hatch operating cylinders.
7.3.3.2 Front Stairs Relief Valve
The front stairs pressure relief valve is a cartridge-type valve assembly. Cartridge-type pressure relief valve assem-blies consist of a valve body that is drilled, tapped, and counterbored to accept a pressure relief valve cartridge, the valve cartridge assembly, and the O-rings and back-up rings that seal the land areas of the valve cartridge. Car-tridge-type valve bodies need not be removed from the system to replace the cartridge assemblies.
Replace the pressure relief valve cartridge as follows:
1. Lower the front stairs.
WARNING!
Inadvertent machine movement during service can cause serious injury, or death. Do notperform maintenance work on a machine without first disabling the operator controls.Lock out and tag the operator controls to prevent inadvertent machine startup duringmaintenance work.
2. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or refitting.
3. Be sure that no pressure exists in any of the low pressure hydraulic system circuits.
4. Turn the Handwell valve off.
CAUTIONClean dirt from the valve assembly and hydraulic hose fittings before loosening any ofthe hydraulic components.
5. With a wrench, loosen and remove the pressure relief valve cartridge from the valve body. Be sure to use the wrench flats provided for removal. Plug the hole in the valve body to prevent contamination of the hydraulic system.
6. Remove and discard the O-rings and back-up rings from the O-ring grooves on the outside diameter of the valve cartridge.
Low Pressure Hydraulic System BD120149 Mechanical Systems Manual
7. Clean and inspect the valve assembly in accordance with the general procedures for cleaning and inspection in Appendix A. The cartridge valves are not field repairable. Replace any faulty valve cartridges, and all O-rings and back-up rings. Refer to the LinkOne electronic parts manual for cartridge and seal kit information.
8. Lightly lubricate the new O-rings and back-up rings for the cartridge valve, and install them in the grooves on the outside diameter of the valve cartridge.
9. Carefully install the valve cartridge into its seat in the valve body. Avoid displacement or cutting of the O-ring seals during installation. Torque the valve securely.
10. Open the Handwell valve.
11. Operate the pump-motor and front stair operating circuit to fill the circuit with hydraulic oil. Bleed all trapped air from the hatch operating cylinders.
7.3.3.3 Cab Roof Hatch Valve
The cab roof hatch directional control valve is a solenoid-operated, cartridge-type assembly. The valve assembly consists of a valve body that is drilled, tapped, and counterbored to accept two directional valve cartridges, the valve cartridge assemblies, and the O-rings and back-up rings that seal the land areas of the valve cartridges. Car-tridge-type valve bodies do not need to be removed from the system to replace the cartridge assemblies. Replace the directional valve cartridges as follows:
1. Lower the cab roof hatch to the closed position.
WARNING!
Inadvertent machine movement during service can cause serious injury, or death. Do notperform maintenance work on a machine without first disabling the operator controls.Lock out and tag the operator controls to prevent inadvertent machine startup duringmaintenance work.
2. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
3. Tag and disconnect the electrical connectors from the valve solenoids.
4. Remove the solenoid retaining nut from the outer end of the solenoid, then remove the solenoid from the valve.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
5. Be sure that no pressure exists in any of the low pressure hydraulic system circuits.
BD120149 Mechanical Systems Manual Low Pressure Hydraulic System
NOTICE
Clean dirt from the valve assembly and hydraulic hose fittings before loosening any of thehydraulic components.
7. With a wrench, loosen and remove the directional valve cartridge from the valve body. Be sure to use the wrench flats provided for removal. Plug the hole in the valve body to prevent contamination of the hydraulic system.
8. Remove and discard the O-rings and back-up rings from the O-ring grooves on the outside diameter of the valve cartridge.
9. Clean and inspect the valve assembly in accordance with the general procedures for cleaning and inspection in Appendix A. The cartridge valves are not field repairable. Replace any faulty valve cartridges, and all O-rings and back-up rings. Refer to the LinkOne electronic parts manual for cartridge and seal kit information.
10. Lightly lubricate the new O-rings and back-up rings for the cartridge valve, and install them in the grooves on the outside diameter of the valve cartridge.
11. Carefully install the valve cartridge into its seat in the valve body. Avoid displacement or cutting of the O-ring seals during installation. Torque the valve securely.
12. Install the solenoid over the valve, and secure.
13. Connect the electrical connector to the solenoid as tagged.
14. Open the Handwell valve.
15. Operate the pump-motor and cab roof hatch circuit to fill the circuit with hydraulic oil. Bleed all trapped air from the hatch operating cylinders.
7.3.3.4 Front Stairs Valve
The front stairs directional control valve is a solenoid-operated, cartridge-type assembly. The valve assembly con-sists of a valve body that is drilled, tapped, and counterbored to accept two directional valve cartridges, the valve cartridge assemblies, and the O-rings and back-up rings that seal the land areas of the valve cartridges. Cartridge-type valve bodies do not need to be removed from the system to replace the cartridge assemblies. Replace the directional valve cartridges as follows:
1. Lower the front stairs.
WARNING!
Inadvertent machine movement during service can cause serious injury, or death. Do notperform maintenance work on a machine without first disabling the operator controls.Lock out and tag the operator controls to prevent inadvertent machine startup duringmaintenance work.
2. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
3. Tag and disconnect the electrical connectors from the valve solenoids.
Low Pressure Hydraulic System BD120149 Mechanical Systems Manual
4. Remove the solenoid retaining nut from the outer end of the solenoid, then remove the solenoid from the valve.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
5. Be sure that no pressure exists in any of the low pressure hydraulic system circuits.
6. Turn the Handwell valve off.
NOTICE
Clean dirt from the valve assembly and hydraulic hose fittings before loosening any of thehydraulic components.
7. With a wrench, loosen and remove the directional valve cartridge from the valve body. Be sure to use the wrench flats provided for removal. Plug the hole in the valve body to prevent contamination of the hydraulic system.
8. Remove and discard the O-rings and back-up rings from the O-ring grooves on the outside diameter of the valve cartridge.
9. Clean and inspect the valve assembly in accordance with the general procedures for cleaning and inspection in Appendix A. The cartridge valves are not field repairable. Replace any faulty valve cartridges, and all O-rings and back-up rings. Refer to the LinkOne electronic parts manual for cartridge and seal kit information.
10. Lightly lubricate the new O-rings and back-up rings for the cartridge valve, and install them in the grooves on the outside diameter of the valve cartridge.
11. Carefully install the valve cartridge into its seat in the valve body. Avoid displacement or cutting of the O-ring seals during installation. Torque the valve securely.
12. Install the solenoid over the valve, and secure.
13. Connect the electrical connector to the solenoid as tagged.
14. Open the Handwell valve.
15. Operate the pump-motor and front stairs circuit to fill the circuit with hydraulic oil. Bleed all trapped air from the hatch operating cylinders.
BD120149 Mechanical Systems Manual Low Pressure Hydraulic System
7.4 Hoist Brake Circuit
While the hoist brake circuit is considered a part of the low pressure hydraulic system, it uses a different pump than the one used for the low pressure hydraulic valve stand in the lubrication room. The low pressure pump and motor and the hoist brake pump and motor share the same low pressure hydraulic stand in the machinery house, but the hoist brake circuit is a completely independent circuit.
The hoist brake circuit provides hydraulic pressure to release the brake on the carriage in the mast. It consists of a solenoid-activated directional control valve with an integrated heater and check valve. The hoist brake valve sole-noid is energized when the operator presses the BRAKE RELEASE button on the operator’s console.
There is no relief valve in the pump circuit. The pump is a pressure compensated pump that runs as long as the DC System switch on the operator’s console is in the ON position. Because the flow is low, little heat is generated; because the pump is always on, brake release is not delayed.
The associated pressure switch indicates to the PLC that there is sufficient hydraulic pressure present to cause the release of the brake. Set the pressure switch to close at 900 psi.
BD120149 Mechanical Systems Manual Automatic Lubrication System
Section 8
Automatic Lubrication System
8.1 General
The automatic lubrication system provides measured amounts of lubricant to specified lubrication points at prede-termined intervals. The drill uses the Lincoln Automatic Lubrication System.
The lubrication tank, pumps and controls are located in a separate enclosure, called the lubrication room, on the front right corner of the drill frame. Also in the lubrication room are the hydraulic tank, the hydraulic oil cooler, and the low pressure hydraulic valve stand. The hydraulic grease pump is driven by the low pressure hydraulic pump in the machinery house.
8.1.1 Automatic Lubrication System Components
8.1.1.1 Tank-mounted Components.
Figure 8-1: Automatic Lubrication System Componentsl
Automatic Lubrication System BD120149 Mechanical Systems Manual
Refer to Figure 8-1. The grease tank (01) holds approximately 60 gallons of multipurpose grease (refer to Section 16, Lubrication for lubricant specifications). Lubricant level is checked using the dipstick (07) and filled through the filler/Breather (07).
The lubrication pump (05) is driven by a low pressure motor/pump in the machinery house (the same pump that supplies hydraulic fluid to the hoist brake. Refer to Section 7, Low Pressure Hydraulic System). Lubrication pump operation is controlled by the grease pump supply solenoid (GPSS), which opens to provide hydraulic flow to the pump when the PLC indicates that a lube cycle should begin. Intake and discharge are controlled by the grease pump cycle solenoid (GPCS), which alternately causes the pump to move upward (to provide intake) for one sec-ond and downward (to provide discharge) for one second for as long as GPSS is energized.
The vent valve (06) is normally open, providing a path for pressure in the system to return to tank. When a cycle starts, pilot pressure from the GPSS closes the vent valve. When the cycle is complete and pilot pressure is removed from the vent valve, system pressure causes the vent valve to open and pressure is vented back to tank.
BD120149 Mechanical Systems Manual Automatic Lubrication System
On the control panel (Figure 8-2), a strainer (01) filters contaminants from the grease before it goes to the injectors. The gauge (02) provides visual indication of the pressure within the system. The system is protected by a 4000 psi relief valve (03).
The grease pressure switch (GPS) (04) sends a signal to the PLC when the system reaches the pressure that indi-cates that the cycle is finished.
The upper grease solenoid (UGS) (05) is normally closed. It opens when a lubrication cycle begins and the drill is in one of the drilling modes (lower systems are greased in every cycle). The upper grease pressure switch (UGPS) (06) sends a signal to the PLC when the system reaches the pressure that indicates that the upper has been lubri-cated. The PLC will de-energize the UGS and the pump will continue to operate until the GPS closes.
BD120149 Mechanical Systems Manual Automatic Lubrication System
8.2.1 Pump Operation
The automatic lubrication system turns on based on signals from timers in the PLC. Typically, the PLC will start an automatic lubrication cycle every 60 minutes when the drill is in one of the drilling modes, and every five minutes when it is in propel mode. The system can also be operated manually through the operator’s touch screen.
Hydraulic fluid used to power the Automatic Lubrication System is supplied by the low pressure hydraulic pump. The pump is active whenever the DC Systems are functioning. When the cycle starts, the motor turns the pump. The pump draws hydraulic fluid from the main hydraulic tank and sends it to the automatic lubrication system cir-cuit.
8.2.1.1 Grease Pump Supply Solenoid (GPSS)
The GPSS is normally closed. Low pressure fluid is available at the GPSS whenever DC Systems are on.
The GPSS energizes when the lubrication cycle begins. This permits hydraulic fluid to flow to the reducing valve.
CAUTION
Incorrect pressure can cause equipment damage. The reducing valve is factory preset at220 psi. Do not adjust the reducing valve.
The grease pump has a 16:1 ratio, which means that for every 1 psi of hydraulic oil pressure, the pump can develop 16 psi of grease pressure. When the hydraulic oil pressure is 220 psi, the grease pressure could be as high as 3520 psi (16 x 220 = 3520) before the pump stalls. If the reducing valve is set too low, some lubrication points may not get lubricated; if it is set too high, it could cause damage to system components.
After the reducing valve, an portion of the oil is used to provide pilot pressure to the vent valve. When this pilot pressure is present, the vent valve closes the grease return line to the grease tank.
Automatic Lubrication System BD120149 Mechanical Systems Manual
8.2.1.2 Grease Pump Cycle Solenoid (GPCS)
The Grease Pump Cycle Solenoid energizes and de-energizes. The intervals are adjustable up to one second by settings used on the GUI lube screen.
When the solenoid is energized, hydraulic fluid flows to the rod end of the grease pump, causing the plunger to draw lubricant from the lube tank. When the solenoid is de-energized, hydraulic fluid flows to the head end of the grease pump, causing the plunger to press lubricant out to the auto lube system. Check valves on the inlet and out-let of the pump plunger ensure that grease flows in the correct direction. The GPCS continues to function in the same cycle as long as the GPSS is energized.
8.2.2 Lube Control
Lubricant supplied by the grease pump flows through a strainer. System pressure is limited by the relief valve and indicated by the gauge.
NOTICE
The 4000 psi relief valve is not adjustable.
8.2.2.1 Grease Pressure Switch (GPS)
The Grease Pump Supply Solenoid (GPSS, item 5, Figure 8-4) energizes with every lubrication cycle. The GPS monitors pressure in the lube lines and closes at 2500 psi, indicating that the lubrication cycle is complete. This causes the PLC to de-energize GPSS.
If the GPS fails to close within three minutes, a lubrication system fault will occur; however, faults in the lubrication system will not cause automatic shutdown of the drill.
BD120149 Mechanical Systems Manual Automatic Lubrication System
8.2.2.2 Upper Grease System Operation
When the drill is in propel mode, only the propel machinery requires lubrication. Therefore, when the drill is in pro-pel mode, the Upper Grease Solenoid (UGS) does not energize. Lubricant flows directly to the propel machinery lubrication points.
When the drill is in one of the drill modes and the GPSS energizes, the UGS also energizes. This opens the line to the upper machinery lubrication points.
As lubricant flows to the upper machinery lubrication points, pressure builds in the system. When pressure reaches 1500 psi, the Upper Grease Pressure Switch (UGPS) closes. This indicates to the PLC that the UGS energized as required.
When the GPS senses 2500 psi, it closes, causing the GPSS to de-energize and the grease pump to stop pump-ing. At the same time, the pilot pressure to the vent valve (Item 6, Figure 8-4) is relieved, allowing the vent valve to open the return line back to the tank. The UGS remains open for two minutes after the GPSS de-energizes. The pressure that has built up in the upper and lower machinery lubrication lines relieves back to the grease tank.
After the two minutes for depressurization, the UGS de-energizes and the cycle is complete.
Automatic Lubrication System BD120149 Mechanical Systems Manual
8.3 Automatic Lubrication System Maintenance
8.3.1 Hydraulic Pump-Motor, 37Q117D2
The pump and motor package is part of the low pressure hydraulic circuit, located in the low pressure hydraulic pump stand in the machinery house. Replace the hydraulic pump-motor assembly as follows:
WARNING!
Inadvertent machine movement during service can cause serious injury, or death. Do notperform maintenance work on a machine without first disabling the operator controls.Lock out and tag the operator controls to prevent inadvertent machine startup duringmaintenance work.
1. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
2. Tag and disconnect the wiring from the pump motor electrical junction box.
WARNING!
Hot hydraulic oil can spray with extreme force and volume, causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
3. Be sure that no pressure exists in any of the low pressure hydraulic system circuits.
BD120149 Mechanical Systems Manual Automatic Lubrication System
CAUTIONClean dirt from the pump-motor assembly and hydraulic hose fittings before looseningany of the hydraulic components.
4. Turn the Handwell valve off.
NOTICE
Failure to execute step 4 will enable oil to siphon from the hydraulic oil tank during removal ofthe pump-motor assembly.
5. Tag and disconnect the pressure and suction hose assemblies and fittings from the pump. Cap and/or plug the hose fittings and pump ports to prevent contamination of the hydraulic system.
6. Remove the capscrews and lockwashers from the pump-motor mounting feet, and remove the pump-motor assembly from the low-pressure hydraulic system panel. The nuts are weld nuts and will remain attached below the panel floor.
7. Clean dirt and oil from the pump mounting surface of the low pressure hydraulic panel. Follow the cleaning pro-cedures in Appendix A.
8. Position the replacement pump-motor assembly on the low-pressure hydraulic panel, and install securely with capscrews and lockwashers.
9. Coat the male pipe threads of the hose fittings with pipe thread sealant, and install the fittings in the suction and pressure ports of the pump-motor assembly.
10. Install the suction and pressure hose assemblies.
11. Disconnect the hose assembly from above the suction filter and fill the suction line with hydraulic oil. Refer to the Lubrication section for oil specifications.
12. Connect the hose assembly above suction filter, and tighten securely.
13. Connect the electrical wiring to the pump motor as tagged.
14. Jog the pump-motor until the system is fully primed, and bleed air from the low pressure hydraulic system, as necessary.
Automatic Lubrication System BD120149 Mechanical Systems Manual
8.3.2 Grease Pump 37U154D1
The grease pump is a Lincoln 16:1 hydraulic reciprocating-type unit. The pump consists of an intensifier cylinder pump, two solenoids valves, and a pressure-reducing valve. The pressure setting is adjustable. Disassembly and repair of this pump requires special tools and methods. If the pump malfunctions, replace it, and send the old unit to a qualified repair facility.
8.3.2.1 Removal
CAUTION!
High-pressure oil or grease can spray and penetrate skin or eyes causing severe injury.Use extreme caution when working around operating lubrication system and wearappropriate face and body protective devices. Shut down, lock out, and tag the machinebefore performing inspection, service, and maintenance of the lubrication system.Obtain medical aid immediately for lube spray into eyes or penetration into the skin. Besure that the hydraulic and air systems are not pressurized before loosening or remov-ing any connections or parts for maintenance.
1. Shut down the machine, and lock out and tag the controls.
BD120149 Mechanical Systems Manual Automatic Lubrication System
3. Tag and disconnect the electrical wiring to the valve solenoids.
4. Tag and disconnect the hoses from the grease pump.
5. Disconnect the grease hose at the pump.
6. Remove the bolts from the cover plate and remove the pump.
7. Remove the capscrews and pump mounting fitting from the grease pump.
8.3.2.2 Cleaning, Inspection and Repair
Refer to Appendix A for general mechanical maintenance procedures, and to Appendix B for general hydraulic component maintenance procedures. Repair of the grease pump is limited to the replacement of worn or damaged parts.
8.3.2.3 Installation
CAUTION!
High-pressure oil or grease can spray and penetrate skin or eyes causing severe injury.Use extreme caution when working around operating lubrication system and wearappropriate face and body protective devices. Shut down, lock out, and tag the machinebefore performing inspection, service, and maintenance of the lubrication system.Obtain medical aid immediately for lube spray into eyes or penetration into the skin. Besure that the hydraulic and air systems are not pressurized before loosening or remov-ing any connections or parts for maintenance.
1. Fasten the pump mounting fitting to the pump.
2. Mount the pump to the cover plate.
3. Insert the grease pump in the tank and attach the cover plate to the tank.
4. Connect the grease supply hose to the pump.
5. Connect the oil pressure supply to the grease pump.
6. Connect the grease return hose to the grease pump.
7. Connect the vent valve to the grease pump.
8. Turn on the main PLC.
9. Bleed the system. Refer to the topic. Bleeding Grease System.
8.3.2.4 Adjustment
The pressure reducing valve is set at 190 psi (13.1 bar). The valve is factory-set and normally should not be changed.
BD120149 Mechanical Systems Manual Automatic Lubrication System
D. Place a catch basin under the end of the hose to collect drained grease.
E. Turn on the lubrication system and initiate a lube cycle. Observe the discharge from the grease return hose and continue to cycle the system until all air is purged from the grease line.
F. Connect the grease return hose to the vent valve.
8.3.3.2 Relief Valve 36Z879D68
CAUTION!
High-pressure oil or grease can spray and penetrate skin or eyes causing severe injury.Use extreme caution when working around operating lubrication system and wearappropriate face and body protective devices. Shut down the machine, and lock out andtag the controls before performing inspection, service, and maintenance of the lubrica-tion system. Obtain medical aid immediately for lube spray into eyes or penetration intothe skin. Be sure that the grease system is not pressurized before loosening or remov-ing any connections or parts for maintenance. The pressure relief valve is set at 4000 psi(276 bar) and is not adjustable.
The relief valve is not adjustable, and cannot be repaired by the user. To replace the valve, proceed as follows.
1. Use lockout-tagout procedures to shut down the drill.
2. Unscrew the valve from the manifold.
3. Install a new valve. Be sure that the connection is tight.
8.3.3.3 Pressure Switches 79Z4843
Pressure switches GPS and UGPS are SPDT snap-action type with automatic reset. The range is adjustable between 235 and 3000 psi (16 to 205 bar) on decreasing pressure, and between 295 and 3400 psi (20.2 to 233 bar) on increasing pressure. The switches are connected normally open.
WARNING!
Hazardous voltage can cause burns, injury, or even death. Disconnect, lock out, and tagthe power source which feeds this device to prevent power from being applied whileinspection and repairs are being performed. Before beginning repairs, try the operationalcontrols to verify that the intended power source is disconnected.
Removal
CAUTION!
High-pressure oil or grease can spray and penetrate skin or eyes causing severe injury.Use extreme caution when working around operating lubrication system and wearappropriate face and body protective devices. Shut down machine, and lock out and tagthe controls before performing inspection, service, and maintenance of the lubrication
Automatic Lubrication System BD120149 Mechanical Systems Manual
system. Obtain medical aid immediately for lube spray into eyes or penetration into theskin. Refer to Figure 7-7 or 7-8 and proceed as follows:
1. Disconnect, lock out, and tag the power source that feeds the system to prevent power from being applied while service is being performed.
2. Disconnect and tag the wiring to the switch to be removed.
3. Unscrew the pressure switch from the fitting.
Repair
Refer to Appendix A for general mechanical maintenance procedures, and to Appendix B for general hydraulic component maintenance procedures. Replace the pressure switch if faulty.
Installation
1. Install the pressure switch onto the fitting.
2. Connect the wiring to the switch.
3. Connect the power source after service is being performed.
4. Bleed the grease system. Refer to the topics, Bleeding Grease System.
Adjustment
To adjust the pressure switches the main PLC must be on. Refer to Figure 8-10 and proceed as follows:
BD120149 Mechanical Systems Manual Automatic Lubrication System
1. Remove the pressure adjustment screw cover to gain access to the adjustment screw.
2. Turn the adjustment screw clockwise to lower the actuation pressure setting. Turn the adjustment screw counter-clockwise to raise the actuation pressure setting. Pressure settings are as follows:
GSPS - 2500 psi (172.5 bar)
UGPS - 1500 psi (103.5 bar)
3. After adjustment, install the pressure adjustment screw cover.
8.3.3.4 Upper Grease Solenoid 36Z1412D2
The Upper Grease Solenoid valve is installed in the line to the upper machinery.
WARNING!
hazardous voltage can cause burns, injury, or even death. Disconnect, lock out, and tagthe power source that feeds this device to prevent power from being applied whileinspection and repairs are being performed. Before beginning repairs, try the operationalcontrols to verify that the intended power source is disconnected.
Automatic Lubrication System BD120149 Mechanical Systems Manual
CAUTION!
High-pressure oil or grease can spray and penetrate skin or eyes causing severe injury.Use extreme caution when working around operating lubrication system and wearappropriate face and body protective devices. Shut down the machine, and lock out andtag the controls before performing inspection, service and maintenance of the lubrica-tion system. Obtain medical aid immediately for lube spray into eyes or penetration intothe skin.
Removal
1. Disconnect, lock out, and tag the power source that feeds the system to prevent power from being applied while service is being performed.
2. Disconnect and tag wiring to the solenoid.
3. If the solenoid is not actuating the valve, remove the screws on top of the valve to detach the solenoid. Inspect the valve for signs of malfunction. If the valve is damaged, replace the entire solenoid valve.
4. Check operation of the solenoid with a 125VAC power source, If faulty, replace the solenoid. Check operation of the valve after installation.
5. If the entire valve must be removed, it will be necessary to remove the components from the panel to access the valve.
A. Disconnect and tag wiring to the pressure switches. Remove the pressure switches.
B. Disconnect and tag the lube hoses.
C. Remove attaching hardware to unfasten the manifold, valve, and fittings.
Repair
Refer to Appendix A for general mechanical maintenance procedures, and to Appendix B for general hydraulic component maintenance procedures. Repair of the solenoid valve is limited to the replacement of worn or dam-aged parts.
Installation
1. Assemble the solenoid, manifold and fittings, and mount these parts on the panel.
2. Connect wiring to the solenoid.
3. Install pressure switches and connect wiring.
4. Connect lube hoses to the tee fittings.
5. Bleed the grease system. Refer to the topic, Bleeding Grease System.
BD120149 Mechanical Systems Manual Automatic Lubrication System
8.3.4 Vent Valve 36Q525
The vent valve is mounted on top of the lubrication tank near the grease pump. It is a hydraulically piloted valve that is normally open to vent the lube system. During lubrication the valve is closed to shut off grease flow to the tank.
8.3.4.1 Removal
Refer to Figure 8-11 and proceed as follows:
Figure 8-11: Vent Valve
01
0203
04
05 06
07
LEGEND01. Vent Valve02. Lubricant Inlet Port03. Tank Return Port
04. Lubricant Outlet Port05. From Grease Pump06. To Injectors07. To Lube Tank
Automatic Lubrication System BD120149 Mechanical Systems Manual
CAUTION!
High-pressure oil or grease can spray and penetrate skin or eyes causing severe injury.Use extreme caution when working around operating lubrication system and wearappropriate face and body protective devices. Shut down the machine, and lock and tagthe controls before performing inspection, service, and maintenance of the lubricationsystem. Obtain medical aid immediately for lube spray into eyes or penetration into theskin.
1. Use lockout/tagout procedures to shut down the drill.
2. Tag and disconnect each of the hoses leading to vent valve.
3. Remove the vent valve from the tank bracket.
8.3.4.2 Disassembly
Refer to Figure 8-12 and proceed as follows:
1. Loosen and remove the valve body from cylinder.
2. Unthread valve seat. Remove the seat and gasket from the valve body.
3. Remove packing assembly from cylinder.
4. Remove piston from the cylinder.
5. Remove V-seal from piston.
6. Remove needle from the packing assembly.
Figure 8-12: Vent Valve Assembly
LEGEND01. Cylinder02. Piston03. V Seal04. Needle05. Packing Assembly06. Valve Seat07. Valve Seat Gasket08. Valve Body
BD120149 Mechanical Systems Manual Automatic Lubrication System
8.3.4.3 Cleaning, Inspection and Repair
Refer to Appendix A for general mechanical maintenance procedures, and to Appendix B for general hydraulic component maintenance procedures. Repair of the vent valve is limited to the replacement of worn or damaged parts.
8.3.4.4 Assembly
Refer to Figure 8-12 and proceed as follows:
1. Apply a light coating of oil to V-seal and install on piston as shown.
2. Apply a light coating of oil to the inside wall of cylinder.
3. Install piston in cylinder, rotating the piston so that the lip of V-seal will not invert.
4. Install needle in packing assembly, and place the packing assembly in the cylinder as shown.
5. Place gasket in valve body; then thread valve seat into the valve body.
6. Thread valve body into cylinder.
8.3.4.5 Installation
1. Mount the vent valve on the tank bracket.
2. Connect the hoses to the valve.
8.3.5 Lubrication Injectors 44Z1169D__
The lubrication injectors are pressure-operated and spring-reset. They are mounted on manifolds, located in groups strategically positioned on the drill. The Lincoln SL-1 injector used on this drill delivers a measured volume of lubricant to the lubrication point. The volume is adjustable from .008 - .080 in3 (131 - 1310 mm3) (refer to Sub-topic 8.3.5.2). The injectors have dual outlets, allowing them to be crossported to deliver increased amounts of lubricant to the lube point.
The injectors operate within a pressure range between 1,850 and 3000 psi. (typical pressure switch setting is 2500 psi).
Maximum vent pressure (the pressure the system must get below to allow the injectors to reset after a cycle) is 300 psi.
Automatic Lubrication System BD120149 Mechanical Systems Manual
8.3.5.1 Theory of Operation
As shown in Figure 8-13 for Position 1, when the lubrication cycle starts, pressure from lubricant entering the injec-tor forces the slide valve to open and allows lubricant to enter the passage leading to the measuring chamber.
BD120149 Mechanical Systems Manual Automatic Lubrication System
.
After the slide valve opens, lubricant is directed into the measuring chamber above the injector piston. The injector piston is pushed down, forcing lubricant from the discharge chamber, through the outlet port to the lube point.
Automatic Lubrication System BD120149 Mechanical Systems Manual
The injector piston completes its stroke by pushing the slide valve, blocking the lubricant supply through the pas-sage to the measuring chamber. The injector piston remains in this position until all the injectors have finished the first half of their cycle.
After all the injectors have cycled, pressure builds up until the pressure switch trips, de-energizing the solenoid valve and stopping the lubrication pump. Excess lube pressure in the supply lines relieves through the vent valve back to the tank.
Position 4 in Figure 8-16 shows the injector spring expanding after pressure has been vented from the supply lines. The injector spring expands, pushing the slide valve to its original position, pushing lubricant from the measuring chamber though the passage and valve port, and into the discharge chamber. The injector cycle is completed and the injector is ready for the next cycle.
BD120149 Mechanical Systems Manual Automatic Lubrication System
8.3.5.2 Adjustment
CAUTIONIn addition to lubricating the various components in the lubrication system, the lubricantsupplied to the lube point flushes dirt and other impurities from the lube point (compo-nent). Reducing the amount of lubricant to the lube point can result in excessive wearand premature component failure. Contact your P&H MinePro Services representativebefore changing (especially before reducing) the amount of lubricant being supplied tothe lube point.
1. Loosen output adjusting screw locknut.
2. Adjust the injector to deliver the desired amount of lubricant to the lube point. Turn the output adjustment screw outward (anticlockwise) to increase the amount of lubricant to the lube point (maximum .08 in3 or 131 mm3), or turn the output adjustment screw inward (clockwise) to decrease the amount of lubricant delivered to the lube point (minimum .008 in3 or 1310 mm3).
3. Tighten the output adjusting screw locknut to lock the adjusting screw in place.
8.3.5.3 Removal
WARNING!
Accidental shovel movement during service procedures can result in serious personalinjury or death. Always park on level ground, and use lockout and tagout procedures toprevent accidental start-up and/or motion.
BD120149 Mechanical Systems Manual Automatic Lubrication System
8.3.5.4 Disassembly
1. Loosen locknut.
2. Loosen and remove adjusting nut with locknut.
3. Loosen and remove piston stop plug with packing and washer.
4. Remove packing and washer from piston stop plug. Discard the packing.
5. Remove injector piston assembly with o-ring. Remove the o-ring and discard.
6. Remove injector spring.
7. Remove spring seat through the top of the injector body.
8. Remove washer, packing, inlet disc packing and slide valve through the bottom of the injector.
8.3.5.5 Repair
Repair of SL-1 injector is limited to replacing worn or defective parts. Whenever an SL-1 injector is disassembled, all gaskets, o-rings, and packings should be replaced.
8.3.5.6 Assembly
Refer to Figure 8-19 and assemble the injector as follows:
1. Install spring seat in injector body with the flat side of the seated flat against the bottom of the cylinder in the injector body.
Automatic Lubrication System BD120149 Mechanical Systems Manual
2. Place injector spring into the cylinder bore in the injector body.
3. Lubricate a new o-ring with a light coating of grease and install in the groove of injector.
4. Place piston assembly with installed o-ring into the cylinder bore of the injector body. Make sure that the tapered portion on the piston assembly is pointed toward the top of the injector body
5. Place washer and new packing into the bore at the bottom of piston stop plug.
6. Place piston stop plug over injector piston onto the injector body. Torque to 25-30 ft-lbs (33.9-40.7 Nm).
7. Install the lock nut onto the adjusting nut. Install the adjusting nut over the injector into the threaded bore in pis-ton stop plug.
8. Install new packing into the bore inside the bottom of the injector body.
9. Place slide valve into the bore of packing.
10. Place inlet disc in the bore at the bottom of the injector.
11. Place new packing in the bore at the bottom of the injector.
8.3.5.7 Installation
Refer to Figure 8-18 and install the injector as follows:
1. Place the injector at the top of the manifold.
2. Install new gasket on the adapter bolt.
3. Install adapter bolt through the bottom of the manifold and thread into the bottom of the injector. Tighten the adapter bolt to 45-50 ft-lbs (61-68 Nm).
4. Install the feeder line into the injector body.
5. Bleed the air from the injector and feeder line, refer to Bleeding Air from Feeder Lines.
6. Start up the drill using lockout and tagout procedures.
8.3.5.8 Bleeding The System
During component replacement procedures, or as a means of resolving a lubrication fault, it may become neces-sary to remove air from the supply or feeder lines. Air can be introduced into the lubrication system for several rea-sons:
• Because lubricant levels in the reservoir become too low before refilling.
• Because the lubrication pump is improperly primed.
• During component replacement.
• It is necessary to bleed air from the system to prevent lack of proper lubrication from causing damage to drill components and to keep the lubrication fault alarm from sounding.
BD120149 Mechanical Systems Manual Automatic Lubrication System
The following procedures are provided for bleeding air from the automatic lubrication system.
WARNING!
Inadvertent movement of the drill during the following procedures can result in injury ordeath. Be sure that an operator is stationed at the controls to prevent inadvertent opera-tion of any drill components.
Bleeding Air From Supply Lines (System)
CAUTION!
High-pressure oil or grease can spray and penetrate skin or eyes causing severe injury.Use extreme caution when working around operating lubrication system and wearappropriate face and body protective devices. Obtain medical aid immediately for lubespray into eyes or penetration into the skin.
1. Set all brakes.
2. Start the machine. Station the operator at the controls to prevent inadvertent operations of the drill.
3. Be sure that the grease pump is primed and free of air. If necessary, adjust the lube cycle time and interval at the GUI to slow grease pump operation.
4. Start a manual lubrication cycle using the GUI. It will be necessary to start a manual lubrication cycle several times to complete the bleeding process.
5. Bleed each supply line in the lubrication system to be bled starting with the shortest section and working up to the longest section. Bleed each section as follows:
A. If there are fittings that could trap air, as shown in Figure 8-20, start with the fitting closest to the grease pump; remove each plug in order and run the grease pump until lubricant flow is free of air or foreign matter. Then install and tighten the plug, and move on to the next fitting.
Automatic Lubrication System BD120149 Mechanical Systems Manual
B. Remove the plug(s) at the end of the section. It will be located on the injector manifold as shown in Figure 8-21.
C. Operate the lubrication pump until lubricant flow is free of air or foreign matter. Use a drain pan to collect the lubricant discharged during the bleeding process.
D. Replace the plug.
6. Bleed air from each section in the lubrication system until all sections of the lubricant supply lines are bled.
7. After all air is removed from the grease system, manually cycle the lubrication system via the GUI Lube screen and check all injectors for proper operation.
Bleeding Air from Supply Lines After Component Replacement
When installing new or repaired lubrication components such as the injectors, air is introduced into the grease sys-tem supply lines. This air will cause a fault warning alarm to sound, or, if undetected, could cause excessive wear and premature component failure.
When bleeding air from the supply lines after installation of a component, it is only necessary to bleed air from the section of supply line into which the component was installed.
To bleed air from the supply lines after installation of a component, proceed as follows:
1. Start the drill. Station the operator at the controls to prevent anyone from operating the drill while performing bleeding procedures.
2. If necessary, adjust the lube cycle time and interval at the GUI to slow grease pump operation.
3. If an injector, or set of injectors, was installed, remove the plug(s) at the injector (Figure 8-21). If a pressure switch was installed, or if a hose or pipe was replaced, loosen the next fitting in that section of the supply line. Collect the lubricant discharged during the bleeding process in a drain pan.
A. Start a manual lubrication cycle using the GUI. It will be necessary to start a manual lubrication cycle several times to complete the bleeding process.
BD120149 Mechanical Systems Manual Automatic Lubrication System
B. Close the air flow control valve. Record the number of turns required to close the valve.
C. Open the flow control valve enough so that the grease pump runs slowly.
4. Operate the grease pump until lubricant flow is free of air or foreign matter.
5. Replace the plug and tighten the fitting.
6. After all air is removed from the system, manually cycle the lubrication system via the GUI Lube screen and check the injector(s) for proper operation.
Bleeding Air from Feeder Lines
To bleed air from feeder lines, refer to Figure 8-22 and proceed as follows:
1. Disconnect the feeder line at the lube point.
2. Remove the cap from the filler fitting on the injector.
3. Using a grease gun containing the same type of grease being used in the lubrication system, attach the grease gun nozzle and pump grease through the feeder line until clean grease, free of dirt and contaminants, exits the feeder line.
4. Remove the grease gun, replace the cap on the filler fitting, and connect the feeder line at the lube point.
8.3.5.9 System Start-up After Repair
When returning the drill to service after repairs, make the following checks:
1. Check the lubrication intervals on the GUI Lube screen. Adjust if necessary.
2. Manually cycle the grease system and check the following for proper operation:
Automatic Lubrication System BD120149 Mechanical Systems Manual
A. Observe the pressure gauge, pressure switches and the Upper Grease Solenoid to verify proper operation and adjustment. Adjust as required.
B. Observe injectors for proper operation. Check injector indicators for complete motion. SL-1 injector indicators will lower when the injector discharges lubricant. The indicator will remain in the lowered state until the pump turns off, and will then raise when the injector is reset.
8.4 Troubleshooting
Problem Possible Cause Remedy
Grease pump does not run Circuit breaker off or PLC off Turn on circuit breaker or PLC
Low or no drive oil pressure Identify and correct problem in low pressure hydraulic system.
Faulty grease pump Repair or replace grease pump
Grease pump does notbuild pressure
Leak at hoses or connections Check condition of hoses and tight-ness of connections. Replace faulty hoses. Tighten all connections.
Pockets of air in system Bleed lube lines
Obstructed pump inlet Clean pump inlet and check valves as required. Drain and clean tank interior to remove debris as required.
Grease pump reducing valve set too low
Adjust reducing valve setting to 220 psi (15.2 bar).
Faulty vent valve Repair or replace valve.
Faulty pump Repair or replace grease pump.
Grease pump runs erratically Erratic drive oil pressure Identify and correct problem in low pressure hydraulic system.
Faulty pump solenoid Repair or replace solenoid
Faulty pump cylinder Repair or replace cylinder
Faulty reducing valve Repair or replace reducing valve
Grease pump operates but cycle does not complete
Incorrect pressure switch setting Set pressure switch to 2500 psi.
Faulty pressure switch Repair or replace pressure switch.
Grease pump reducing valve set too low
Adjust reducing valve setting to 220 psi (15.2 bar).
BD120149 Mechanical Systems Manual Automatic Lubrication System
Lack of grease at lube point Leaking lines Inspect hose from lube point to injector for loose connections or ruptured hose. Correct deficiencies.
Blocked line Check injector stem for movement during lube cycle. If unit is not working, disconnect supply hose and flush at the fitting with a grease gun to clear line. Connect supply hose.
Faulty injector Repair or replace faulty injector.
Lack of grease at injector manifolds Clogged or rupturedsupply hose(s)
Disconnect supply hose and flush using a grease gun to clear the line. Replace faulty hose and con-nect hose after service.
Blocked manifold Remove injectors or measuring valves. Disconnect supply hose and flush manifold using a grease gun to clear. Install injectors or valves and connect hose after service.
Inadequate grease at lube points No grease supply Check grease tank and replenish as required.
Incorrect viscosity Check grease weight. Grease may be too heavy for operating environ-ment.
Leaking lines Inspect applicable lines for leak-age. Correct deficiencies.
The drill is propelled by left and right hand crawler tracks mounted on crawler side frames. The crawler assemblies are identical to each other except that they are configured as left- and right-hand units.
9.2 Theory of Operation
Each crawler track is driven by a reversible hydrostatic drive system. Pressurized hydraulic oil is supplied to each hydraulic motor by individual pumps in the main hydraulic system. The direction of crawler travel is reversed by reversing the direction of fluid flow through the motors. This is accomplished when the operator moves the propel control levers on the operator console.
Propel speed is controlled by modulating the volumetric rate of hydraulic fluid passed through the motors. Each propel drive transmission is flange-mounted at the front end of the crawler frame. The transmission consists of a three stage planetary gear reducer with an integrated spring-set, hydraulically released, disc brake. The propel motor is flange-mounted to the input shaft end of the transmission, as an integral part of the transmission unit. Each transmission has a manually operated mechanical coupling (only used with the optional towing package, which is included with this drill).
The propel brakes are automatically released when hydraulic pressure is applied to the propel motors. When hydraulic pressure is removed or lost, the brakes automatically apply, thus preventing uncontrolled machine travel.
The crawler transmissions multiply the torque received from the hydraulic motors and produce output torque to rotate the drive tumblers, which are bolted to the transmission hub. The drive tumblers engage and drive the crawler tracks. The crawler side frames are connected to the main frame at the rear of the machine by a rigidly mounted main axle. A compensating equalizer axle at the front of the crawlers is designed to maintain the machine in a stable condition while traversing uneven terrain.
NOTICE
Power for the propel system is provided by the main hydraulic system. Because of its complex-ity, the main hydraulic system is covered as a separate section in this manual. Refer to Section4, Main Hydraulic System..
9.2.1 Propel Motor 41U100D2
The propel transmissions are driven by variable-displacement, plug-in type, axial piston hydraulic motors of bent axis design. The propel motor is an integral component of the propel transmission assembly, but it can be removed independently.
When the operator places the drill in PROPEL mode, the PLC allows the joystick to control the propel pump ser-vos. As the joystick is moved, hydraulic pressure is ported to the propel motor, and the propel motor causes the propel transmission to turn.
The propel brakes are an integral part of the propel transmission. When the operator’s BRAKE RELEASE button is in the RELEASE position and when the joystick is moved off its neutral position, oil is ported from the main pumps
to special brake ports in the motor (not the same pressure lines as those that drive the motor) to cause the brakes to release. When the joystick is in the neutral position, the brakes are not released.
The piston displacement is hydraulically actuated, and can be controlled by the drill operator. When the operator places the DRILL SPEED switch to LOW speed setting, the motor’s maximum displacement provides high torque, low speed propelling. When the switch is in the HIGH speed setting, the motor’s minimum displacement provides low torque, high speed propelling.
The high speed/low torque setting provides for a specific minimum motor displacement. The motor’s swash plate is in its destroked configuration. The amount the swash plate can move in the destroked direction is limited by a phys-ical stop that can be adjusted by turning the stop in or out, adjusting the degree to which the plate can be destroked.
The low speed/high torque setting provides for a specific maximum motor displacement. The motor’s swash plate is in its fully stroked configuration. The amount the swash plate can move in the stroked direction is limited by a physical stop that can be adjusted by turning the stop in or out, adjusting the degree to which the plate can be stroked.
9.2.2 Propel Transmission 53R176D2
The propel transmission (refer to Figure 9-3) is a three-stage planetary gear reducer with an integral hydraulically-released, multiple-disc brake. The transmission and motor can be removed or installed as a unit, without need for disassembly or subassembly of its components.
The drive tumbler, R54640D2, meshes with lugs on the crawler track shoes, causing them to move. The crawler track shoes are supported by rollers at the top of the crawler frames and provide a continuous track on which the drill propels.
There are two crawler assemblies, one on either side of the drill. They are connected to the drill’s main frame by means of two axles:
9.2.3.1 Equalizer Axle R11405F1
The equalizer axle is mounted to the forward end of the main frame by a large pin and clevis at the center bottom of the frame. It attaches to the two crawler frames by means of pins. This arrangement permits some flexibility side-to-side as the drill propels over uneven terrain.
9.2.3.2 Main (Pivot) Axle R41245D1
The main axle, also called the pivot axle, is mounted to the underside of the main frame by two split collars. To attach the crawler frames, the axle extends through an unbushed bore at the rear of each crawler frame. The con-nection is secured by a retainer plate bolted into the end of the shaft. This arrangement permits some flexibility front-to-back as the drill propels over uneven terrain.
The crawler frames support and distribute the weight of the drill to the ground. In addition to the propel transmis-sion assembly and the two axles, the crawler frames contain three upper rollers, ten lower rollers, and an idler roller.
9.2.3.4 Upper and Lower Rollers 13P627F1
On each crawler frame, thirteen rollers support the track as it moves around the crawler frame. Three upper rollers support the weight of the track as it moves across the top of the crawler frame. Ten lower rollers support and dis-tribute the weight of the drill to the crawler track.
At the rear of each crawler frame, an idler roller is used to maintain alignment of the track shoes as they move around the crawler frame. The idler roller is mounted in sliding bearing blocks, which enable it to move fore and aft in the crawler frames. This provides a means of adjusting track tension.
9.2.3.6 Crawler Track R3122F2
The crawler track provides a surface on which the drill propels. It consists of a series of shoes pinned together to form a continuous track. The shoes are 36" wide. The original set includes 58 shoes, 1/3 of which are cleated.
The propel transmissions are driven by variable-displacement, plug-in type, axial piston hydraulic motors of bent axis design.
The piston displacement control is hydraulically actuated, and can be positioned by the drill operator to either the maximum displacement for high-torque/low-speed propelling, or to the minimum displacement for low-torque/high-speed propelling. The minimum and maximum displacement adjustments are factory set.
The motor is an integral part of the propel transmission. However, it can be removed from the transmission for replacement without having to remove the transmission from the crawler frame.
9.3.1.1 Removal
To remove either propel motor proceed as follows:
1. Position the machine on level ground. Block the machine to prevent movement in either direction.
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
2. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
3. Clean all dirt away from the hydraulic motor and hose assemblies.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
4. Check to be certain that the hydraulic pressure is completely vented from the high-pressure and control pres-sure circuits.
5. Close the Handwell valves.
6. Tag and remove the hydraulic hoses from the motor. Cap or plug all hose fittings and motor ports.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects.
7. Attach a suitable hoist to the motor to prevent an overhung load on the shaft when the mounting bolts are loos-ened.
8. Mark the mounting position of the motor on the transmission so that the hose connection ports will be correctly located when the motor is reinstalled. Identify the motor, if more than one is being removed, to assure that it is remounted on the same transmission.
9. Remove the capscrews and lockwashers from the mounting flange of the motor, and pull it away from its mounting. Use care to prevent binding of the shaft or damage to the spline teeth when withdrawing the motor.
10. Remove and discard O-ring from the pilot diameter on the motor.
9.3.1.2 Cleaning, Inspection, And Repair
Clean and inspect the propel motor and motor mounting area in accordance with the general cleaning and inspec-tion procedures described in Appendix A of this manual. Inspect the drive splines for wear or tooth damage. Inspect the hydraulic hoses and fittings for damage or signs of leaking. The motor shaft seal can be replaced, but
the propel motors are not field repairable, and must be replaced if they become worn or damaged. Replace O-ring whenever the motor is removed from the transmission. Refer to the LinkOne electronic parts manual for compo-nent identification.
9.3.1.3 Installation
Install the hydraulic motor on the propel transmission as follows:
1. Lubricate O-ring with oil, and install on the hydraulic motor pilot diameter.
2. Grease the motor output shaft spline with lithium grease.
CAUTION!
Assembling heavy components with inadequate hoisting apparatus can injure personneland/or damage equipment. Use suitable slings and hoisting equipment to stabilize andlift heavy objects.
3. Using a suitable lifting device, lift the hydraulic motor and insert the shaft into the bore of the transmission input shaft. Note the identification markings to ensure correct location of the motor. The motor case drain fitting should be positioned at the top. Be careful to avoid side loading and/or binding of the shaft as the motor is moved into position against the transmission.
4. Fasten the motor to the transmission with socket head capscrews, M30X180, DIN 10.9.
5. Fill the motor case with clean oil, then install the hydraulic hose assemblies in accordance with the identifica-tion tags placed during motor removal.
6. Open the Handwell valves.
7. Start the hydraulic pumps, and bleed air from the control and high-pressure circuits.
9.3.1.4 Adjustment
Technician Tip
Propel motors are preset and should only need adjustment in rare instances. Consider that themotors receive their flow from the main pumps, and the main pump minimum and maximumdisplacement settings affect the propel speed as much as the motor displacement. Beforeadjusting any motor settings, be certain that all pump settings are as specified and that theother components of the propel system are working properly.
The propel motor features variable displacement, and provides either high speed and low torque, or low speed and high torque. This feature is activated by a switch on the operator’s console.
The motors are adjusted at the factory for both high speed and low speed, and in most instances do not require re-adjustment once the drill is in production. In the event that the drill does not propel evenly, however, the capability to adjust the high speed and low speed settings is provided. Confirm that the pumps are properly adjusted prior to adjusting the propel motors.
Refer to Figure 9-9 and adjust the propel motor settings as follows:
NOTICE
The motor displacement adjustments are not capable of modulating the servo settings to inter-mediate positions. Their function is limited to establishing the maximum and minimum setpointsfor motor piston displacement. At the maximum displacement position, the motor has the lowestoutput speed and highest torque capability. At minimum displacement, the motor has the high-est speed and lowest torque capability.
1. Start the main drive, and raise the drill with the jacks until the crawler tracks are completely clear of the ground.
CAUTION!
Operation of the propel system with the drill partially supported on the jacks can causeinjury to personnel and damage to the equipment. Check visually to be certain that thecrawler tracks are raised completely off the ground before operating the propel drive.
2. Place the PROPEL MODE - MAINTENANCE switch, located on the operator console, in the MAINTENANCE position to enable operation of the propel drive while the drill is supported on the jacks.
Figure 9-9: Propel Motor Adjustments
01
02
BD0523a01
LEGEND01. Maximum Displacement Adjustment02. Minimum Displacement Adjustment
Motor displacement caps are part of the sealing system designed to prevent oil from leakingaround the adjusting screw. Always re-install the cap after adjustments have been made.
4. Adjust the maximum displacement stops on each propel motor to obtain drive tumbler speed of 4.0 rpm at maximum pump output. Turn the adjusting screw inward (clockwise) to increase tumbler speed.
5. Adjust the minimum displacement stops to obtain drive tumbler speed of 8.0 rpm at maximum pump output. Turn the adjusting screw outward (counterclockwise) to increase tumbler speed.
Lower the drill from the jacks, and test the propel mode for straightness of tracking.
The transmission and motor can be removed or installed as a unit, without need for disassembly or subassembly of its components.
9.3.2.1 Removal
Refer to Figure 9-11 and remove the propel transmission from the crawler frame assembly as follows:
1. Position the drill on firm even ground, and rotate the crawler drive so that the transmission oil drain plug is at the six o'clock position.
2. Raise the drill with the jacks to relieve the weight from drive tumbler, and place blocking under the machine frame for support.
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
3. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
4. Separate two track links (08), and remove the crawler track from the top of the drive tumbler (Refer To Sub-topic 9.3.5.1).
5. Clean all dirt away from the hydraulic motor and hose assemblies.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
6. Check to be certain that the hydraulic pressure is completely vented from the high-pressure and control pres-sure circuits.
7. Turn Handwell valves off.
8. Tag and remove the hydraulic hoses from the motor. Cap or plug all hose fittings and motor ports.
9. Tag and remove the hydraulic hose assembly from the brake pressure supply fitting on the transmission. Cap or plug the hose fitting and brake hydraulic supply port.
10. Remove thirty capscrews from drive tumbler.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects.
11. Attach suitable lifting equipment to drive tumbler, and remove it from transmission.
12. Remove the transmission lubricant fill and drain plugs, and drain the oil into a suitable disposal container. Install the plugs again, when all of the lubricant has been drained.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects. The transmission and motorassembly weighs approximately 2800 lbs (1270 kg).
13. Support propel transmission with adequate lifting/moving equipment. Be sure it is positioned straight and level in relation to the crawler frame bore.
14. Remove thirty capscrews that fasten transmission to crawler frame.
15. Slide transmission out of the pilot bore in the crawler frame, being careful to move straight out to prevent cock-ing of the spindle in the frame bore. Protect the motor from contacting the frame as it is being withdrawn through the frame.
16. Transport the transmission to a suitable, clean work area for disassembly.
9.3.2.2 Disassembly
Disassemble the propel transmission as follows:
1. Place the transmission on blocks with the hydraulic motor located at the top.
2. Remove the hydraulic motor from the input end of the transmission, as described under the Subtopic 9.3.1.1, Steps 6 through 8, inclusive.
3. Remove bolt, retaining plate and coupler.
4. Remove hydraulic hose adapter and ring seal from the spindle.
5. Attach a spring cage fixture and protective buffer (Figure 9-13) to the spindle, and apply enough axial force against coupler to enable removal of snap ring.
6. Back out the adjustment screw slowly to allow concentric compression springs to completely relax while they push back-up plate and coupler away from piston.
7. Remove the spring cage fixture from the spindle, then pull coupler and back-up plate out of the spindle coun-terbore.
8. Remove compression springs from the spring pockets in piston. Discard the springs.
Figure 9-13: Spring Cage Fixture
01
02
03
04
BD0524a01
LEGEND01. Spring Cage Fixture02. Buffer03. Adjusting Screw04. 20MM Screw
9. Place a large, clean, protective rag into the counterbore of the spindle, then apply very-low-pressure com-pressed air through the brake hydraulic pressure supply port. Increase the air pressure slowly until piston is forced out of the bore and onto the rag. Remove the piston and rag from the spindle.
10. Remove and discard the O-ring and back-up ring from piston. Notice the relative positions of the O-ring and back-up ring for reassembly.
11. Remove snap ring from the inside end of shifter shaft, then remove coupler from the shifter shaft.
12. Remove and discard the O-ring and back-up ring from the spindle bore. Notice the relative positions of the O-ring and back-up ring for reassembly.
13. Remove and discard the eleven inner and five outer brake disks.
14. Remove brake back-up plate from the assembly.
15. Remove snap ring from the counterbore of the spindle.
16. Remove snap ring from bearing carrier.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects
17. Attach suitable hoisting equipment, and reposition the transmission assembly so that the motor-mounting face of the spindle is down, and well supported on wooden blocking.
18. Remove bolts from spacer, then remove spacer and cap from the end cover.
19. Remove the twenty-four bolts, and remove the end cover.
Figure 9-14: Brake Disk Arrangement
01
02
03BD0525a01
LEGEND01. Piston02. Outer disk (5 pieces)03. Inner disk (11 pieces)
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects
20. Place lifting eyes in the threaded screw holes in the end cover, support the cover with adequate lifting/moving equipment, then lift the end cover and entire shifter shaft assembly away from the transmission.
CAUTIONTo avoid damage to the shifter shaft, be sure to lift the end cover straight up to enablethe shifter shaft to be withdrawn without binding.
21. Loosen the thrust washer from the pilot diameter in the end cover, then remove the thrust washer from shifter shaft.
22. Remove snap ring from shift ring.
23. Remove bolts from shift ring, then remove the shift ring, with shifter shaft and ball bearing intact, from the end cover.
24. Remove snap ring from shift ring, and remove shifter shaft and ball bearing from shift ring.
25. Remove and discard O-ring from shift ring bore.
26. Remove locking nut, then press the ball bearing from the shifter shaft.
27. Carefully lift the third stage planetary out of the ring gear, and away from input shaft.
28. Loosen ring gear A from the pilot diameter in ring gear B, and remove ring gear A from the assembly.
29. Remove and discard the two O-rings from ring gear A.
30. Remove input shaft and thrust washer. Be careful to prevent the thrust washer from dropping off the end of the input shaft.
31. Remove thrust washer from input shaft.
32. Lift sun gear shaft, including snap ring, out of the assembly. Then, remove snap ring from the sun gear shaft.
33. Carefully lift the second planetary stage gear assembly out of ring gear B.
34. Lift sun gear shaft out of engagement with the first stage planetary.
35. Remove locating ring from bearing carrier.
36. Carefully lift the first stage planetary, bearing carrier, ball bearing, and coupler as a unit out of ring gear B.
37. Remove coupler and ball bearing from bearing carrier by removing snap ring.
38. Remove ball bearing from coupler by removing snap ring.
39. Remove the crimping on the eight locations of shaft nut, then loosen and remove the shaft nut from the spindle.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects.
40. Attach a suitable lifting device to ring gear B, and lift the ring gear away from the spindle. The cups and one cone of the two tapered roller bearings, and one half of face seal, will remain with the ring gear.
41. Remove tapered roller bearing cone from inside ring gear B.
42. Remove the other tapered roller bearing cone from the hub of the spindle.
43. If bearings are going to be replaced, remove the two bearing cups from ring gear B.
44. Remove each half of face seal from ring gear B and the spindle.
9.3.2.3 Cleaning, Inspection, And Repair
Clean and inspect the propel transmission components in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. None of the components are repairable, and, therefore must be replaced if worn or damaged. If a component in any one of the three planetary gear assemblies needs replace-ment, that entire planetary unit must be replaced. It is recommended that all O-rings be replaced whenever the transmission is disassembled for repair. Refer to the LinkOne electronic parts manual for component identification.
9.3.2.4 Assembly
Refer to Figure 9-11 and assemble the propel transmission as follows:
1. Position the spindle with the motor mounting side down on clean wooden blocking.
2. Install the two cups from tapered roller bearings (19) in the bearing seats of ring gear (B). Be certain that the cups remain seated firmly against the shoulder in the counterbore.
NOTICE
Dry ice may be used to freeze the cups, so they may be installed. If the cups are pressed intothe housing, extreme care should be taken so they are not damaged.
3. Install one half of face seal (18) on the spindle.
4. Install one cone of tapered roller bearing (19) on the spindle.
5. Pack the half of face seal (18) and bearing cone (19) with an excess of clean grease.
6. Install the other half of face seal (18) in ring gear (B).
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects.
7. Attach suitable hoisting equipment to ring gear (B), and position the ring gear on the spindle so bearing (19) and face seal (18) halves are correctly mated.
8. Pack bearing (19) seat area with an excess of clean grease.
9. Install remaining tapered bearing cone (19) with shaft nut (20). Tighten the nut finger tight. Be sure that the bearing cone seats correctly in the cup.
10. Measure the axial position of ring gear (B) relative to the spindle, then torque shaft nut (20) until the bearing is preloaded 0.3mm (0.012"). Crimp the torque nut flange in eight equally spaced locations.
NOTICE
Ring gear (B) may be rotated in only one direction during preloading of the tapered roller bear-ings.
11. Install ball bearing (22) on coupler (39), and retain it with snap ring (11).
12. Install coupler (35) and mounted bearing (22) in the bore of bearing carrier (23), and fasten with snap ring (21).
NOTICE
The bearing retainer should already be assembled as a factory-installed component of the thirdstage planetary (25).
13. Install the third stage planetary (25) in ring gear (B). Mesh the planetary gear/ring gear teeth and the planetary gear carrier/spindle splines with care to avoid causing nicks and burrs. Lubricate the teeth with gearcase oil before assembly.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects.
14. Attach a suitable hoisting apparatus to ring gear assembly (B), and position the unit on its side.
15. Install snap ring (31) on bearing carrier (23). Access can be gained through the input shaft opening in the spin-dle.
16. Reposition the transmission assembly so the unit is resting securely on wooden blocking with the motor mount-ing face of the spindle down.
17. Install locating ring (24) in pilot counterbore of bearing carrier (23).
18. Install sun gear shaft (27) in the third stage planetary (25). Be sure the relieved face of the sun gear is inserted first, and that it seats against locating ring (24).
19. Install the second stage planetary (26) into ring gear (B) and over the end of sun gear shaft (27). Retain the planetary gear assembly with snap ring (28).
20. Install the sun gear (15) in the second stage planetary (27). Be sure that the counterbored end of the gear is positioned at the top after installation.
21. Slide thrust washer (15) over end of the input shaft (34), then insert the splined-end of the input shaft through the center of the sun gear shafts, and mesh the splines with those in coupler (35). The thrust washer bottom face should be seated on the bottom of the counterbore in sun gear (15).
22. Lubricate two O-rings (16) with oil, and install them in O-ring grooves of ring gear (A).
23. Line up the through-bolt holes in ring gear (A) with the tapped holes in ring gear (B), then insert ring gear (A) pilot diameter into the counterbore of ring gear (B). Be sure that the matching faces of the two ring gears are tight together, when installed. Do not install the mounting bolts at this time.
24. Carefully install the first stage planetary (13) in ring gear (A) and over input shaft (34).
25. Install ball bearing (07) on shifter shaft (33), and retain the bearing securely with lock nut (06).
NOTICE
Apply Loctite compound to the threads of the lock nut before assembling to the shifter shaft.
26. Install shifter shaft (33) and mounted bearing (07) into the counterbore of shift ring (05), and fasten in place with snap ring (08).
27. Lubricate and install O-ring (10) in the bore of the end cover.
28. Assemble shift ring (05) with mounted shifter shaft to the end cover, and fasten with bolts (04). Torque the bolts to 38 ft lbs (51 N.m).
NOTICE
Apply molybdenum-based protectant/sealant to sealing surfaces and threads. AVOID contactwith sealant and O-ring (10). Assemble the parts only after sealant has cured (dried).
29. Install snap ring (11) on shift ring (05).
30. Slide thrust washer (12) over shift shaft (33) and position in the pilot counterbore of the end cover.
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects.
31. Attach suitable hoisting equipment to the end cover assembly and lift it into position above the ring gear. Lower the end cover so that the shift shaft feeds through the center of input shaft (34), and the cover closes com-pletely over the pilot diameter of ring gear (A). Install twenty-four bolts (09) and torque in a crisscross pattern evenly, and uniformly to 85 N.m (63 ft-lbs).
NOTICE
Input shaft (34) should have 0.039-0.079" (1-2 mm) end play after the end cover is installed.
32. Apply molybdenum-based protectant/sealant to the sealing surfaces of the cap (02) and spacer (03), and to the threads of bolts (01). Allow to dry before assembling to the end cover. Torque the bolts to 38 ft-lbs (51 N.m).
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects.
33. Attach suitable hoisting apparatus to the propel transmission and position it so that the end cover is on the bot-tom and the input shaft side is exposed on top for assembly.
34. Install snap ring (32) in the brake disk area of the spindle.
35. Install back-up plate (36) against snap ring (32).
36. Install inner and outer brake disks (38 and 39), and be sure that they are correctly engaged with the spindle and coupler (35). Refer to Figure 9-14 for the arrangement of the inner and outer brake disks.
37. Lubricate back-up ring (41) and O-ring (42) with gear oil, and install in the spindle. The back-up ring must be installed before the O-ring.
38. Install coupler (48) on shifter shaft (33), and retain it with snap ring (49). Lubricate splines with gear oil before inserting coupler (48) into coupler (35).
39. Lubricate back-up ring (44) and O-ring (43) with gear oil, and install on the outside diameter of piston (45). The back-up ring must be installed before the O-ring.
40. Install piston (45) in the counterbore of the spindle, and push it in as far as it will go against the brake disks. Lubricate the counterbore with gear oil before installing the piston.
41. Position back-up plate (46) subassembly in the counterbore of the spindle until it contacts the brake springs.
42. Attach the spring cage fixture and protective buffer to the spindle, and apply enough axial force against coupler (48) to enable compression of the brake springs. Press the shaft in only to the point where back-up plate (46) seats firmly against the bottom of the counterbore in the spindle. Over-tightening can cause damage.
43. Install snap ring (47) in the spindle to retain back-up plate (46).
44. Remove the spring cage fixture from the spindle.
45. Install seal ring (29) and adapter (30) in the brake hydraulic pressure port, and tighten securely.
46. Install coupler (52) on the motor spindle with retaining plate (51) and bolt (50).
47. Install the hydraulic motor on the propel transmission as described above under Subtopic 9.3.1.3, Step 1 through Step 4.
Refer to Figure 9-15 and install the propel transmission on the crawler frame as follows:
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects. The transmission and motorassembly weigh approximately 2800 lbs (1270 kg).
1. Attach suitable hoisting apparatus to propel transmission (15) and position it so that the hydraulic motor end is aligned with the pilot bore in crawler frame (18). Be sure that the lube drain plug is located at the six o'clock position, then insert the transmission into the frame.
2. Align the screw holes in the transmission with those in the frame, then install the thirty capscrews (14). Torque the capscrews to 1526-1873 ft-lbs (2070-2540 N.m).
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects.
3. Attach suitable lifting equipment to drive tumbler (16), and install it on transmission (15) with thirty capscrews (17). Torque the capscrews to 1526-1873 ft-lbs (2070-2540 N.m).
4. Install crawler track (08) on drive tumbler (16). Refer to Subtopic 9.3.5.3 for installation procedures.
5. Install the hydraulic pressure hose assembly for the brake to the fitting on the transmission spindle.
6. Install the high-pressure and control pressure hoses to the motor.
7. Remove the transmission lubrication fill/level plug and fill the transmission with approximately 9.5 gallons (36 liters) of gear oil (refer to Subtopic 16.3.5). Check and replace the fill plug seal if damaged, then install the plug securely.
9.3.3 Idler Roller 13N385D1F1
The idler roller keeps the crawler track aligned. The idler roller is mounted in sliding bearing blocks, which enable it to move fore and aft in the crawler frames. This provides a means of adjusting track tension.
9.3.3.1 Removal
Remove the idler roller assembly as follows:
1. Position the machine on level ground.
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out and
tag the operator controls to prevent inadvertent machine start-up during maintenancework.
2. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
3. Separate the crawler track as described under Subtopic 9.3.5.1 and remove it from the idler roller.
4. Remove two cotter pins (02) from each upper shim pin (20) on the inside and outside frame locations, then remove both upper shim pins from the crawler frame.
5. Note the locations of shims (22 and 23) ahead of and behind inner and outer idler bearings (25), then remove all shims (refer to Subtopic 9.3.5.4 for shim removal procedure).
6. Remove the lubrication hose assembly from idler shaft (30).
7. Remove cotter pins (24) from each idler shaft pin (26), and remove the idler shaft pins from two idler bearings (25).
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects.
8. Attach suitable lifting equipment to the idler roller, and lift the weight of the idler from idler shaft (30).
9. Remove two idler bearings (25) and idler thrust washers (27) from each end of idler shaft (30).
10. Remove idler shaft (30) from idler roller (28), then lift the idler away from the crawler frame.
9.3.3.2 Cleaning, Inspection, And Repair
Clean and inspect the idler roller components in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. None of the components are repairable, therefore, replace any that are damaged or worn. Refer to the LinkOne electronic parts manual for component identification.
9.3.3.3 Installation
Refer to Figure 9-15 and install the idler roller assembly as follows:
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects.
1. Using suitable lifting equipment, position idler roller (28) in the pocket of crawler frame (19).
2. Lubricate idler shaft (30) with oil and install it in the bore of idler roller (28). Position the shaft so that the grease hole is horizontal, and is pointed toward the tumbler end of the crawler.
3. Install thrust washer (27) on idler shaft 30) at each side of the idler roller.
4. Install idler bearing (25) on each end of idler shaft (30), and fasten it with idler shaft pin (26) and two cotter pins (24).
5. Install shims (22 and 23) in the same positions on each side of inner and outer idler bearings (25) as before removal.
6. Lock the shims in place with upper shim pins (20) and two cotter pins (03).
7. Install the lubrication hose assembly to idler shaft (30).
8. Refer to Subtopic 9.3.5.3 and reassemble the crawler track.
9. Adjust the crawler track tension as described under Subtopic 9.3.5.4.
9.3.4 Upper and Lower Rollers 13P627F1
On each crawler frame, thirteen rollers support the track as it moves around the crawler frame. Three upper rollers support the weight of the track as it moves across the top of the crawler frame. Ten lower rollers support and dis-tribute the weight of the drill to the crawler track.
Each roller is supported by a shaft mounted in a bushing along the side frame. The rollers are lubricated by the auto-lube system.
To remove the upper or lower rollers, proceed as follows:
1. Position the machine on level ground.
WARNING!
Inadequate blocking of a raised drill can enable the machine to drop causing severeinjury, death, and/or equipment damage. Do not perform maintenance work under thedrill until it is securely blocked.
2. Raise the machine and position secure blocking beneath the frame.
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
3. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
4. Separate the crawler track as described under Subtopic 9.3.5.1. Remove the lubrication hose assembly from the roller shaft.
5. Remove the cotter pins from the roller shaft pin.
6. Remove the roller shaft pin from lower or upper roller shaft.
7. Place blocking below the roller to prevent the roller from dropping when the roller shaft is removed.
8. Remove the lower or upper roller shaft from the roller, then remove the roller and thrust washers from the frame.
9.3.4.2 Cleaning, Inspection, and Repair
Clean and inspect the track support roller components in accordance with the general cleaning and inspection pro-cedures described in Appendix A of this manual. None of the components are repairable; therefore, replace any that are damaged or worn. Refer to the LinkOne electronic parts manual for component identification.
9.3.4.3 Installation
Install the roller as follows:
9. Block the support roller with shim thrust washers in position within the crawler frame.
10. Lubricate the roller shaft with grease, and install the shaft through the frame supports and roller.
11. Install roller shaft pin in the roller shaft, and fasten it with two cotter pins.
12. Install the grease lubrication hose to roller shaft.
13. Manually operate the lubrication system and bleed the lines to the crawlers as required. Refer to Section 8, Automatic Lubrication System..
9.3.5 Crawler Track Assembly
The crawler track assembly consists of a series of individual links (shoes), which are connected with link pins to form the continuous track upon which the drill is propelled. The links are available in various widths and configura-tions to accommodate differing soil conditions. The links on this drill are 36” wide; 2/3 of the links are cleated.
9.3.5.1 Track Link Removal
Remove track links as follows:
1. Propel the drill so the link to be removed is located behind the idler roller, and as near to ground level as possi-ble, but with sufficient clearance to drive out the link pins.
2. Place temporary blocking between the under-side of the track links and the top of the crawler frame to support the track when the link pins are removed.
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
Figure 9-17: Crawler Links
LEGEND01. Track Link02. Cleated Link03. Link Pin04. Pin Retainer05. Nut
NOTE: Nut is tack welded to pin retainer. Nut must be tight prior to welding. Torque nut to 75 ft lbs (102 Nm) and tack weld.
3. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
4. Remove the link pin retaining capscrew and hex nut from the track link (refer to Figure 9-17). The hex nut is tack welded to the capscrew to prevent it from vibrating loose during operation. Cut off the weld, or break the capscrew to remove it from the track link.
5. Remove the link pins at the place where the track is to be separated using one of the following two methods:
WARNING!
The weight of a falling track can cause serious injury or death. Do not stand in the pathof a crawler track when the link pin is being removed.
Slide Hammer Method
CAUTION!
Sparks or flying metal chips can injure eyes or face. Wear eye and face protection whenusing hammers.
A. Obtain a rod with one end threaded for a nut.
B. Grind a 3/4" (19mm) x 45 degree chamfer on the other end of the rod.
C. Weld the ground end to the link pin (refer to Figure 9-18). Use sufficient weld to prevent the rod separating from the pin.
D. Slide the slap hammer onto the rod, and install the hex nut on the rod end.
E. Remove the rod by slapping the hammer against the rod nut (refer to Figure 9-19).
A. Obtain a smooth threaded rod of sufficient length and strength, with a mating hex nut on one end. The threaded rod must be less than 1.5 inches (38 mm) diameter to fit into the bore of the track link.
B. Thread the hex nut on the striking end of the threaded rod.
C. Insert the rod into the bore of the track link, and drive the link pin out. The rod will need to be bent slightly at the pin end to clear the link.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects.
D. Attach suitable lifting equipment to stabilize the link being removed, then disassemble the remaining link pins that fasten the link to the track. Link weight is approximately 450 Ibs (200 kg).
E. Remove the uncoupled link from the crawler track.
9.3.5.2 Cleaning, Inspection, and Repair
Clean and inspect the idler roller components in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. Repair of the crawler track is limited to replacement of defective link pins and welding of the damaged track links.
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities, if the track link is being repaired while mounted to the drill.
2. Check suspected cracks with liquid dye penetrant or Magnaflux.
3. Clean the area to be welded. Remove all surface grease, oil, etc.
4. Grind or air-gouge the crack completely.
5. Pre-heat the weld zone to 600-700°F (315-370°C) and maintain this temperature during welding, checking with a temperature indicating crayon.
6. Weld the track link with 10018-M electrodes. Pre-heat the electrodes in an oven at 350°F (175°C). Remove only two electrodes from the oven at a time for use.
7. Slowly cool the track link after welding by wrapping the weld area with an insulating blanket.
9.3.5.3 Track Link Installation
Refer to Figure 9-17 and install track links as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator - controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can cause the load todrop, resulting in personal injury and/or damage to equipment. Use suitable slings andhoisting equipment to stabilize and lift heavy objects.
2. Using a lifting device of sufficient capacity, align the open track ends. Use a drift pin to help align the link pin bores.
3. Install the link pins in the bores in the track links. There should be a slip-fit between the pin and the bore.
4. Install the link pin retaining capscrew and hex nut. Tighten the nut to 75 ft-lbs (102 Nm) maximum.
5. Tack weld the hex nuts to the capscrews to prevent loosening.
6. Repeat Step 2 through Step 5 to install addition track links and pins.
9.3.5.4 Track Tension Adjustment
Adjustment of crawler track tension is accomplished by adding or removing shims to the track adjustment mecha-nism. A manually-operated hydraulic pump and two hydraulic rams with the required connecting hoses are fur-nished with the machine, and are used to assist with track adjustment. To adjust track tension, proceed as follows:
1. Position the machine on level ground, then use the drill jacks to raise the drill enough to lift the crawler tracks clear of the ground.
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
2. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
3. Remove two cotter pins from each upper shim pin on the inside and outside frame locations, then remove both upper shim pins from the crawler frame.
4. Remove loose shims from behind inner and outer idler roller bearings (24).
5. Install one ram on the inboard side of the crawler frame between the ram support bracket on the crawler frame and the idler bearing. Position the other cylinder similarly on the outboard side of the frame.
6. Connect the hydraulic hand pump to the two rams.
7. Operate the hand pump to pressurize the rams. This action moves the idler bearings to the rear, and removes slack from the crawler track. Continue operating the pump until the crawler track sag is approximately 12" - 14" (300mm - 350 mm), as measured at the track midpoint, between the top of the crawler link and the underside of the crawler frame. Refer to Figure 9-21
8. Add shims as required on the ram side of the idler bearings to maintain the new position and ensure that the track sag will remain as set. Use the shims which were removed from behind the idler bearings to fill the required gap. The number and sizes of shims used should be identical at both idler bearing locations.
NOTICE
Shims are furnished in two thicknesses, 0.5 and 0.75 inch (12.7 and 19 mm).
9. Relieve the pressure on the rams, then remove them from the crawler frame brackets.
BD120149 Mechanical Systems Manual Levelling System
Section 10
Levelling System
10.1 General
This section provides descriptive and maintenance information for the leveling jacks and jack hydraulic cylinders.
NOTICE
During maintenance procedures, apply standard torque to fasteners, unless otherwise speci-fied. Refer to Appendix A for general mechanical maintenance procedures, and to Appendix Bfor general hydraulic component maintenance procedures. It is advisable to replace all sealsand O-rings whenever hydraulic components are disassembled. Refer to the Parts Manual foridentification of components and service kits.
10.2 Theory of Operation
The four leveling jacks, attached to the corners of the main frame, are hydraulically actuated units that establish and maintain a level and stable position for the drill during drilling operations. Hydraulic pressure is supplied from the auxiliary hydraulic system. Refer to Section 3, Auxiliary Hydraulic System..
Operation of the jacks is controlled from the operator cab. The rear jacks (nearest the mast) are independently adjustable. The front jacks cylinders are connected in parallel so that they raise or lower as a self-equalizing pair. The jacks can also be placed in the automatic mode, which automatically raises the drill deck to the lowest level elevation for good drill stability.
Levelling System BD120149 Mechanical Systems Manual
10.2.1 Rear Jacks 100J6691F5 and 100J6691F6
Each of the two rear jacks consists of a hydraulic cylinder, spud, and shoe with housing and mounting hardware. The rod end of the cylinders is pinned to the jack cap on top of the jack housing. The cylinder barrel is pinned to the spud; the spud, in turn, is pinned to the shoe. The operator controls each jack independently by separate switches on the operator’s console. Hydraulic pressure is applied to the cylinder piston through internal passages in the rod, causing the spud and shoe to extend or retract.
Figure 10-1: Rear Jack (left shown, right similar)
LEGEND01. Jack Cap02. Lockwasher03. Capscrew04. Housing05. Upper Cylinder Pin
BD120149 Mechanical Systems Manual Levelling System
10.2.2 Front Jacks 100J6692F3 and 100J6693F3
Each of the two front jacks consists of a hydraulic cylinder, spud, and shoe with housing and mounting hardware. The rod end of the cylinders is pinned to the jack cap on top of the jack housing. The cylinder barrel is pinned to the spud; the spud, in turn, is pinned to the shoe. The operator actuates both jacks simultaneously through a single switch on the operator’s console. Hydraulic pressure is applied to both cylinder pistons through internal passages in the rods, causing the spuds and shoes to extend or retract.
10.2.3 Leveling Jack Shoes R56352D1, R56353D1
On the lower end of each front and rear jack is the jack shoe. Jack shoes provide a wide area of support, distribut-ing the drill’s weight over a relatively large surface area. Jack shoes are 127 cm (50") in diameter and weigh approximately 730 kg (1610 lbs).
Figure 10-2: Front Jack (left shown, right similar)
Levelling System BD120149 Mechanical Systems Manual
10.3 System Maintenance
10.3.1 Leveling Jack Shoes R56352D1, R56353D1
10.3.1.1 Removal
1. Lower the drill so that the shoes rest on the ground, but without weight bearing on the shoes.
WARNING!
Inadvertent operation of the blasthole drill during maintenance could cause severeinjury and/or death. Lock out and tag out the drill operating controls to prevent opera-tion.
2. Lock out and tag out the drill operating controls to prevent inadvertent start-up or movement of the drill during maintenance activities.
3. Remove the cotter pin and lockwasher that attaches the retainer pin to the to the spud.
4. Drive out the retainer pin.
WARNING!
Some blasthole drill components are extremely heavy. Dropping or mishandling ofthese parts can cause severe injury or death, and damage to the equipment. Always sup-port heavy components using a suitable hoist or other means for removal, disassembly,assembly and installation. Provide appropriate support for any components that are notsupported by the machinery during maintenance. Jack shoes weigh approximately730 kg (1610 lbs).
5. Remove the shoe.
10.3.1.2 Repair
Clean and inspect the jack components in accordance with the general cleaning and inspection procedures pro-vided in Appendix A of this manual. Repair consists of the replacement of all worn or damaged components. Refer to the LinkOne electronic parts manual for component identification.
10.3.1.3 Installation
1. Position the shoe under the spud and align the mounting holes.
2. Push or drive in the retainer pin.
3. Install the cotter pins to attach the retainer pin to the to the spud.
BD120149 Mechanical Systems Manual Levelling System
10.3.2 Jack Hydraulic Cylinders R4102D2
Removal of all jack cylinders and spuds is similar. To remove the front cylinders or spuds, the mast must be raised and locked in position and the back braces disconnected at the jack caps. Refer to Section 11, Mast. for instruc-tions.
10.3.2.1 Removal
It is advisable to service one jack at a time, as follows:
1. Lower the drill so that the shoes rest on the ground, but without weight bearing on the shoes.
2. If necessary, raise the mast and lock it in position.
3. Disconnect the applicable back brace from the jack cap and secure the brace. Refer to Section 11, Mast. for instructions.
Levelling System BD120149 Mechanical Systems Manual
WARNING!
Inadvertent operation of the blasthole drill during maintenance could cause severeinjury and/or death. Lock out and tag out the drill operating controls to prevent acciden-tal operation.
4. Lock out and tag out the drill operating controls to prevent inadvertent start-up or movement of the drill during maintenance activities.
5. Remove the cotter pins that attach the retainer pin to the spud. Drive out the retainer pin.
6. Close the Handwell valve.
WARNING!
Hot hydraulic oil under pressure can spray and burn with extreme force and volume,causing injury or death. Use lockout and tagout procedures to guard against inadvertenthydraulic system or machine start-up during service or maintenance. Allow the hydrau-lic system to cool prior to any maintenance or repair. Slowly release pressure or vent cir-cuits before disconnecting hydraulic lines. Wear appropriate face and body protectivedevices while carefully loosening any connection or fitting.
7. Install a pressure gauge into the test port on the regeneration valve. Check pressure on both the head end and the rod end of the cylinder. If any pressure remains, take action to remove the pressure before beginning any disassembly.
8. Tag and disconnect the hydraulic hoses to the jack cylinder. Allow oil to drain into a catch basin. Cap and/or plug all hoses and fittings to prevent contamination of the hydraulic system.
9. Remove the mounting hardware that attaches the jack cap.
WARNING!
Some blasthole drill components are extremely heavy. Dropping or mishandling of theseparts can cause severe injury or death, and damage to the equipment. Always supportheavy components using a suitable hoist or other means for removal, disassembly,assembly and installation. Provide appropriate support for any components that are notsupported by the machinery during maintenance.
10. Support and lift the jack cap with a suitable hoist to withdraw the cap, cylinder, and spud as a unit.
11. Remove the cotter pins, flat washers, and upper cylinder pin. Remove the jack cap.
12. Remove the pipe plugs and drive out the lower cylinder pin. Remove the spud.
10.3.2.2 Disassembly
Refer to Figure 10-4 and proceed as follows:
1. Use a spanner wrench to remove retainer (03) from barrel (10).
BD120149 Mechanical Systems Manual Levelling System
2. Remove rod (01) and related components from the barrel.
3. Remove parts from the rod and barrel to access the seals and other parts of the service kit.
10.3.2.3 Repair
Clean and inspect the cylinder components in accordance with the general cleaning and inspection procedures provided in Appendix B of this manual. Repair consists of the replacement of all service kit components. If other parts are worn or damaged, the entire cylinder must be replaced. See the LinkOne electronic parts manual for component identification.
10.3.2.4 Assembly
Refer to Figure 10-4 and proceed as follows:
1. Lubricate service kit parts and other sliding parts with clean hydraulic oil before installation.
2. Install and assemble parts in the reverse order of removal.
3. When installing the piston, pre-set nylon plug (08) in place using a grade 8 hex head capscrew to 150 ft-lbs (203 Nm). Then remove the capscrew, install setscrew (09), and tighten the setscrew to 75 ft-lbs (102 Nm).
10.3.2.5 Installation
Refer to Figure 10-1 or 10-2 and proceed as follows:
1. Align the cylinder and spud. Drive in the lower cylinder pin and install he pipe plugs.
2. Align the cylinder and jack cap. Be sure that the cylinder ports are aligned correctly to mate with the hydraulic hose assemblies. Install the upper cylinder pin, flat washers, and cotter pins.
3. Support and position jack cap, cylinder, and spud with a suitable hoist. Lower the unit into the housing.
4. Install the mounting hardware to attach the jack cap.
5. Align the shoe and spud. Push in the retainer pin. Install the capscrew and lockwasher to attach the retainer pin to the spud.
6. Install the hydraulic hose assemblies in accordance with their identification tags.
7. If necessary, connect the applicable back brace to the jack cap and secure. Refer to Section 11, Mast. for instructions.
8. Bleed the hydraulic circuits. Refer to Section 10, Levelling System..
10.4 Troubleshooting
10.4.1 Basic Operational Test for Auto Level System
P&H Mining Equipment provides detailed procedures to be use when setting up the Auto Level System in the Auto Level Setup Procedure, ELEC 3724. It is expected that once the drill is commissioned, there will be little or no need
Levelling System BD120149 Mechanical Systems Manual
(unless major components of the system need to be replaced) to engage in the extensive setup procedures defined in ELEC 3724.
During Preventive Maintenance Inspection periods, this procedure provides a quick way to check the Auto Level System without executing the meticulous and time-consuming process required by the Auto Level Setup Proce-dure. If unexpected results are noted, contact your local MinePro Services representative to obtain a copy of the Auto Level Setup Procedure, ELEC 3724.
WARNING!
It is essential that any repairs be completed to the jack circuit prior to initiating the AutoLevel Basic Operational Test.
The pages that follow provide a checklist for the Basic Operational Test. It is also recommended that a copy of the current auxiliary hydraulic schematic (R57349. Contact P&H MinePro Services for latest change mark) be available during this test.
MECHANICAL CHECKED
1.0) Make sure Jack Spuds are well greased to prevent binding. _______OK
1.1) Check Hydraulic Oil tank for proper amount of oil. _______OK
1.2) Operate system components to warm oil to at least 70°F (21°C) before test-ing.
_______OK
1.2) Manually Level Drill ensuring all jacks are taking load _______OK
1.3) Visually check all four Leveling Jack cylinders and their components for leaks or cylinder drift.
Note: Repairs to the Leveling Jack circuit should be made if cylinder drift exceeds ½ inch (13mm) per hour before continuing on with this procedure.
_______OK
HYDRAULIC CHECKED
2.0) Verify Jack System Pressure (2900 PSI on VB1, 2850 PSI on VB3 [maxi-mum]).
To Test: Retract all four Jack Cylinders to the full retract position. Next, select and press one of the Jack Leveling rocker switches in the retract position (dead heading the pump) while observe the Hydraulic Pressure Meter (HPM) on the cab console.
To Adjust [see 10-5]: Install a 0 - 5000 psi Pressure Gauge into the Relief/Unload Oil Diverter Valve test port. Set controls at neutral and manually depress the valve plunger on Valve Bank 1. Adjust to a maximum of 2900 psi.
Leave the pressure gauge installed and depress the valve plunger on Valve Bank 3. Adjust to 2850 psi. Remove gauge.
Note: To prevent “hunting” between the two relief valves, differential should always be at least 50 psid.
_______OK
2.1) Verify Right Rear Leveling Jack Counterbalance Valve Pressure
To Test: Manually Extend the Right Rear Leveling Jack Cylinder from the full retracted position. As the jack is moving freely downward and before the jack touches the ground, observe the Hydraulic Pressure Meter (HPM) on the cab console. Jack pressure should range from 650-800* psi.
Note: During the Auto Leveling mode the instant the Jack pressure exceeds that of the Jack Pressure Switch setting, the switch will close signaling the PLC to stop that particular Jack operation.
BD120149 Mechanical Systems Manual Levelling System
*If pressure exceeds 800 psi, contact your local P&H MinePro Services representative.
2.2) Verify Left Rear Leveling Jack Counterbalance Valve Pressure
To test: Manually Extend the Left Rear Leveling Jack Cylinder from the full-retracted position. As the Jack is moving freely downward and before the Jack touches the ground, observe the Hydraulic Pressure Meter (HPM) on the cab console. Jack pressure should range from 650-800* psi.
Note: During the Auto Leveling mode the instant the Jack pressure exceeds that of the Jack Pressure Switch setting, the switch will close signaling the PLC to stop that particular Jack operation.
_______OK
3.0) Verify Front Leveling Jack Counterbalance Valve Pressure
To test: Manually Extend the Front Leveling Jack Cylinders from the full-retracted position. As the jacks are moving freely downward and before the jacks touch the ground, observe the Hydraulic Pressure Meter (HPM) on the cab console. Jack pressure should range from 650-800* psi.
Note: During the Auto Leveling mode, the instant the Jack pressure exceeds that of the Jack Pressure Switch setting, the switch will close signaling the PLC to stop that particular Jack operation.
BD120149 Mechanical Systems Manual Levelling System
ELECTRICAL CHECKED
4.0) Ensure GUI Auto Level screen is in working order. _______OK
4.1) Verify Jack Pressure Switches operation
To confirm operation: Manually extend the front & rear Leveling Jack Cylinders one at a time from their full-retracted position. When the jack pad makes contact with the ground and just begins to lift the drill, the pressure switch for that jack will mechani-cally close the electric contacts, turning “ON” the input signal to the PLC. Next, manu-ally retract the jack cylinder. As soon as the jack pad retracts from the ground, the pressure switch contacts will mechanically open turning “OFF” the input signal.
Jack Input Signal PS Setting
a. Right Rear I:07/15 950 psi ± 50 psi
b. Left Rear I:07/16 950 psi ± 50 psi
c. Front I:07/14 950 psi ± 50 psi
d. Front Over-pressure I:07/13 950 psi ± 50 psi
Note: Pressure Switches produce a feedback signal to the PLC for the Auto Level sequence. To ensure consistent Auto Leveling function and performance, pressure switches must be working properly. Repairs and or adjustments must be made before continuing on with this procedure. Refer to 10-6.
_______OK
_______OK
_______OK
_______OK
4.2) Verify level sensors operation (located inside the PLC cabinet on 120125 & future)
To test (Refer to 10-7): Manually tilt each sensor and observe the GUI screen or PLC input card I:30. Shims can be placed under the Sensor to simulate drill angle of tilt.
a. Tilt LS3 towards the front of drill = I:30/5 “ON” @ ½°
b. Tilt LS3 towards the rear of drill = I:30/4 “ON” @ ½°
c. Tilt LS2 towards the right of drill = I:30/3 “ON” @ ½°
d. Tilt LS2 towards the left of drill = I:30/2 “ON” @ ½°
e. Tilt LS1 any direction = I:30/1 “OFF” @ 6°
Note: There is a slight time delay on the sensor outputs as observed on the GUI or the PLC card. The LED indicators on the bottom of the sensors are real-time corre-sponding to the PLC inputs. Refer to Figure 2.
Levelling System BD120149 Mechanical Systems Manual
MANUAL AND AUTO LEVELING CHECKED
5.0) Verify Machine is Level (refer to Figure 10-8 on page 15)
Position a 3 foot (1m) level along main frame I-beam = bubble centered
Position a 3 foot (1m) level along the rear axle = bubble centered
Note: Manually adjust individual Jacks until machine is level. Refer to Figure 3.
_______OK
_______OK
5.1) Verify Clinometer Gauges inside operators cab are set at zero once machine is level. Adjust if necessary.
_______OK
5.2) When the Machine is Level, the 'MACHINE LEVEL' lamp on the operator's con-sole should illuminate.
_______OK
5.3) Verify That All Four (4) Jacks Indicate Ground Pressure on GUI Auto Level Screen
Note: It is essential that repairs be completed to the jack circuit to ensure the Auto Level testing is accurately measured.
_______OK
5.4) Press the Auto Level Switch to “LOWER”.
a. The front Jacks should retract lowering the front of the machine until the load is off of the front jacks.
b. Both rear jacks should retract and maintain L-R level while lowering the rear of the machine until the load is off of the rear jacks.
c. When all jacks are fully retracted, the auto level system will turn off.
_______OK
_______OK
_______OK
5.5) Press the Auto Level Switch to “Raise”.
a. The front and rear jacks will begin to extend.
b. When all four (4) Jacks just make contact with the ground, the rear will equalize side-to-side.
c. If the machine is level side-to-side, all jacks will extend simultaneously.
d. When the machine is level side-to-side and the front is low, the front will continue to rise until the machine is level front-to-back.
e. Once the machine is level for 6 seconds, the system will not react to a change
f. If the machine is out-of-level for longer than 4 seconds and there is no move-ment, the “MACHINE LEVEL” light will blink. See note.
Note: If pump pressure and or pump flow is low, jack(s) may stall during Auto Level. As a result, the 4-second timer will cause a fault. Check pump operation, pressures, etc.
_______OK
_______OK
_______OK
_______OK
_______OK
_______OK
5.6) After the previous tests are complete, the system should be checked at different positions to simulate different operating conditions.
a. With the machine level, turn the auto level system “off” and retract one jack to force the machine out of level.
b. Turn the Auto Level system on again to “RAISE”. Monitor system for proper level-ing
c. During Auto Level raise operation, side to side and front to back movement should be smooth and steady.
d. If, during the Auto Level process the drill ratchets from one Jack to the other, it's possible that the Level Sensor(s) time delay adjustment interval is too short.
Refer to Step 5.1.
e. Repeat Auto Leveling Raise & Lowering after adjustments if necessary.
Levelling System BD120149 Mechanical Systems Manual
10.4.2 Troubleshooting Chart
Problems with the leveling system will almost always be caused by hydraulic system malfunction or electrical con-trol circuit malfunction. the troubleshooting chart from Section 3, Auxiliary Hydraulic System. is included here for convenience.
Problem Possible Cause Remedy
System fails to build pressure
Control valve does not shift cor-rectly
Replace the Relief/unload/oil diverter valve
System oil level is low Replenish tank supply
External leak in systemTighten components and bleed air from sys-tem
dirty filters Replace the filters
clogged inlet line Clean the inlet line
clogged tank breather Clean or replace the breather
fluid is too cold Heat the fluid
main drive motor is not operating Repair or replace the main drive motor
pump drive coupling failed Repair or replace the coupling
relief or unloading valve set too low Adjust the valve to the correct setting
pump is damaged Repair or replace the pump
Excessive hydraulic pump noise
pump is cavitating Refer to “System fails to build pressure”
air in the fluid
Leak in the inlet line to the pump.Tighten the fittings
Faulty pump shaft seal. Replace the seal
Excessive system heat
pump is cavitating Refer to “System fails to build pressure”
air in the fluid
Leak in the inlet line to the pump.Tighten the fittings
Faulty pump shaft seal. Replace the seal
contaminated fluid Change filters and replace the fluid
Drill pipe racks operate too slow or too fast
the needle valve is out of adjust-ment or faulty
Adjust the needle valve for correct operating speed. If unable to adjust, replace the nee-dle valve
Leveling jacks and winch move slowly
the needle valve is out of adjust-ment or faulty
Adjust the needle valve for correct operating speed. If unable to adjust, replace the nee-dle valve
The unloading relief valve is faultyAdjust the unloading relief valve to operate at 1100 psig (75.9 bar). If unable to adjust, repair or replace valve
Breakout Wrench moves too fast or too slow faulty flow control valves Adjust or replace the flow control valves
Table 10-1: Auxiliary Hydraulic System Troubleshooting
The mast supports the drilling components including the rotary machinery, pulldown/hoisting mechanism and brakes, guide rollers, pipe handling components, and some of the bit air components. The mast is mounted on hinge pins to allow the mast to be raised to the vertical position from the stored horizontal position and back. The hinge pins are located at the top of the mast support frame uprights. Raising and lowering of the mast is accom-plished by two operator-controlled hydraulic cylinders that are connected to the mast and the main frame. The mast is locked in the vertical drilling position by the two operator-controlled, hydraulically-actuated anchor pins. The mast is also supported in the drilling position by two articulated back braces that are pinned to the mast and
the front jack caps. Hydraulically-actuated locking collars slide over the back brace joints to secure the extended braces. When the mast is lowered, the locking collars are retracted and the back braces automatically fold. Each back brace has an adjusting screw to allow adjustment of fixed length.
11.1.1 Mast Weldment R53818D1
The mast is 20.1 meters (66 feet) in length, and is made of structural steel welded in a lattice arrangement to pro-vide strength and light weight. The four legs of the mast are tied together at the top by a crown block; the crown block also supports the auxiliary winch sheaves. The winch acts as a support structure for the rotary carriage, which contains the rotary motion motor and transmission as well as the pulldown motor and transmission. The rotary machinery is covered in Section 12, Rotary Machinery..
The rearward part of the mast is provided with racking on both sides. This racking meshes with drive pinions on the carriage to permit the pulldown and hoist systems to move up and down the mast. The pulldown machinery is cov-ered in Section 12, Rotary Machinery..
11.1.2 Ladder 29J333F3
A ladder is mounted to the right side of the mast to permit inspection of the upper structure. The ladder is equipped with safety hoops and the Saf-T-Climb® system.
Figure 11-2: Saf-T-Climb®
Figure 1. Pawl in unlocked position as worker climbs. The mechanism allows hands-free climbing.
Figure 2. Pawl automatically slides into locked position during fall. When descending, the pawl must be manually released at each catch point.
Always use the correct harness when using the Saf-T-Climb system.
Two articulated structures are pinned to the mast and to the front jack caps. When the mast is hoisted to its vertical position, the back braces extend to form a support for the mast. Hydraulically-actuated locking collars slide over the articulated joints to secure the extended braces. When the mast is lowered, the locking collars are retracted and the back braces automatically fold. Each back brace has an adjusting screw to allow adjustment of fixed length.
11.1.4 Mast Lock Pins GH1302T14
The mast is locked in the vertical drilling position by the two pins, one on either side. These operator-controlled, hydraulically-actuated anchor pins are mounted under the drilling deck.
.The mast is raised and lowered by two large-bore, long stroke hydraulic cylinders. The cylinder rod end is mounted with a clevis and pin joint to the mast. The cylinder head end is clevis and pin mounted to brackets on the drill main deck.
11.2 Mast Maintenance
11.2.1 Mast Weldment R53818D1
It should seldom, if ever, be necessary to remove the entire mast assembly, except in the event of severe damage to structural parts. Most service and replacements of components can be performed in the field. During mainte-nance procedures, apply standard torque to fasteners, unless otherwise specified. Refer to Appendix A for general mechanical maintenance procedures, and to Appendix B for general hydraulic component maintenance proce-dures
11.2.2 Auxiliary Winch 23U52D1
11.2.2.1 General
The winch is mounted inside the machinery house, between the mast hoist cylinders.
11.2.2.2 Removal
1. Remove the clamps, hook and thimble from the end of the winch wire rope.
2. Tie one end of a 30 meter (200 foot) nylon, poly, or hemp line to the free end of the wire rope. Fasten the other end of the line to the mast frame at a convenient point. This line will be used to pull the winch wire rope back through the sheaves when the winch is reinstalled.
3. Operate the winch to rewind the wire rope onto the drum, allowing the line to pass over the guide sheave and down to the drill deck. Fasten the wire rope to the drum to prevent unspooling, then untie the line, and fasten the end to the mast frame at a convenient point.
4. Lock out and tag the drill operator controls to prevent inadvertent startup during maintenance procedures.
WARNING!
Hot hydraulic oil under pressure can spray and burn with extreme force and volumecausing injury or death. Use lockout and tagout procedures to guard against inadvertenthydraulic system or machine startup during service or maintenance. Allow the hydraulicsystem to cool prior to any maintenance or repair. Slowly release pressure or vent cir-cuits before disconnecting hydraulic lines. Wear appropriate face and body protectivedevices while carefully loosening any connection or fitting.
5. Tag and disconnect the hydraulic hoses and fittings from the winch motor and brake housing. Cap and/or plug all hoses and motor ports to prevent undesired drainage and contamination of the hydraulic system. Refer to Appendix B for information on the hydraulic connections.
Some blasthole drill components are extremely heavy. Dropping or mishandling of theseparts can cause severe personal injury or death, and damage to the equipment. Alwayssupport heavy components using a suitable hoist or other means for removal, disassem-bly, assembly and installation. Provide appropriate support for any components whichare not supported by the machinery during any maintenance.
6. Remove the capscrews and lockwashers that attach the winch to the deck. Remove the auxiliary winch.
7. Note the direction that the wire rope is wound on the winch drum. Remove the wire rope from the winch drum if necessary.
If components of the winch require repair, refer to the following component repair instructions as necessary:
Subtopic 11.2.3
Subtopic 11.2.4
Subtopic 11.2.5
Subtopic 11.2.6
11.2.2.3 Installation
WARNING!
Some blasthole drill components are extremely heavy. Dropping or mishandling of theseparts can cause severe personal injury or death, and damage to the equipment. Alwayssupport heavy components using a suitable hoist or other means for removal, disassem-bly, assembly and installation. Provide appropriate support for any components whichare not supported by the machinery during any maintenance.
1. Position the winch on the deck. Check the mounting surface for unevenness. Be sure that all four mounting pads contact the mounting surface. If not, one pad should be shimmed to compensate. Install three mounting capscrews and lockwashers. Measure the space underneath the fourth pad with a feeler gauge and install shim stock of corresponding thickness with the capscrew and lockwasher. Apply new lockwire to the capscrew heads.
2. Install the hydraulic hoses and fittings in accordance with the identification tags previously attached.
3. Be sure that the planetary is filled with lubricant. Refer to the lubrication section.
4. Start the drill and operate the winch to bleed air from the hydraulic circuit. Check for flow through the return line when the winch is run in reverse to make sure that oil is being circulated through the brake. If not, investigate the hydraulic circuit for the cause of malfunction and correct the problem.
5. Pull the wire rope through the sheave on the upper mast by using the temporary reeving line. Secure the free end of the wire rope to the mast to prevent it from being pulled too far through the sheaves. Leave enough length of wire rope to enable attachment to the winch drum.
Inadvertent operation of the blasthole drill during maintenance on the machine couldcause severe bodily injury and/or death. Lockout and tagout the drill operating controlsto prevent accidental operation.
6. Lock out and tag the drill operator controls to prevent inadvertent startup during maintenance procedures.
7. Remove the temporary reeving line. Install the hook (04) and thimble (03) with clamps (02) on the free end of the wire rope.
CAUTION!
Use the slot for clockwise rotation. Do not use the slot for counterclockwise rotation.The slots are marked. If the wire rope is wound onto the drum for counterclockwise rota-tion, the winch will not have any braking. This could result in uncontrolled lowering of aload, resulting in personal injury and property damage. Be sure that the wire rope isinstalled into the slot for clockwise forward rotation (clockwise when looking at themotor end of the winch).
8. Detach the other end of the wire rope. Wrap the wire rope around the drum anchor and pull the anchor firmly into the slot in the winch drum.
9. Operate the winch to wind the wire rope onto the winch drum. The wire rope will wind around the drum in the proper direction.
NOTICE
The drum should always have at least four wraps around the drum to be sure that the rope doesnot come off the drum
11.2.3 Winch Motor Repair
Motor repair requires removal of the motor from the winch motor adapter. If the motor does not need repair, do not remove it from the adapter.
When prying off parts, take care not to damage the machined surfaces of parts. This particularlytrue of the cover and housing. Surface damage will cause motor leakage or other malfunction.
2. Remove end cover (09) with bearings (10), seal (16) and thrust plate (01). Pry the cover if necessary. The thrust plate may remain in the housing (12). Leave the dowel pins (11) in the housing.
3. If the thrust plate came off with the cover, pry it off the bearings (10). Remove and discard pocket seals (13).
4. Remove gear set (14) and thrust plate, if necessary, from the housing.
Figure 11-5: Auxiliary Winch
LEGEND01. Thrust Plate02. Body Seal03. Hex Head Capscrew04. Lockwasher05. Motor Assembly06. CCW Rotation Port07. Pipe Plug08. CW Rotation Port09. End Cover10. Needle Bearing11. Dowel Pin
12. Gear Housing13. Pocket Seal14. Gear Set15. Motor Adapter16. Ring Seal (Consists of Items 06
through 18)17. Pipe Plug18. O-ring19. Hex Head Capscrew20. Lockwasher21. Pipe Plug
5. Carefully pry off the housing from the adapter (15). Use care to avoid damage to the splined shaft and gear bore. The thrust plate may remain in the housing. Leave the dowel pins (11) in place.
6. If the thrust plate remained in the adapter, pry it off the bearings (10). Remove and discard pocket seals (13).
7. Remove bearings (10). Remove and discard ring seals (16) and body seals (02).
11.2.3.2 Cleaning, Inspection and Repair
Clean and inspect parts as specified inAppendix A. Replace all worn and/or damaged parts. Replace all seals using the motor seal kit. The seal kit includes two strips of rubber. The pocket seals must be cut to length from the strips with a sharp knife to fit the openings in the thrust plates.
11.2.3.3 Assembly and Installation
Refer to Figure 11-5 and proceed as follows:
1. Apply grease liberally to all seals.
2. Install new ring seals (16) in end cover (09) and adapter (15), followed by the bearings (10).
3. Install six new pocket seals (16) in each thrust plate (01). Press one thrust plate with seals onto the bearings and adapter.
4. Install a new body seal (02) into one side of housing (12). Position the housing over dowel pins (11) in the adapter and press into place. Tap the housing with a soft faced hammer if necessary.
5. Install gear set (14) into the housing. The longer gear goes on top with the internal spline toward the adapter.
6. Install a new body seal (02) into the other side of the housing. Press the second thrust plate with seals onto the housing with the pocket seals facing away from the gears
7. Position the assembled end cover over the dowel pins and press into place. Tap the end cover with a soft faced hammer if necessary.
8. Install capscrews (03) and lockwashers (04). Tighten the cap- screws evenly to 270 Nm (200 ft-lbs) torque.
If the motor does not require repair, do not remove it from the adapter.
11.2.4.1 Removal and Disassembly
Refer to Figure 11-6 and proceed as follows
CAUTION!
The brake springs (13, Figure 11-6) are under considerable tension against the motoradapter. They can release unexpectedly with great force and cause severe personalinjury. Unscrew capscrews one turn at a time in sequence until the spring pressure isrelieved. Then remove capscrews (19) and lockwashers (20) to detach the winch motorand adapter.
1. Remove and discard O-rings (08 and 09). O-ring (09) is located on the brake housing flange.
2. Remove brake springs (13).
3. Pull drive shaft (25) from brake housing (16) with the brake hub assembly.
4. Remove circlip (11) from the drive shaft. Remove washers (02), brake hub (14), and clutch aligners (12 and 15). Note the position of the sprag clutches (03) and remove them.
5. Pull piston (05) from the brake housing.
6. Remove and discard O-rings (06 and 07).
7. Remove friction plates (18) and divider plates (04).
8. Remove brake spacer ((19).
9. Remove thrust bearing (22) and thrust washers (01).
10. Remove and discard oil seal (23).
11. Do not remove brake housing (16) unless repair of the drum is required. Refer to Winch Drum Repair.
11.2.4.2 Cleaning, Inspection and Repair
Clean and inspect parts as specified in Appendix A. Replace all seals and O-rings using the winch seal kit. Replace all scored, worn and/or damaged parts.
1. If the outside diameter of the piston is scratched. polish it with fine emery cloth. Wash the piston thoroughly after polishing.
2. Inspect the bore of the brake hub and outside of the drive shaft where both places contact the sprag clutches. If these areas are indented or otherwise damaged, replace the shaft and/or hub.
1. Apply grease liberally to new seals and O-rings.
2. Install sprag clutches (03) in the bore of the brake hub (14). The clutches must be positioned so that the motor end of the drive shaft (25) will turn freely in the clockwise direction and lock in the counterclockwise direction.
3. Install washers (02) and clutch aligners (12 and 15) on each side of brake hub (14). Slide the hub assembly onto the drive shaft. Install circlip (11).
4. Install a new oil seal (23) in the bore of the connecting shaft (27).
5. Slide thrust bearing (22) with a thrust washer (01) on each side onto the large end of the drive shaft against cir-clip (20). Insert the end of this assembly through the connecting shaft (25) so that the splines engage the sun gear (28). Take care not to damage the oil seal (23) or needle bearing (24) during installation.
6. Install brake spacer (19) and one divider plate (04). Then starting with a friction plate (18), alternately install a friction plate and a divider plate until all plates are in place. The brake disc stack must finish with a divider plate.
7. Install O-rings (06 and 07).
8. Install brake piston (05) in the brake housing(l6) so that the spring holes facing outward.
9. Install sixteen brake springs (13) into the piston. There are 18 holes for the springs. The two empty holes should be opposite each other.
10. Apply grease to O-rings (08 and 09) and install. O-ring (09) should be placed over the transfer hole for the automatic release pressure on the motor adapter flange.
11. Slide the winch motor and adapter over the drive shaft so the splines engage and the pressure transfer holes and brake spring holes are aligned.Install capscrews (19) and lockwashers (20) to attach the winch motor and adapter. Tighten the capscrews evenly one turn at a time in a cross sequence until the adapter is fully in place.
1. Remove pipe plug (21) and drain the oil from the planetary and drum interior. Tip the unit at an angle to drain all oil from the drum.
2. Remove capscrews (15) and lockwashers (17) to detach base (16) from the planetary and drum.
3. Remove internal retaining ring (22) and end cover (25) with O-ring (20). Discard the O-ring.
4. Remove stoppers (23 and 24).
5. Withdraw planet hub assembly from housing (18).
6. To remove planet gears (03), remove circlips (05) and press pins (26) from hub (19). Slide out the planet gears with needle bearings (04) and thrust washers (02).
7. Withdraw sun gear (I 3) from drum (1 4).
8. Remove circlip (10). Insert two pry bars between the flange of drum (14) and housing (18) and carefully pry the drum from bearing (07).
9. Remove circlip (06) and bearing (07). disassemble the position the (08) in the (I8). Re- move and discard the oil seal.
11.2.5.2 Cleaning, Inspection and Repair
Clean and inspect parts as specified in Appendix A. Replace all seals and O-rings using the winch seal kit. Replace all scored, worn and/or damaged parts.
1. Inspect stoppers for excessive wear. Minimum thickness of the stoppers is 114 inch (6.4 mm). Replace exces-sively worn or damaged stoppers.
2. Inspect thrust washers for excessive wear. Replace excessively worn or damaged washers.
11.2.5.3 Assembly and Installation
Refer to Figure 11-7 and proceed as follows:
1. Install a new oil seal (08) in housing (18).
2. Install circlip (06) and bearing (07) in the housing.
3. Align drum (14) with bearing (07). Apply pressure to the bearing inner race to press the drum and bearing into place. Install circlip (10).
4. Install sun gear (13) in drum (14).
5. Slide planet gear (03) with needle bearing (04) and thrust washers (02) into hub (19). Align the bores and push pin (26) into o place. Install circlips (05 and 27).
6. Repeat preceding step 5 for the other planet gears.
1. Insert two pry bars between the flange of drum (20) and housing (22) and carefully pry the housing from bear-ings (15 and 17). The connecting shaft (14) will come off with the housing.
2. Pull connecting shaft (14) from brake housing (22). Remove and discard O-ring (18).
3. Remove needle bearing (01) and retaining ring (02) from the connecting shaft.
4. Withdraw sun gear (11) from the planet assembly in the drum.
5. Remove and discard oil seal (19).
6. Using a standard puller, remove bearings (15 and 17).
7. Remove the planet assembly with internal gear (13) from the drum.
8. To remove planet gears (09), remove circlips (03) and press pins (08) from hub (12). Slide out the planet gear with needle bearing (05) and thrust washers (06).
9. Remove stoppers (04 and 10)
11.2.6.2 Cleaning, Inspection and Repair
Clean and inspect parts as specified in Appendix A. Replace all seals and O-rings using the winch seal kit. Replace all scored, worn and/or damaged parts.
1. Inspect sun gear stopper for excessive wear. Minimum thickness of the sun gear stopper is 114 inch (6.4 mm). Replace an excessively worn or damaged stopper.
2. Inspect internal gear stoppers and thrust washers for excessive wear. Replace excessively worn or damaged washers and/or stoppers.
11.2.7 Assembly and Installation
The planetary components should be assembled before the drum components. Refer to Subtopic 11.2.5. Refer to Figure 11-8 and proceed as follows:
1. Slide planet gear (09) with needle bearing (09) and thrust washers (09) into hub (12). Align the bores and push pin (08) into o place. Install circlips (03 and 07).
2. Repeat preceding step 2 for the other planet gears.
3. Install stoppers (04 and 10).
4. Install planet assembly in internal gear (13) and install sun gear (1 1) in the planet assembly. Place the unit in the drum so the splines on the planetary sun gear mesh with the planet hub (12).
5. Install bearings (15 and 17).
6. Install new oil seal (19).
7. Install needle bearing (01) in connecting shaft (14). Install retaining ring (02)
8. Apply grease to O-ring (18) and install on connecting shaft (14). Install connecting shaft (14) in brake housing (22).
9. Insert the assembled brake housing into bearings (15 and 17) so that the connecting shaft (14) engages inter-nal gear (13). Press into place. If necessary, use a soft faced hammer to tap the brake housing.
10. Install capscrews (15, Figure 10-4) and lockwashers (17) to attach base (16) to the planetary and drum.
11. Assemble and install the brake components. Refer to topic, Winch Brake Repair
12. Fill the winch with oil. Refer to Subtopic 16.3.3.
13. Install pipe plug.
11.2.8 Auxiliary Winch Sheaves
The two removable sheaves for the auxiliary winch wire rope are installed at the ends of a support on top of the mast crown block. The support and one sheave are extended beyond the rear side of the mast so that the wire rope drops just behind the drilling centerline.
NOTICELower the mast to its horizontal position to gain access to the mast crown block and sheaves.
Refer to Figure 11-9 and proceed as follows:
WARNING!
Inadvertent operation of the blasthole drill during maintenance on the machine couldcause severe bodily injury and/or death. Lock out and tag out the drill operating controlsto prevent accidental operation.
1. Lock out and tag out the drill operating controls to prevent inadvertent startup or movement of the drill during maintenance activities.
2. To remove the sheaves, remove the cotter pins from the lock pins.
3. Support the sheave parts, then remove the capscrews and lockwashers, and withdraw the lock pins.
4. Remove and disassemble the bearings, retainers, and sheaves.
CAUTIONTo remove the sheaves without first removing the wire rope, place steel rods under thewire rope and clamp them in position on the sheave support. This will hold the wire ropein place, and away from the sheaves, so that they can be removed. Do not clamp the wirerope in a working section; this can cause rope damage, crushing, or kinking.
11.2.8.2 Cleaning, Inspection, and Repair
Clean and inspect the sheave components in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. Sheave repair consists of the replacement of all worn or damaged compo-nents. See the LinkOne electronic parts manual for component identification.
11.2.8.3 Installation
Refer to Figure 11-9 and proceed as follows:
1. Install the bearings and retainers in the sheaves.
2. Support the sheave parts and position them in the crown block support.
3. Insert the lock pins through the support holes and sheave assemblies.
4. Install the capscrews, lockwashers, and cotter pins to secure the assembly.
The back braces must be adjusted when the crawlers are on the ground on a smoothlevel surface. If back brace adjustment is made when the drill is elevated on jacks, or ifthe back brace adjustment in not correct, unnecessary loading will be placed on theback braces, mast and front jack assemblies that could result in early fatigue crackingand/or structural failure.
This procedure assumes the mast has been correctly adjusted to be vertical when the mastanchor pins are engaged and the drill is correctly leveled.
1. Raise the mast to the vertical position. Ensure that the mast anchor pins are engaged and that the back brace locks are extended.
2. Place drill on a smooth level surface with the crawlers on the ground and the leveling jacks fully raised.
3. Retract the mast anchor pins and note if mast anchor pin bores on mast move relative to the anchor pin bores on the main frame. No misalignment between the bores should be noted when the crawlers are on the ground. If misalignment is noted with crawlers on the ground, the back brace length needs to be adjusted until there is very little misalignment between the mast anchor in bores on the mast and main frame when the anchor pins are removed.
4. Back brace length adjustment is accomplished by turning the threaded adjusting nuts/rods on the ends of the back brace legs. Refer to Figure 11-11.
Figure 11-11: Back Brace Adjustment
01
02
03
04
05
BD0983a01
LEGEND01. Adjusting Rod02. Lower Brace
03. Locknuts04. Clevis05. Top of Front Leveling Jack
CAUTION
Minimum of 102mm (4") of thread engagementis required on both ends of the extension rod.
5. After length adjustment, the back brace appearance will be a slight bow downward due to gravity with the crawlers on the ground and the mast anchor pins engaged. When the machine is raised on jacks, the main frame deflects in a direction that will reduce tension on the back brace members, resulting in a “slack” condition when the machine is on jacks and drilling. This “slack” condition will produce slightly more “sag” in the back braces when the drill is on jacks as compared to when the drill is on the ground.
NOTICE
It is critical to adjust both back braces to have equal loading on each side. This can be verifiedby ensuring that each back brace has approximately the same amount of “sag”, verified by lineof sight viewing along the axis of each back brace leg.
6. After adjustments have been made, lower the mast, propel for about one machine length, raise the mast, engage the mast anchor pins and then retract the mast anchor pins. Check the mast anchor pin displacement with the machine still on the ground. If the bores displace more than 0.06" from each other, repeat the adjust-ment procedure.
7. Engage the mast anchor pins and raise machine on leveling jacks to the point that both crawler belts are off the ground and the machine is level.
8. Retract the mast anchor pins and note if the mast anchor pin bores move relative to the anchor pin bores on the main frame. Note that adjusting back brace length to result in little anchor pin bore displacement when the drill is on the ground will result in some anchor pin bore displacement when the drill is sitting on the jacks. Slight bore misalignment (less than 3mm or 1/8") when the pins are removed is acceptable.
9. With mast anchor pins disengaged, lower the mast to the mast rests, then raise the mast to the vertical posi-tion.
10. Engage the mast anchor pins to verify that the anchor pins can be readily inserted. If the mast pins are difficult to engage, slight modifications may have to be made to remove some of the anchor pin bore misalignment with the drill on jacks.
NOTICE
Any adjustments must result in approximately the same amount of “sag” on each back brace,verified by line of sight viewing along the axis of each back brace leg. Also, any adjustmentmust still result in the minimum amount of anchor pin bore misalignment when the drill is on theground.
After final adjustments are made, it is recommended to lock the back brace adjustment. This can be done by weld-ing a small plate across the back brace and the adjusting block, being careful not to weld to the adjustment threads.
11.2.8.5 Removal
CAUTIONThe mast must be locked in the vertical upright position to service the back braceassemblies. Back braces should be serviced one at a time.
To remove one back brace assembly, refer to Figure 11-10 and proceed as follows:
WARNING!
Inadvertent operation of the blasthole drill during maintenance could cause severebodily injury and/ or death. Lockout and tagout the drill operating controls to preventaccidental operation.
1. Lock out and tag the drill operating controls to prevent inadvertent startup or movement of the drill during main-tenance activities.
2. Securely fasten locking collar (03) and cylinders (02) in the extended (locked) position with rope, or other means, to prevent retraction of the cylinders when the hydraulic hoses are disconnected.
WARNING!
Hot hydraulic oil under pressure can spray and burn with extreme force and volumecausing injury or death. Use lockout and tagout procedures to guard against inadvertenthydraulic system or machine startup during service or maintenance. Allow the hydraulicsystem to cool prior to any maintenance or repair. Slowly release pressure or vent cir-cuits before disconnecting hydraulic lines. Wear appropriate face and body protectivedevices while carefully loosening any connection or fitting.
3. Tag and disconnect the hydraulic hoses and fittings to the back brace cylinders. Cap and/or plug all hoses and fittings to prevent contamination of the hydraulic system. Refer to Appendix B for information on hydraulic con-nections.
WARNING!
Some blasthole drill components are extremely heavy. Dropping or mishandling of theseparts can cause severe personal injury or death, and damage to the equipment. Alwayssupport heavy components using a suitable hoist or other means for removal, disassem-bly, assembly and installation. Provide appropriate support for any components whichare not supported by the machinery during any maintenance.
4. Support the upper and lower braces with a suitable hoist and sling.
5. Remove four pins (5) and drive out clevis pins (6) to unfasten the brace assembly. Remove the brace assembly and place it in an appropriate location for disassembly.
2. Remove six cotter pin (16), flat washers (15) and collar pins (17). Remove band (01) and cylinders (03).
3. Note the position of the extension rod engagement before disassembly. Unscrew lower clevis (08), nuts (9 and 11) and extension rod (10). Use the special spanner wrench tool 5002096 to loosen the nuts.
4. Remove roll pins (12), hinge pins (13) and link (14) 5. Separate braces (04 and 07) and collar (03).
11.2.8.7 Cleaning, Inspection and Repair
Clean and inspect the back brace components in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. Repair consists of the replacement of all worn or damaged components. Refer to the Parts Manual for component identification.
11.2.8.8 Assembly
Refer to Figure 11-10 and proceed as follows:
1. Place collar (03) onto the upper brace (04). Connect link (14) to upper brace (04) and lower brace (07) with pins (13) and roll pins (12).
2. Apply anti-seize compound to the threads of the lower clevis (08), nuts (9 and 11) and extension rod (10). Screw these parts into the into lower brace (07). Use special tool, backbrace spanner (PN 5002096) to install the nuts.
3. Attach the base ends of the hydraulic cylinders (03) to the brackets on the upper brace (04) with cotter pins (16), flat washers (15) and collar pins (17).
NOTICE
Be sure that the cylinder ports are aligned correctly to mate with the hydraulic hose assemblies.
4. Position and install band (01) onto the lower base ends of cylinders (03). Secure the band with two capscrews (19), lockwashers (20) and hex nuts (21). Apply lockwire (18).
5. Attach the rod ends of the hydraulic cylinders to the brackets on the collar (06) with cotter pins (16), flat wash-ers (15) and collar pins (17).
11.2.8.9 Installation
Refer to Figure 11-10 and proceed as follows:
1. Position the upper and lower braces in a straight line, then slide locking collar (03) into locking position over the middle joint.
2. Securely fasten locking collar (03) and cylinders (02) in the extended (locked) position with rope, or other means, to prevent unlocking the back braces.
WARNING!
Inadvertent operation of the blasthole drill during maintenance on the machine couldcause severe bodily injury and/or death. Lockout and tagout the drill operating controlsto prevent accidental operation.
3. 3. Lock out and tag the drill operating controls to prevent inadvertent startup or movement of the drill during maintenance activities.
Some blasthole drill components are extremely heavy. Dropping or mishandling of theseparts can cause severe personal injury or death, and damage to the equipment. Alwayssupport heavy components using a suitable hoist or other means for removal, disassem-bly, assembly and installation. Provide appropriate support for any components that arenot supported by the machinery during any maintenance.
4. Using a suitable hoist and sling, lift up the back brace assembly and position it so that the upper and lower ends are aligned with the mounting caps.
NOTICE
If the back brace cannot be connected because the brace is too short or too long, adjust theextension rod as required. Refer to Subtopic 11.2.9.5.
5. Insert pin (06) and install pins (05) to attach the brace to the front jack caps.
CAUTION!
There must be a minimum of 4 inches (100 mm) of adjusting screw threads engaged withboth the clevis and upper brace. Less thread engagement could result in brace failure.
6. Align the upper brace end with the mast cap. If the cap and clevis cannot be aligned, loosen nuts (9 and 11) and adjust the rod (10) to permit alignment. Measure and record the distance between the clevis and lower brace. This distance will be used in checking and adjusting the other back brace if serviced.
7. Check the length adjustment for the back brace on the other side. Adjust as required.
8. Connect the hydraulic hose assemblies in accordance with their identification tags.
3. Unscrew the cylinder head until the threads become disengaged from the cylinder body, then remove the pis-ton/piston rod and cylinder head assembly from the cylinder body.
4. Remove the locknut from the piston rod. Then separate the piston, wipers (01), seal assembly (02), O-ring (03), backup ring (04), washer, and cylinder head assembly from the piston. Discard all seal parts.
5. Remove and discard O-rings (05 and 09), backup ring (06), rod seal (07), and rod wiper (08) from the cylinder head. Note the orientation of these components for assembly.
11.2.9.3 Cleaning, Inspection and Repair
Clean and inspect all cylinder components in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. After cleaning and inspection, cover all parts with a light film of oil and pro-tect the parts from dirt and moisture. Cylinder repair consists of the replacement of wipers, seals, and all worn or damaged components. See the LinkOne electronic parts manual for component identification.
11.2.9.4 Assembly
Refer to Figure 11-12 and proceed as follows:
1. Lubricate and install O-rings (05 and 09), backup ring (06), rod seal (07), and rod wiper (08) on the cylinder head.
2. Install the cylinder head assembly on the piston rod.
3. Lubricate and install piston, wipers (01), seal assembly (02), O-ring (03), and backup ring (04) on the piston.
4. Install the washer and piston assembly on the piston rod with the locknut and torque securely.
5. Lubricate the bore of the cylinder body (with hydraulic oil, and insert the piston/cylinder head assembly). Take care to avoid cutting or pinching the seals and O-rings during insertion.
6. Thread the cylinder head into the bore of the cylinder body, and torque securely with a spanner wrench.
7. Retract the piston rod and install port plugs to prevent contamination of the hydraulic system with dirt.
11.2.9.5 Installation
Cylinder is installed as a part of installing the back braces. Refer to Subtopic 11.2.8.8
11.2.10 Mast Lock Pin 19T6502D3 And Cylinder R51992D2
The mast lock cylinders may removed from the drill with the mast either raised or lowered. The lock pins may be removed and replaced with the mast vertical but only one at a time. The mast must be locked in the vertical posi-tion with the back braces before starting the removal procedure.
11.2.10.1 Removal
Refer to Figure 11-13 and proceed as follows:
1. Check to be sure that the mast back brace locking collars are in locked position and the other lock pin is engaged.
Inadvertent operation of the blasthole drill during maintenance on the machine couldcause severe bodily injury and/or death. Lock out and tag out the drill operating controlsto prevent accidental operation.
2. Lock out and tag out the drill operator controls to prevent inadvertent startup during maintenance procedures.
WARNING!
Hot hydraulic oil under pressure can spray and burn with extreme force and volumecausing injury or death. Use lockout and tagout procedures to guard against inadvertenthydraulic system or machine startup during service or maintenance. Allow the hydraulicsystem to cool prior to any maintenance or repair. Slowly release pressure or vent cir-cuits before disconnecting hydraulic lines. Wear appropriate face and body protectivedevices while carefully loosening any connection or fitting.
3. Tag and disconnect the hydraulic hoses and fittings from the mast lock cylinders. Cap and/or plug all hoses and cylinder ports to prevent contamination of the hydraulic system. Refer to Appendix B, General Hydraulic System Maintenance, for information on hydraulic connections. Plug the cylinder ports tightly to keep the cylin-der rod from extending or retracting during transport off the drill.
WARNING!
Some blasthole drill components are extremely heavy. Dropping or mishandling of these partscan cause severe personal injury or death, and damage to the equipment. Always support heavycomponents using a suitable hoist or other means for removal, disassembly, assembly andinstallation. Provide appropriate support for any components which are not supported by themachinery during any maintenance.
4. Remove the cotter pins and push the end bar and cylinder pins from the ends of the cylinder(s)
5. If a locking pin is to be replaced, drive it out and replace immediately to maintain the locked condition.
11.2.10.2 Disassembly
Refer to Figure 11-13 and proceed as follows:
1. Extend piston rod to provide clearance for a spanner wrench.
2. Clamp the cylinder body in a vise and loosen the cylinder head with a spanner wrench.
3. Unscrew the cylinder head until the threads become disengaged from the cylinder body, then remove the pis-ton/piston rod, bearing retainer and cylinder head assemblies from the cylinder body.
4. Remove the locknut from the piston rod. Then remove the U-cup retainers, O-rings (07), and U-cups (06) and piston bearing. Note the orientation of these components for assembly. Discard all seal parts.
5. Remove the bearing/seal retainer and cylinder head assembly from the piston rod.
6. Remove O-ring (05), backup ring (04), rod bearings, and packing set (03) from the bearing/seal retainer. Dis-card all seal parts.
7. Remove O-ring (02) and rod wiper (01) from the cylinder head.
11.2.10.3 Cleaning, Inspection, and Repair
Clean and inspect all cylinder components in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. After cleaning and inspection, all parts must be covered with a light film of oil and protected from dirt and moisture. Cylinder repair consists of the replacement of wipers, seals, and all worn or damaged components. See the LinkOne electronic parts manual for component identification.
11.2.10.4 Assembly
Refer to Figure 10- 11 and proceed as follows:
1. Lubricate and install O-ring (02) and rod wiper (01) on the cylinder head.
2. Lubricate and install packing set (03) and rod bearings in the bearing/seal retainer.
3. Lubricate and install O-ring (05) and backup ring (04) on the bearing retainer.
4. Install the cylinder head and bearing/seal retainer assemblies on the piston rod.
5. Lubricate and install the U-cup retainers, O-rings (07), piston bearing and U-cups (06) on the piston rod. Be sure that the orientation of these parts is correct.
6. Install the locknut on the piston rod and torque securely.
7. Lubricate the bore of cylinder body with hydraulic oil, and insert the piston cylinder head assembly. Take care to avoid cutting or pinching the seals and O-rings during insertion.
8. Thread the cylinder head into the bore of the cylinder body, and torque securely with a spanner wrench.
9. Retract the piston rod, and install port plugs to prevent contamination of the hydraulic system with dirt.
Inadvertent operation of the blasthole drill during maintenance on the machine couldcause severe bodily injury and/or death. Lock out and tag out the drill operating controlsto prevent accidental operation.
1. Lock out and tag out the drill operator controls to prevent inadvertent startup during maintenance procedures.
WARNING!
Some blasthole drill components are extremely heavy. Dropping or mishandling of theseparts can cause severe personal injury or death, and damage to the equipment. Alwayssupport heavy components using a suitable hoist or other means for removal, disassem-bly, assembly and installation. Provide appropriate support for any components whichare not supported by the machinery during any maintenance.
2. Position the cylinders in the guide plates and lock pins.
3. Install the cylinder and end bar pins and the cotter pins to secure the ends of the cylinder(s).
4. Install the hydraulic hose assemblies to the cylinder ports in accord with the identification tags.
5. Operate the mast lock cylinders until full hydraulic pressure is achieved. This will ensure that the air has been purged from the system.
6. Check operation of the mast lock indicating lamps.
7. If the lock pins are in position and the lamps are illuminated, continue with operation or shutdown as desired.
11.2.11 Mast Raise/Lower Cylinder R6268D1
The mast is raised and lowered by two large-bore, long-stroke hydraulic cylinders. The cylinder rod end is mounted with a clevis-and-pin joint to the mast. The cylinder head end is clevis-and-pin-mounted to brackets on the drill main deck.
11.2.11.1 Removal
The mast raise/lower hydraulic cylinders must be removed from the drill to service the seals and rod wipers. The mast must be locked in the vertical position with the back braces, also in locked position, before starting the removal procedure. To remove the cylinders, Refer to Figure 11-15 and proceed as follows:
1. Check to be sure that the mast locking pins and the back brace locking collars are in locked position.
WARNING!
Inadvertent operation of the blasthole drill during maintenance on the machine couldcause severe bodily injury and/or death. Lock out and tag out the drill operating controlsto prevent accidental operation.
2. Lock out and tag out the drill operator controls to prevent inadvertent startup during maintenance procedures.
WARNING!
Hot hydraulic oil under pressure can spray and burn with extreme force and volumecausing injury or death. Use lockout and tagout procedures to guard against inadvertenthydraulic system or machine startup during service or maintenance. Allow the hydraulicsystem to cool prior to any maintenance or repair. Slowly release pressure or vent cir-cuits before disconnecting hydraulic lines. Wear appropriate face and body protectivedevices while carefully loosening any connection or fitting.
3. Tag and disconnect the hydraulic hoses and fittings from the mast raise/lower cylinders. Cap and/or plug all hoses and cylinder ports to prevent contamination of the hydraulic system. Refer to Appendix B, General Hydraulic System Maintenance, for information on the hydraulic connections. Plug the cylinder ports tightly to keep the cylinder rod from extending or retracting during transport off the drill.
Some blasthole drill components are extremely heavy. Dropping or mishandling of theseparts can cause severe personal injury or death, and damage to the equipment. Alwayssupport heavy components using a suitable hoist or other means for removal, disassem-bly, assembly, and installation. Provide appropriate support for any components whichare not supported by the machinery during any maintenance.
4. Support the rod end (top) of the cylinder with a suitable hoist.
5. Remove the two capscrews, lockwashers, and retainer bar from each end of the pin that fastens the rod end of the cylinder to the mast, then drive out the pin.
6. Remove the pin from the head end clevis and mounting bracket, and lift the cylinder free of the bracket.
7. Move the cylinder to a clean work area for disassembly.
11.2.11.2 Disassembly
Refer to Figure 11-16 and proceed as follows:
1. Disconnect and remove tube (04). Remove adapters (03 and 05):
2. Remove screws (02) and counterbalance valve (01).
3. Extend piston rod to make clearance for spanner wrench.
CAUTIONDo not clamp on the body diameter. Damage to the cylinder could result.
4. Secure the fixed end of the cylinder in a suitable vise or fixture.
5. Using a spanner wrench, unscrew retainer (03) from barrel (12). Pull the entire piston rod assembly from the body.
6. Remove bearings (07) and seal (08) from the piston. Unscrew the piston from the piston rod. Remove O-ring (16) from the piston rod and discard.
7. Remove O-ring (10) and backup ring (1 1) from the cylinder head. Discard all seal parts.
8. Slide the cylinder head and retainer with rod bearing (09), seal (12), O-rings (13 and 14) and wiper (15) from the piston rod. Remove and discard all seal parts.
11.2.11.3 Cleaning, Inspection and Repair
Clean and inspect the cylinder as described in Appendix A. Repair of the mast cylinder is limited to replacement of the rod wipers, O-rings, bearings and seals. Refer to the LinkOne electronic parts manual for component identifica-tion.
1. Lubricate and install O-ring (14) on the retainer. Slide assembled retainer onto the piston rod.
2. Lubricate and install rod bearing (09), seal (12), O-rings (13 and 14) and wiper (15) in the cylinder head. Slide the assembled cylinder on the piston rod.
3. Lubricate and install O-ring (10) and backup ring (1 1) on the cylinder head.
4. Lubricate and install O-ring (16) on the piston rod. Screw the piston onto the piston rod.
5. Lubricate and install bearings (07) and seal (08) on the piston.
6. Lubricate the bore of cylinder body with hydraulic oil, and insert the piston/cylinder head assembly. Take care to avoid cutting or pinching the seals and O-rings during insertion.
7. Thread the retainer into the bore of the cylinder body and torque securely with a spanner wrench.
8. Attach counterbalance valve (01) to he cylinder with screws (02).
9. Retract the piston rod and install port plugs to prevent contamination of the hydraulic system with dirt.
10. Install adapters (03 and 05). Connect tube (04).
11.2.11.5 Installation
Refer to Figure 11-15 and proceed as follows:
WARNING!
Inadvertent operation of the blasthole drill during maintenance on the machine couldcause severe bodily injury and/or death. Lock out and tag out the drill operating controlsto prevent accidental operation.
1. Lock out and tag out the drill operator controls to prevent inadvertent startup during maintenance procedures.
WARNING!
Some blasthole drill components are extremely heavy. Dropping or mishandling of theseparts can cause severe personal injury or death, and damage to the equipment. Alwayssupport heavy components using a suitable hoist or other means for removal, disassem-bly, assembly, and installation. Provide appropriate support for any components whichare not supported by the machinery during any maintenance.
2. Support the rod end (top) of the cylinder with a suitable hoist, and lift the cylinder into mounting position on the drill deck.
3. Install the head end clevis to the mounting bracket on the drill deck, while supporting the cylinder directly above the bracket. Do not apply side force with the hoist to avoid damaging the cylinder or mounting bracket.
4. While continuing to support the top end of the cylinder with the hoist, swing the top of the cylinder toward the mast. Adjust the extension of the cylinder until the rod mounting hole is aligned with the mounting bracket on the mast.
5. Insert the pin through the mast bracket and cylinder, and lock the pin in position with the pin retainer bars, cap-screws, and lockwashers.
6. Remove the hoist from the top of the cylinder.
7. Install the hydraulic hose assemblies to the cylinder ports in accordance with the identification tags.
8. Before lowering the mast, operate the mast raise/lower cylinder several times, holding the valve in the “raise” and “lower” positions until full hydraulic pressure is achieved. This will ensure that the air has been purged from the system.
LEGEND01. Retainer02. Lock Washer03. Hex Head Cap Screw04. Grease Fitting05. Mast Hinge Pin06. Hex Head Cap Screw07. Hex Head Cap Screw08. Flex Lock Nut09. Boss Drillers Platform
10. Pin11. Retainer12. Lock Washer13. Hex Head Cap Screw14. Bottom Assembly Plate15. Door Installation16. Door Panel17. Upper Plate Hinge18. Cotter Pin19. Drilled Pin
20. Hex Head Cap Screw21. Lower Arm Hinge22. Lower Block Hinge23. Hardened Washer24. Nut25. Jam Nut26. Cotter Pin27. Drilled Pin28. Hydraulic Cylinder29. Rod End
The mast bottom plate is pinned and bolted to the bottom of the lower mast. A drill bushing is welded to the deck plate in line with the drilling centerline. The bushing is fitted with a dust deflector which is secured with four remov-able T-bolts and a deflector ring.
Clean and inspect components as described in Appendix A. Refer to the LinkOne electronic parts manual for com-ponent identification.
Remove components selectively for repair or replacement. The location and method of attachment is shown in Fig-ure 10-14.
WARNING!
Inadvertent operation of the blasthole drill during maintenance on the machine couldcause severe bodily injury and/or death. Lockout and tagout the blasthole drill operatingcontrols to prevent accidental operation.
11.2.12.1 Deflector Ring
Refer to Figure 11-17. To remove loosen hex nuts (7), lockwashers (8) and flat washers (9) from the four T-bolts (6) to free the deflector ring (5) from underneath the drill deck plate. Remove dust deflector (3 1). Install in the parts in the reverse order of removal.
WARNING!
Some blasthole drill components are extremely heavy. Dropping or mishandling of theseparts can cause severe personal injury or death and damage to the equipment. Alwayssupport heavy components using suitable hoist or other means for removal, disassem-bly, assembly and installation. Provide appropriate support for any units which are notsupported by the equipment machinery during any maintenance.
11.2.12.2 Adjustable Platform
Refer to Figure 11-17.
1. Support access cover (10) with a suitable hoist. Remove two straight cover pins (12) and hardware, and remove the access cover.
2. Support adjustable work platform (18) with a suitable hoist. Drive two roll pins (14) from each of four platform brace pins (15), withdraw the brace pins, and remove the two braces. Lower platform (1 8).
3. Drive eight roll pins (16) from four platform hinge pins (17), withdraw the brace pins, and remove the platform (18). 4. Install in the parts in the reverse order of removal
11.2.12.3 Mast Hinge Pins
The mast must be lowered to the horizontal position before replacing pivot pins. Support the lower end of the mast with a suitable crane. Replacement parts should be available so that repair can be effected as soon as possible after hinge pin removal.
Refer to Figure 11-17.Remove two capscrews (03) and lockwashers (02) to free the retainers (01). Push out the hinge pins (04). Remove the lube fittings (30) from the hinge pins Install in the parts in the reverse order of removal. Lubricate the hinge pins as specified in Subtopic 16.6.1.1.
The location the bailing air components is shown on Figure 11-18. The hoses are attached to the air pipes with unions and hose clamps. Remove and install to as required to replace any parts that are deteriorated or otherwise damaged.
11.2.12.5 Upper Mast Repair
Under most conditions, the mast need not be removed from the drill either to service the components it supports or to repair its structure. Contact your local P&H MinePro Services representative regarding mast structural repairs and/or physical removal from the drill.
11.3 Troubleshooting
Figure 11-1 provides generic guidelines to aid in troubleshooting problems of the mast and related components.
Problem Probable Cause Remedy
Winch does not run at rated speed Winch sheaves are not turning freely
Inspect winch sheaves for obstruc-tion, binding or damage. Remove any obstruction, lubricate bearings, or replace damaged parts. Leak at brake piston
Relief valve set too low Relief valve should be set to 2200 psi (152 bar). Refer to Section 3, Auxiliary Hydraulic System..
Binding winch drum Check mounting of winch. Winch must be level. Refer to installation instructions.
Winch motor malfunction Repair winch motor.
Winch will not reverse Leak at brake piston lnspect O-rings at brake piston. Replace O-rings.
Defective seal at brake release channel
Check for leakage between motor adapter and brake housing which indicates O-ring failure. Replace O-rings.
Plugged brake release passage Remove winch motor and adapter. Clean brake release passage.
Insufficient hydraulic pressure. Check pressure. Brake releases at approximately 600 psi (41 bar). Refer to Section 3, Auxiliary Hydraulic System..
Oil leakage at winch breather and/or at brake housing and drum
Damaged seal between drum inte-rior and brake housing
Replace oil seal. Seal failure may be caused by excessive pressure doe to incorrect hydraulic oil or a restriction in the return line to the tank. Check for deficiencies and correct.
Oil leakage at winch motor flange and adapter
Loose motor mounting Tighten mounting screws
Faulty O-rings between adapter and motor flange
Replace O-rings
Winch brake will not hold Wire rope is attached to wrong cable
Check for obstruction in the return line to tank. Correct deficiency.
Damaged brake plates lnspect brakes. Replace damaged brake plates. Check oil for contami-nation which will cause failure. Replace oil in system if contami-nated.
Hydraulic control malfunction Hydraulic control malfunction
Winch brake vibrateswhen lowering a load
Entrained air in hydraulic oil Check for foam in oil. Check sys-tem for
Damaged brake plates Inspect brakes. Replace damaged brake plates. Check oil for contami-nation which will cause failure. Replace oil in system if contami-nated.
Mast anchor pins secure but indica-tors do not illuminate
Air trapped in cylinders Bleed air from hydraulic control cir-cuit. Pressurize cylinders at end of stroke and hold at pressure until pressure reaches maximum.
Rotary Machinery BD120149 Mechanical Systems Manual
12.1.1 Rotary Motor 83013-1
There are two rotary motors. The rotary drive motors are variable speed electric motors that are mounted to the top of the rotary gearcase. Each motor is fitted with a pinion to transmit power to the intermediate drive shaft.
12.1.2 Rotary Gear Case R10678F2
Two reversible electric motors are coupled to a double-reduction rotary gearcase (refer to Figure 12-1). The motors are mounted on top of the gearcase. The drive shaft spindle terminates at the drill pipe coupling, which connects to the drill pipe. Internal lubrication is provided by a gear-driven oil pump. Pressurized bit air for the pipe string is con-nected to the main drive shaft through a rotary seal and piping.
The rotary gearcase is mounted to the lower end of the carriage. Hoisting/pulldown components, which provide vertical gearcase motion, are also mounted on the carriage. Refer to Section 14, Hoist/Pulldown Machinery. for information.
12.1.3 Rotary Drill Pipe Coupling R12253F9
The rotary subassembly adapter is a short section of pipe that allows transition with the fine API thread on the rotary head to the coarse BECO thread on the drill pipe.
The coarse BECO thread is used in mine drilling applications because it can better withstand the frequent coupling and breaking of pipe without being damaged beyond use.
A Duraquest Smoothdrive shock sub is used as an adapter. This shock absorber coupling reduces the severity of rotary and vertical vibrations. These are largely absorbed by the rubber element in the device. The reduction in vibration severity translates into longer bit life and higher penetration rates. In addition, it will compensate for minor drill stem misalignment.
BD120149 Mechanical Systems Manual Rotary Machinery
Reducing the harshness vibrations also has benefits for the blasthole drill. These repeated shocks are often the cause of fatigue cracks in the rotary head, mast and other structural components. Dampening these shocks can reduce the amount of downtime for maintenance and increase the life of the drill and its components.
12.2 Rotary Machinery Maintenance
12.2.1 Rotary Motor 83013-1
There are two rotary motors. The rotary drive motors are variable speed electric motors that are mounted to the top of the rotary gearcase. Each motor is fitted with a pinion to transmit power to the intermediate drive shaft.
12.2.1.1 Removal
The rotary carriage should be positioned at deck level to permit convenient access to the rotary gearcase. Support the drive motor during removal using a suitable hoist or other appropriate means.
WARNING!
Hazardous voltage can cause burns, injury, or death. Disconnect, lock out, and tag thepower source which feeds this device to prevent power from being applied while inspec-tion and repairs are being performed. Before beginning repairs, try the operational con-trols to verify that the intended power source is disconnected.
1. Disconnect, lock out, and tag the disconnect switch which feeds the machine to prevent power from being applied while service is being performed.
2. Tag and disconnect the wiring to the motors.
3. Remove eight capscrews and lockwashers to free the motor.
Rotary Machinery BD120149 Mechanical Systems Manual
WARNING!
Dropping or mishandling of heavy drill parts can cause personal injury, or death. Alwaysmove heavy components using the auxiliary winch, or other suitable lifting device, andslings for removal and installation. Provide support for components that may release ormove during any maintenance.
4. Carefully raise the motor straight up from the gearcase until the pinion clears the intermediate gear to prevent damage to gear teeth.
5. Remove the hex nut and lockwasher from the motor shaft. Pull the pinion off the shaft using a suitable puller. It may be necessary to heat the pinion before removal.
6. Remove the key from the motor shaft.
7. Place the motor in an appropriate repair area.
12.2.1.2 Cleaning, Inspection and Repair
Clean and inspect parts as described in Appendix A of this manual. Repair consists of the replacement of worn or damaged parts. Observe all safety precautions.
Rotary Machinery BD120149 Mechanical Systems Manual
6. Try the pinion on the shaft to be sure it does not bind on the key. Rework the key if binding is evident.
7. Clean the pinion and shaft again.
8. Place the pinion on the shaft and snap it into position by hand. Measure the “cold” position of the pinion using a micrometer depth gauge. Mark the places where the depth gauge was resting so that measurements can be made from the same positions after the pinion has been mounted.
CAUTIONExcessive heat can damage the pinion. The pinion must never be heated to a tempera-ture above 374°F (190°C).
9. Remove the motor pinion from the motor shaft. Heat the pinion in a suitable oven to the temperature specified in Table 12-1
10. If the pinion is heated in oil, the bore must be thoroughly cleaned before mounting. The use of an oven is rec-ommended to avoid the cleaning step.
11. Pinion temperature is indicated as a temperature difference between the motor shaft and pinion. This tempera-ture is estimated only, and can be adjusted to maintain the specified advance. Heat the pinion in the oven until the temperature is uniform at the required number of degrees above the shaft temperature.
For example: if the shaft temperature is 25°C (78°F) and the estimated difference is 125°C (225°F), heat the pinion to 150°C (302°F) for mounting.
Frame ShaftDiameter
PinionDimension
Shrunk On Pinion
Advance
Estimated Temperature Difference
“D” “X” ºC ºF
K504T 3.000" 2.9935" 4.75" .020 to .025" 70 126
Table 12-1: Pinion Mounting Data (refer also to Figure 12-5)
BD120149 Mechanical Systems Manual Rotary Machinery
12. A quick accurate method must be provided for measuring pinion temperature and the shaft before mounting the pinion. This can best be done with a hand pyrometer. When a hand pyrometer is not available, a celsius thermometer can be used by placing putty over the thermometer to hold it against the pinion. Heat the pinion to a few degrees above the desired temperature before removing the pinion from the oven. Wait until the pinion has cooled to the desired temperature, remove the thermometer, and quickly mount the pinion as described in the following steps.
A. After assuring that the pinion bore is clean, quickly mount the hot pinion on the motor shaft. When the pinion is nearly engaged with the taper fit (but not in contact), snap it forcibly into place with a quick push. It is important that the pinion be instantly snapped into position before it has cooled appreciably; otherwise the pinion will “freeze” to the shaft and cannot be adjusted further.
B. Check the hot, or “shrunk-on,” position of the pinion on the shaft using a micrometer depth gauge. The actual advance is the difference between the depth gauge readings at the hot and cold positions. To control stresses in the pinion, the advance must be within the limits specified in Table 12-1.
C. If the advance is not within limits, the pinion must be pulled and remounted.
D. Assemble the lockwasher and hex nut on the motor shaft, tighten firmly, and then lock.
12.2.1.4 Motor Installation
. Refer to Figure 12-4 and proceed as follows:
1. Immediately before installation, thoroughly clean the mounting surfaces on the motor and gearcase with Per-chloroethylene or Toluol. Keep dust off the surfaces.
2. Raise the motor with the winch and position it over the gearcase. Be sure that the motor duct is correctly posi-tioned so it will mate with the blower duct when installed.
3. Apply a continuous, thin coat of non-hardening gasket sealer (Permatex No. 2 or equivalent) to the mounting surface of the gearcase and around the eight bolt holes.
4. Without allowing extra “setting up” time for the sealer, mount the motor without damaging the sealer surface.
5. Carefully lower the motor straight down into the gearcase so the pinion engages the intermediate gear without damage.
6. Apply a “no gall” thread lubricant to the entire thread and bearing surfaces of all eight mounting capscrews. Remove excess lubricant.
7. Install the capscrews and the flanged lockwashers.
8. Torque the capscrews in stages to between 678 and 780 Nm (500 and 575 ft-lbs) using a tightening pattern.
NOTICE
Capscrews must be Grade 5 or better.
9. If any capscrews will not accept a torque wrench due to mechanical interference, use the following method:
A. Snug all capscrews to approximately the same initial torque, using a hand wrench.
Rotary Machinery BD120149 Mechanical Systems Manual
B. Using a tightening pattern in several stages of tightening for all the accessible capscrews, torque to the specified torque (preceding Step 8). Record how far the capscrews turn from the initial torque.
C. Using a hand wrench, tighten the remaining capscrews the same number of turns.
D. Retorque the original capscrews that were tightened down with a torque wrench.
E. Tighten the remaining capscrews the same amount.
10. Connect the electrical wiring to the rotary drive motor.
11. Check and fill the rotary gearcase to the required lubrication level. Refer to Subtopic 16.4.1.
Rotary Machinery BD120149 Mechanical Systems Manual
The gearcase assembly consists of gear-driven main and intermediate drive shafts, main-gear driven oil pump for internal lubrication, bit air coupling and tubing, and gearcase housing with drive motor mounts, access covers, and breather. The drive shafts are supported in tapered roller bearings. The main drive shaft is bored so that bit air entering the shaft at the top flows through to the drill pipe coupling and drill pipe.
It should seldom, if ever, be necessary to remove the entire rotary gearcase assembly. All adjustments, service, and repair of components can be accomplished in the field, except in the event of extreme damage to internal parts.
Figure 12-7: Legend for Figure 12-6
LEGEND01.Lubrication Pump Gear02. Snap Ring03. Lubrication Pump Mounting04. Hex Head Capscrew05. Lock Washer06. Plain Washer07. Shoulder Bolt08. Self-Locking Nut09. Motor Pinion10. Seal Retainer11. Seal Retainer Gasket12. Tapered Bearing13. Spacer14. Lock Washer15. Take Up Nut16. O-ring17. Seal18. Breather19. Pipe Coupling20. Pipe Nipple21. Hose Assembly22. JEC Male Pipe Elbow23. Hose Assembly24. Straight Fitting25. Close Nipple26. Hose Assembly27. JIC Male Pipe Elbow28. Hose Assembly29. JIC Male Pipe Adapter30. Fitting31. Male Cross32. Rotary Gear Case33. Tapered Bearing34. Snap Ring35. First Intermediate Gear36. Spacer37. Intermediate Pinion38. Tapered Bearing39. Shim
40. Shim41. Shim42. O-ring43. Pump Housing44. Cover Gasket45. Cover46. Drain Cock47. Socket Head Capscrew48. Lock Washer49. Drill Head Capscrew50. Lock Wire51. Magnetic Plug52. Seal Retainer53. Seal Carrier54. Grease Fitting55. Seal56. Seal Spacer57. Relief Fitting58. Drill Head Capscrew59. Main Rotary Shaft60. Tapered Bearing61. Spacer62. Fitting63. Magnetic Plug64. Main Gear65. Pipe Bushing66. Close Nipple67. Drain Cock68. Cover Gasket69. Gear Case Cover70. Drill Head Capscrew71. Inspection Cover72. Inspection Cover Gasket73. Socket Head Capscrew74. Lubrication Pump75. Key76. O-ring77. Socket Head Capscrew78. Straight Fitting
BD120149 Mechanical Systems Manual Rotary Machinery
12.2.3 Bit Air Components
The bit air components consist of a rotary air pipe with seals, swivel housing, pipe joint, and air pipe with seals and related hardware. These components are mounted above the main drive shaft on the gearcase.
12.2.3.1 Removal And Disassembly
The rotary machinery carriage should be positioned at deck level to permit convenient access to the gearcase assembly. Refer to Figure 12-8 and proceed as follows:
Figure 12-8: Bit Air Components
LEGEND01. Air Pipe02. Hose Clamp03. Air Hose04. Self-Locking Nut05. Stud06. Housing Cover07. Pipe Coupling
08. Air Swivel09. Special Flange10. O-ring11. Take Up Nut12. Lock Wire, Lock 13. Drill Head Capscrew14. Swivel Housing
Rotary Machinery BD120149 Mechanical Systems Manual
WARNING!
Inadvertent operation of the drill during service, inspection, or maintenance on themachine can cause severe bodily injury, or death. Use lockout and tagout procedures toprevent accidental operation of the drill.
1. Shut down the drill. Lock out and tag the disconnects that supply electrical power to prevent inadvertent move-ment of the drill during inspection, service, or maintenance.
2. Disconnect and remove the flexible pipe joint (03) at the air pipe (01) and remove clamps (02) as required.
3. Remove air pipe (01) and pipe coupling (07) from the air swivel (08).
4. Disconnect lube hoses and related hardware (refer to inset A on Figure 12-6). If necessary, tie up the lower lube hose to prevent oil from draining from the gearcase. Remove parts as required.
5. Remove lockwire (12) and capscrews (13) that attach swivel housing (14) to the gearcase. Remove housing. This will expose the main drive shaft adjustment components and seals.
12.2.3.2 Cleaning, Inspection And Repair
Clean and inspect parts as described in Appendix A of this manual. Observe all safety precautions. Replace all worn or damaged parts. Refer to the LinkOne electronic parts manual for parts identification.
12.2.3.3 Assembly And Installation
Install parts in the reverse order of removal. Refer to Figures 12-6, and 12-8.
A. Position the swivel housing (14) on the gearcase so that the lube holes in the housing and in the seal retainer are aligned. This is necessary to permit proper lube venting. Refer to Figure 12-9.
BD120149 Mechanical Systems Manual Rotary Machinery
12.2.4 Oil Pump and Lines
The oil pump circulates lubricating oil to the gearing through hoses and fittings to both sides of the gearcase. The pump is mounted behind the front covers on a bracket that is attached to the larger front cover. The main drive gear meshes with the oil pump gear; meshing is adjustable. Oil flows through external hoses to fittings on top of the gearcase.
12.2.5 Removal And Disassembly
The rotary machinery carriage should be positioned at deck level to permit convenient access to the gearcase assembly. Refer Figure 12-10 (see also Figure 12-6) and proceed as follows:
Rotary Machinery BD120149 Mechanical Systems Manual
WARNING!
Inadvertent operation of the drill during service, inspection, or maintenance on themachine can cause severe bodily injury, or death. Use lockout and tagout procedures toprevent accidental operation of the drill. Determine and provide support for componentswhich may release or move during any maintenance. Lock out and tag the disconnectsthat supply electrical power to the drill to prevent inadvertent movement of the machin-ery during inspection, service, or maintenance.
1. Shut down the drill. Lock out and tag the disconnects that supply electrical power to the drill, to prevent inad-vertent movement of the machinery during inspection, service, or maintenance.
2. Drain the oil from the rotary gearcase.
3. Disconnect the external hoses at the fittings and indicator on the gearcase assembly.
4. Remove the lockwire and capscrews to detach the small cover and its gasket, and gain access to the oil pump.
5. Disconnect the hose from the gearcase cover bulkhead fitting to the pump flange.
6. Remove capscrews and lockwire to detach the large cover with attached pump, mount, and cover gasket.
7. Remove the retaining ring from the oil pump shaft. Pull the pump gear up off the pump shaft. The shaft is keyed.
8. Remove socket head screws and lockwashers to detach the flange from the pump.
9. Remove two socket head screws and lockwashers to detach the pump from the mount.
10. Remove the capscrew and lockwasher from the slot in the pump mount.
11. Remove the capscrew and hex nut to detach the pump mount from the cover.
12. Remove fittings from the pump and case as required.
12.2.5.1 Cleaning, Inspection and Repair
Clean and inspect parts as described in Appendix A of this manual. Observe all safety precautions. Replace all worn or damaged parts. Refer to the LinkOne electronic parts manual for parts identification.
12.2.5.2 Assembly and Installation
Refer to Figures 12-6, and 12-10 and proceed as follows:
WARNING!
Inadvertent operation of the drill during service, inspection, or maintenance on themachine can cause severe bodily injury, or death. Use lockout and tagout procedures toprevent inadvertent operation of the drill.
BD120149 Mechanical Systems Manual Rotary Machinery
1. Lock out and tag the disconnects that supply electrical power to the drill to prevent inadvertent movement of the machinery during inspection, service, or maintenance.
2. Install the fittings into the pump and case.
3. Install the capscrew and hex nut to attach the pump mount to the large cover. Install the capscrew and lock-washer through the cover bracket and into the pump mount. Do not tighten at this time.
4. Attach the flange to the pump with four socket head screws and lockwashers.
5. Attach the oil pump with the flange to the pump mount with two socket head screws and lockwashers.
6. Push the pump gear onto the keyed pump shaft. Install the snap ring into the groove in the oil pump shaft to secure the gear.
7. Position the large cover with attached pump and cover gasket on the gearcase. Apply a thin coat of sealant (GE RTV-102 or Permatex No. 2) to the gasket and mounting surfaces. Install capscrews with lockwire to secure.
8. Connect the hose from the gearcase bulkhead fitting to the pump flange.
9. Adjust the drive gear to pump gear mesh. Refer to the topic, Adjustment, below.
10. If removed, screw the indicator into the elbow.
11. Connect the hoses at the fittings on the gearcase assembly.
12. Apply a thin coat of sealant (GE RTV-102 or Permatex No. 2) to the small cover, gasket, and mounting sur-faces. Install the small cover and gasket with twelve capscrews. Apply lockwire to the capscrews.
13. Check hose connections and fittings to be sure that connections are tight. Tighten loose connections as required.
12.2.5.3 Adjustment
Refer to Figure 12-10 and proceed as follows:
WARNING!
Inadvertent operation of the drill during service, inspection, or maintenance on themachine can cause severe bodily injury, or death. Use lockout and tagout procedures toprevent inadvertent operation of the drill.
1. Lock out and tag the disconnects that supply electrical power to the drill to prevent inadvertent movement of the machinery during inspection, service, or maintenance.
2. Remove the lockwire and capscrews to detach the small cover and its gasket, and gain access to the oil pump.
3. Loosen the adjusting capscrew in the slot in the mount.
Rotary Machinery BD120149 Mechanical Systems Manual
5. While holding the pump gear against the main drive gear for full tooth engagement without binding, tighten the adjusting capscrew. Then tighten the pivot capscrew and hex nut.
6. Install the small cover and gasket with twelve capscrews and lockwire.
12.2.6 Intermediate Drive
The intermediate shafts and gears are supported on roller bearings. Access is through the bottom of the gearcase and the front cover. Shaft end play should be checked and adjusted anytime that the gearcase is down for other service or repair.
12.2.6.1 Check And Adjust end play
Lower the carriage to a convenient level for access to the gearcase. A minimum of disassembly is required to check and adjust intermediate shaft end play. The procedure is the same for each intermediate shaft. Refer to Fig-ure 12-6 and proceed as follows:
WARNING!
Inadvertent operation of the drill during service, cause severe bodily injury, or death.Use lockout and tagout procedures to prevent inadvertent operation of the drill.
1. Disconnect, lock out, and tag the disconnect switch which feeds the machine to prevent power from being applied while service is being performed.
2. Remove the two drain cocks (46) from their covers (45). Allow oil to drain from the gearcase into a suitable container.
3. Remove socket head screws (47) and lockwashers (48) that attach the cover and gasket (44).
4. Remove plug (62). Install a dial indicator so that the spindle contacts the upper end of the intermediate shaft through the plug hole. Zero the indicator.
5. Apply force to the bottom of the intermediate shaft and check the indicator reading. Intermediate shaft end play should be 0.076 to 0.127 mm (0.003 to 0.005").
6. If end play is not within tolerance, remove lockwire (50) and capscrews (49) which attach the bearing housing. Remove housing (43), O-ring (42), and shims (39, 40 and 41).
BD120149 Mechanical Systems Manual Rotary Machinery
7. Adjust for correct end play using existing shims and shims from the available shim pack. Refer to Figure 11-12 for a sectional view of installation.
8. If further work is to be done on the rotary gearcase, shimming can be performed during assembly of the gear-case. Note the thickness of the shim pack.
9. Apply a thin coat of sealant (GE RTV- 102 or Permatex No. 2) to the shims the mounting surface. Reinstall pump housing and shims. Re-check end play.
10. Install cover (45) and gasket (44) with mounting hardware. Install lockwire (50) on capscrews (49) to secure the housing. Apply lockwire to screw heads in pairs similar to the arrangement shown in Figure 12-9.
Rotary Machinery BD120149 Mechanical Systems Manual
12.2.6.2 Removal and Disassembly
The rotary machinery carriage should be positioned at a convenient level to permit access to the gearcase assem-bly. For drills with two drives the procedure is the same for each. Refer to Figure 12-6 and proceed as follows:
WARNING!
Dropping or mishandling of heavy drill parts can cause personal injury, or death. Alwaysmove heavy components using the auxiliary winch, or other suitable lifting device, andslings for removal and installation. Provide support for components that may release ormove during any maintenance. Inadvertent operation of the drill during service, inspec-tion, or maintenance on the machine can cause severe bodily injury, or death. Use lock-out and tagout procedures to prevent inadvertent operation of the drill.
1. Disconnect, lock out and tag the disconnect switch that feeds the machine to prevent power from being applied while service is being performed.
2. Check intermediate shaft end play. Refer to Subtopic 12.2.6.1.
NOTICE
Note the number and size of the shims. This will be helpful information when adjusting shaft endplay.
3. Remove the front cover and oil pump. Refer to Subtopic 12.2.4.
4. Remove the drive motor. Refer to Subtopic 12.2.1.
5. Remove snap ring (34) from intermediate shaft (37).
6. Support gear (35). Carefully push the intermediate shaft, with bearings in place, down through spacer (36), the intermediate gear, and gearcase. Bearing (33) may tend to hang up and remain in its seat. To prevent damage to the bearing, do not allow it to fall from the bearing seat.
7. 7. Remove bearings (33 and 38) from the shaft and gearcase.
8. Remove intermediate gear (35) and spacer (36) through the front case opening.
12.2.6.3 Cleaning, Inspection and Repair
Clean and inspect parts as described in Appendix A of this manual. Observe all safety precautions. Replace all worn or damaged parts. Refer to the LinkOne electronic parts manual for parts identification.
12.2.6.4 Assembly and Installation
Refer to Figure 12-6 and proceed as follows:
1. Position intermediate gear (35) in the gearcase above main gear (64), and over the intermediate shaft bore. Support the intermediate gear to prevent binding and damage during installation of the shaft.
2. Install upper bearing (33) and lower bearing (38) on intermediate shaft (37).
BD120149 Mechanical Systems Manual Rotary Machinery
3. Carefully push the intermediate shaft with bearings in place through the lower shaft bore, spacer (36), and gear (35) so that the upper bearing seats in the upper bearing bore. Be sure that the splines on the shaft and in the gear are aligned to prevent binding and possible damage to the splines.
4. Install retaining ring (34) on the intermediate shaft.
5. Support the intermediate shaft assembly while installing housing (43).
6. Install the shims and adjust end play. Refer toSubtopic 12.2.6.1.
7. Install the oil pump. Refer to Subtopic 12.2.4.
8. Install the drive motor and pinion. Refer to Subtopic 12.2.1.
9. Fill the gearcase with oil. Refer to Subtopic 16.3.1.
12.2.7 Main Drive
The main shaft rotates on roller bearings and is fitted with seals. Provision has been made for adjustment of bear-ing preload. Refer to the topics, Main Drive Bearing Preload Check, and Main Drive Bearing Preload Adjustment.
12.2.7.1 Removal and Disassembly
The rotary machinery carriage should be positioned at deck level to permit convenient access to the gearcase assembly. Refer to Figure 12-6 and proceed as follows:
WARNING!
Dropping or mishandling of heavy drill parts can cause personal injury, or death. Alwaysmove heavy components using the auxiliary winch, or other suitable lifting device, andslings for removal and installation. Provide support for components that may release ormove during any maintenance.
WARNING!
Inadvertent operation of the drill during service, inspection, or maintenance on themachine can cause severe bodily injury, or death. Use lockout and tagout procedures toprevent inadvertent operation of the drill.
1. Lock out and tag the disconnects that supply electrical power to the drill to prevent inadvertent movement of the machinery during inspection, service, or maintenance.
2. Drain the oil from the rotary gearcase.
3. Remove the bit air components on the gearcase. Refer to the topic, Bit Air Components.
4. 4. Remove lock washer (14), take up nut (15), and O Ring (16).
5. Remove retainer (10) and gasket (11). Remove seal (17) from the retainer.
Rotary Machinery BD120149 Mechanical Systems Manual
6. Disconnect the lube hose that is connected to the seal carrier (53) on the bottom of the rotary gearcase. Cap the hose to prevent leakage.
7. Remove lockwire (24), capscrews (64) and carrier (54) with retainers (53).
8. If necessary, remove lockwire (50), capscrews (58), retainer (52) and seals (55), and spacer (56), from carrier (53).
CAUTION!
The main drive shaft could slip out of the case, causing personal injury or equipmentdamage. Provide support under the shaft when it is removed to prevent accidental dam-age. Keep away from shaft during lifting, lowering, or moving.
9. Carefully push the main drive shaft at the top to force the shaft out of the main gear and gearcase. The lower main bearing cone (60) will come out with the shaft (59).
10. Remove main bearing (12) and spacers (13 and 61).
11. Remove main bearing (60).
12. Remove gear (64) through the front opening in the gearcase.
12.2.7.2 Repair
Clean and inspect parts as described in Appendix A of this manual. Observe all safety precautions. Replace all worn or damaged parts. Refer to the LinkOne electronic parts manual for parts identification.
12.2.7.3 Assembly and Installation
Refer to Figure 12-6 and proceed as follows:
1. Place gear (64) into the gearcase through the front opening so that it is aligned with the main shaft bore.
2. Install bearing cup (13) into upper main shaft gearcase bore.
3. Install main bearing (60) and spacer (61) onto main shaft (66).
4. Carefully push the assembled main shaft through the gearcase, main gear (64), spacer (13) and bearing (12) until the lower bearing seats in the gearcase bore. Be sure that the splines on the shaft and in the gear are aligned to prevent binding and possible damage to the splines. Secure the shaft in this position.
5. If necessary, install new seal (17) into retainer (10). The seal spring must face the oil side (downward).
6. Install retainer with seal and gasket (11).
7. Install O-ring (18) and take up nut (15). Torque the take up nut enough to secure the main shaft. Install lock-washer (14).
8. If necessary, install new seals (55) and spacer (56) into carrier (53). The seal springs must face the oil side (upward) with the spacer in between.
Rotary Machinery BD120149 Mechanical Systems Manual
12.2.7.4 Main Drive Bearing Preload Check
The rotary gearcase main bearing preload should be checked every 1000 hours of operation, or 6 months, as a minimum. Refer to Figure 12-12 and proceed as follows:
1. While drilling a hole, stop operation with the rotary gearcase 3 to 4 feet from the drill platform.
2. With the drill pipe weight suspended on the machinery, mount a dial indicator on the main shaft spindle to indi-cate to the bottom of the gearcase.
3. Apply a 311,360 N (70,000 lb) pulldown force and observe the dial indicator. Any dial movement indicates the need for preload adjustment. No dial movement indicates that preload is correct.
4. Release the pulldown force and remove the dial indicator.
5. Proceed with operation. If necessary, schedule adjustment at the earliest opportunity.
BD120149 Mechanical Systems Manual Rotary Machinery
12.2.7.5 Main Drive Bearing Preload Adjustment
The rotary machinery carriage should be positioned above deck level to permit convenient access to the gearcase assembly. Support the unit so that it is stable during removal and installation of components. Refer to Figure 12-6 and proceed as follows:
WARNING!
Inadvertent operation of the drill during service, inspection, or maintenance on themachine can cause severe bodily injury, or death. Use lockout and tagout procedures toprevent accidental operation of the drill.
1. Shut down the drill. Lock out and tag the disconnects that supply electric power to the machine to prevent inad-vertent movement of the machinery during inspection, service, or maintenance.
2. Disconnect and remove the bit air components from the gearcase. Refer to Subtopic 12.2.3.
3. Remove lockwasher (14) and remove the lockwasher.
4. Loosen take up nut (15), then Re-tighten to obtain zero main shaft end play. Check with a dial indicator.
5. Tighten take up nut from 9° to 15° beyond “0” end play to obtain 0.08 to 0.13 mm (0.003 to 0.005") preload on the bearings.
6. Hold the position of the take up nut. Apply anti-seize compound to the main shaft threads. Wipe off excess compound, then install lockwasher (14), lock down take up nut (15) and bend a tab on the lockwasher.
7. Install slinger ring (15) and retaining rings 16).
8. Install bit air components that were removed in Step 2. Refer to the topic, Assembly and Installation, under Bit Air Components.
9. Check gearcase lubrication level and replenish if necessary. Refer to the Lubrication section.
Rotary Machinery BD120149 Mechanical Systems Manual
12.2.8 Rotary Drill Pipe Coupling R12253F9
The rotary drill pipe coupling is a Duraquest Smoothdrive™ unit manufactured to a strict set of design specifica-tions that ensure control over unwanted shock and vibrations, resulting in savings on equipment repair as well as savings on the overall drilling operation.
Since the drill pipe coupling is designed to function as a system, all parts and components that are a part of the system are required to ensure proper operation. Additionally, replacements should be made using OEM parts.
Figure 12-13: Rotary Drill Pipe Coupling
01 02 03 04 05 06
0704 08
BD0571b01
LEGEND01. Hex Head Cap Screws02. Lift Ring03. Pin Connection04. Hex Head Bolt
BD120149 Mechanical Systems Manual Rotary Machinery
WARNING!
Inadvertent movement of the drill during maintenance activities can cause severe bodilyinjury or death. When it is necessary to operate the machine before making an adjust-ment, or during an operational inspection, obtain the assistance of a second operatorwho is thoroughly familiar with the machine. Maintain constant communication and havethe operator at the control panel to be sure that nothing is actuated that can be hazard-ous to you or the machine.
12.2.8.1 Inspection
The rubber element should be checked every 500 hours of operation as follows:
1. Drill down to the point where the rotary coupling is at eye level. Rest the drill bit at the bottom of the hole.
2. Inspect the rubber element. The rubber should maintain its original look and feel. If the rubber appears discol-ored or deteriorated, or if it feels sticky or gummy, replace the element.
3. Inspect the housing in the area of the torque limiter lugs. If the lugs have peened the edge of the housing, the metal could cut the rubber element. Remove peened metal from the housing using a hand grinder or sander.
12.2.8.2 Removal and Disassembly
The rotary machinery carriage should be positioned at deck level to permit convenient access to the rotary drill coupling. Remove welded straps and disconnect the rotary drive shaft from the rotary coupler. Support the coupling parts during removal of components. Refer to Figure 12-13 and proceed as follows:
WARNING!
Inadvertent operation of the drill during service, inspection, or maintenance on themachine can cause severe bodily injury, or death. Use lockout and tagout procedures toprevent accidental operation of the drill.
1. Disconnect, lock out, and tag the disconnect switch that feeds the machine to prevent power from being applied while service is being performed.
2. Remove the lift ring capscrews and remove the lift ring from the rotary coupling.
3. Remove the torque limiter capscrews and discard them. Torque limiter capscrews should not be re-used.
4. Remove the torque limiter.
5. Remove the lower capscrews and discard them. Lower capscrews should not be re-used.
6. Remove the element from the housing.
7. If the body or the BECO box connector require replacement, remove them from the drill string.
Rotary Machinery BD120149 Mechanical Systems Manual
12.2.8.3 Cleaning, Inspection and Repair
Clean, inspect, and repair parts as described Appendix A. Observe all safety precautions. Replace all worn or damaged parts. Refer to the LinkOne electronic parts manual for parts identification.
12.2.8.4 Assembly and Installation
Support the coupling parts during installation of the components. Refer to Figure 12-13 and proceed as follows:
1. If the housing or the BECO box connector was removed, replace the housing and/or the BECO box connector onto the drill string.
2. Place the new element into the housing.
3. Use new bolts. Visually inspect bolt threads prior to installation. Threads must be clean and free of damage, and the yellow Nylok™ patch must be in good condition.
4. Spray bolt threads and threaded holes in the element with a light cote of dry film corrosion preventative and let dry.
5. Apply a small amount of grease to the first two or three threads of the bolt and screw it into the rubber element as far as possible by hand.
CAUTIONInstall bolts slowly to minimize heat buildup, which could cause galling of the threads.
6. Using a 1" impact wrench, slowly run the bolts into the element the rest of the way.
7. Torque bolts to 3,000 ft-lbs (4067 Nm). Verify torque after application. Re-check torque after bolts have had a chance to “settle.”
12.2.9 Gearcase Removal and Installation
The following procedures can be used if it is necessary to remove the entire gearcase. The pipe string must be removed. Proceed as follows:
12.2.9.1 Removal
The rotary carriage positioned to permit convenient access to the gearcase assembly. The unit may be serviced with the mast up or down. Use appropriate support in all cases.
WARNING!
Inadvertent operation of the drill during service, inspection, or maintenance on themachine can cause severe bodily injury, or death. Use lockout and tagout procedures toprevent inadvertent operation of the drill.
1. Lock out and tag the disconnects that supply electrical power to the drill to prevent inadvertent movement of the machinery during inspection, service, or maintenance.
BD120149 Mechanical Systems Manual Rotary Machinery
2. Drain the rotary gearcase.
3. Disconnect the bit air components. Refer to Subtopic 12.2.3.
WARNING!
Dropping or mishandling of heavy drill parts can cause personal injury, or death. Alwaysmove heavy components using the auxiliary winch, or other suitable lifting device, andslings for removal and installation. Provide support for components that may release ormove during any maintenance.
4. Remove the drive motors. Refer to Subtopic 12.2.1.
5. Remove the drill pipe coupling. Refer to Subtopic 12.1.3.
6. Disconnect the lube hose that is connected to the seal carrier on the bottom of the rotary gearcase. Cap the hose to prevent leakage.
7. Place jack(s) underneath the rotary gearcase for support, and/ or a hoist from above.
8. Remove the idler pinions and related mounting parts. Refer to Section 14, Hoist/Pulldown Machinery..
9. Remove the lower guide rollers. Refer to Section 14, Hoist/Pulldown Machinery..
10. Remove lockwires, capscrews, bolts and nuts to detach the rotary gearcase.
11. If used, lower the jack(s) so that the rotary gearcase clears the carriage legs. Move the rotary gearcase to an appropriate area for repair.
12.2.9.2 Installation
WARNING!
Inadvertent operation of the drill during service, inspection, or maintenance on themachine can cause severe bodily injury, or death. Use lockout and tagout procedures toprevent inadvertent operation of the drill.
1. Lock out and tag the disconnects that supply electrical power to the drill to prevent inadvertent movement of the machinery during inspection, service, or maintenance.
WARNING!
Dropping or mishandling of heavy drill parts can cause personal injury, or death. Alwaysmove heavy components using the auxiliary winch, or other suitable lifting device, andslings for removal and installation. Provide support for components that may release ormove during any maintenance.
BD120149 Mechanical Systems Manual Rotary Machinery
12.3 Troubleshooting
Table 12-2 provides general guidelines to aid in troubleshooting problems of the rotary machinery.
Problem Probable Cause
Remedy
No Rotary Power
No voltage to drive motor
Check for tripped circuit breaker in power or control circuits.
Investigate cause of power interruption. Refer to Section 15 for troubleshooting of electrical circuits. Repair deficiencies.
Faulty drive motor or pin-ion
If motor does not run, inspect rotary motor for signs of overheating and burnout. Refer to Section 15 for troubleshooting of motor. Repair deficiencies.
If motor runs, drain gearcase.Remove front cover and inspect for stripped pinion. Repair as required
Damaged rotary gear-case
Check gearcase oil level and inspect for leakage at seals.
Drain gearcase. Remove magnetic plug and inspect for metal particles indicating exces-sive wear or damage.
Remove front cover and inspect internal components for wear and damage. Repair as required.
Insufficient Rotary Power
Faulty rotary gearcase
Drain gearcase. Remove magnetic plug and inspect for metal particles indicating exces-sive wear.
Remove front cover and inspect internal components for binding and damage. Repair as required.
Incorrect voltage to drive motor
Investigate control and power circuits for cause of incorrect voltage and repair any deficiencies. Refer to Section 15 for trou-bleshooting of electrical system.
Faulty drive motor
If motor control and power circuits are functioning properly, inspect rotary motor for evidence of overheating or other dam-age. Refer to Section 15 for troubleshooting of motor. Repair deficiencies
Faulty rotary gearcase
If motor control and power circuits are functioning properly, check gearcase oil level and inspect for leakage at seals.
Hoist/Pulldown Machinery BD120149 Mechanical Systems Manual
The Hoist/Pulldown drive system is mounted in the Rotary Carriage (refer to Figure 14-1).
14.1.1 Pulldown Motor 83013-1
An electric motor is mounted to the upper end of the carriage. It is coupled to a two-reduction transmission. The pulldown motor is cooled by air through an electric motor blower.
14.1.2 Pulldown Motor Blower R37819D2
The pulldown motor is air-cooled by the electric motor blower (2 HP, 380 V, 50 Hz @ 1470 RPM 3.2 F.L.A.) attached to the motor housing.
BD120149 Mechanical Systems Manual Hoist/Pulldown Machinery
14.1.3 Pulldown Transmission 914J434F1
The electric motor drives a triple-reduction pulldown gearcase (refer to Figure 14-4). A disc-type hydraulic brake is attached to the transmission intermediate shaft to hold the carriage when it is at rest. This is a holding brake only. Dynamic braking is accomplished using the electric motor’s reversing capabilities.
The transmission’s output shaft, the shipper shaft, extends out both sides of the pulldown gearcase. On either end of the shipper shaft is a pinion that meshes with racking that is attached to the mast legs. These pinions drive against the racking to move the drill bit and pipe string.
14.1.4 Pulldown Drive Pinions R5544D1
The pulldown drive pinions are mounted to the ends of the shipper shaft, which is driven by the pulldown motor and gearcase. The idler pulldown pinions are mounted on shafts on the rotary gearcase. Grease to lubricate the pull-down pinion bearings and the gear racks is provided by the automatic lubrication system.
Hoist/Pulldown Machinery BD120149 Mechanical Systems Manual
14.1.5 Pulldown Idler Pinions R7560D3
The pulldown idler pinions are mounted to shafts that extend from the sides of the rotary gearcase. Grease to lubri-cate the idler pinion bearings and the gear racks is provided by the automatic lubrication system.
The drive pinions and idler pinions engage the racks welded to the mast verticals.
Idler pinions do not drive, but engage the racks to provide stability in carriage movement. Guide rollers, mounted to the carriage on the side opposite the pinions, maintain proper carriage tracking.
BD120149 Mechanical Systems Manual Hoist/Pulldown Machinery
14.1.6 Upper Guide Rollers R54361F3
The upper guide roller mounts to the rotary carriage. It limits the movement of the carriage to maintain the correct engagement between the drive pinion teeth and the mast racking teeth.
14.1.7 Lower Guide Rollers R54362F3
The lower guide roller mounts to the rotary carriage. It limits the movement of the carriage to maintain the correct engagement between the idler pinion teeth and the mast racking teeth.
Hoist/Pulldown Machinery BD120149 Mechanical Systems Manual
14.1.8 Pulldown Brake 15R55D1
The hoist/pulldown brake is spring set and hydraulic released. Braking action is provided by a stack of two rotating brake discs and three stationary plates (wear, center, and pressure). The lined brake discs are splined to a hub on the pulldown gearcase intermediate shaft. When the brake is set, powerful springs apply braking force to the pres-sure plate, holding the pulldown gearcase and preventing it from moving.
14.1.9 Pulldown Resolver Assembly 975N20F1
The pulldown resolver is attached through a flexible speedometer-type cable linkage to a shaft on the pulldown brake. The resolver itself is mounted on a bracket inside the base. he resolver senses rotation of the pulldown gearcase and signals the PLC, which translates pulldown movement into the corresponding drilling depth.
Hoist/Pulldown Machinery BD120149 Mechanical Systems Manual
14.2.1.1 Removal
The machinery carriage should be positioned at deck level to permit convenient access and resting on the drill bit, or otherwise supported, to prevent falling. Refer to Figure 14-12 and proceed as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
WARNING!
Hazardous voltage can cause burns, injury, or death. Disconnect, lock out, and tag thepower source which feeds this device to prevent power from being applied while inspec-tion and repairs are being performed. Before beginning repairs, try the operational con-trols to verify that the intended power source is disconnected.
WARNING!
Dropping or mishandling of heavy drill parts can cause severe injury, or death. Alwaysmove heavy components using the auxiliary winch, or suitable lifting device, and slingsfor removal and installation. Determine and provide support for components, which mayrelease or move any during maintenance.
1. Disconnect, lock out, and tag the power source that feeds system to prevent power from being applied while service is being performed.
2. Remove the blower. Refer to Subtopic 14.2.2.1.
3. Tag and disconnect wiring to the pulldown motor.
4. Remove the mounting hardware and disconnect the halves of coupling (34).
5. Refer to Figure 12-5. Remove locknuts (23), conical washers (22), washers (21), and capscrews (35) from the motor flange.
6. Use a lifting device to support motor (11). Remove locknuts (23), conical washers (22), washers (21), and cap-screws (13) to detach motor support (12) and motor. Record the thickness and number of shims (14 through 18). Maneuver the motor to clear the flanged support (36), and remove to an appropriate area.
7. Remove capscrews (20), washers (19), and support (12).
8. Remove the nut, bent washer, and key from the end of the motor shaft.
14.2.1.2 Cleaning, Inspection and Repair
Clean and inspect parts as described in Appendix A of this manual. Repair consists of the replacement of worn or damaged parts. Observe all safety precautions.
BD120149 Mechanical Systems Manual Hoist/Pulldown Machinery
14.2.1.3 Assembly and Installation
Refer to Figure 14-12 and assemble the pulldown motor components in the reverse order of disassembly. Note the following:
1. On the coupling, bend the tab on the lockwasher to lock the nut.
Figure 14-13: Pulldown Motor Alignment
0203
04
01
LEGEND01. Adjusting Capscrew and Nut02. 0.19" (4.8 mm) Shaft-to-Shaft Clearance03. Key, Bent Washer, and Nut are supplied with the motor04. Key is supplied with the pinion
Hoist/Pulldown Machinery BD120149 Mechanical Systems Manual
2. Using a suitable lifting device, position motor (11), with support (12), over shims (14 through 18) on base (24). Install the same shim stack that was removed.
3. Install the motor mounting hardware.
4. Refer to and align the motor to the transmission within 0.05 mm (0.002") TIR. If necessary, remove or add shims to adjust the vertical position of the motor. Loosen nuts and adjust the capscrews to align the horizontal position of the motor. Tighten the nuts after adjustment. Confirm that the coupling is aligned within 0.05mm (.002") TIR.
5. Install the coupling mounting hardware.
6. Be sure all mounting hardware and electrical connections are tight.
14.2.2 Pulldown Motor Blower R37819D2
14.2.2.1 Removal and Disassembly
The machinery carriage should be positioned at deck level to permit convenient access and resting on the drill bit, or otherwise supported, to prevent falling. The blower can be serviced in place unless complete replacement is required. Proceed as follows:
BD120149 Mechanical Systems Manual Hoist/Pulldown Machinery
WARNING!
Inadvertent machine movement can cause serious injury, or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
WARNING!
Hazardous voltage can cause burns, injury, or death. Disconnect, lock out, and tag thepower source that feeds this device to prevent power from being applied while inspec-tion and repairs are being performed. Before beginning repairs, try the operational con-trols to verify that the intended power source is disconnected.
1. Disconnect, lock out, and tag the power source that feeds the system to prevent power from being applied while service is being performed.
2. Refer to Figure 14-12. Tag and disconnect wiring to the blower motor).
3. Remove locknuts (04), lock screws (05), and shield (06).
4. If necessary, remove lock screws (02) to remove blower (03), gaskets (07 and 09), and base (08).
5. Refer to Figure 14-14. Remove wheel (02) and motor (03).
14.2.2.2 Cleaning, Inspection and Repair
Clean and inspect parts as described in Appendix A of this manual. Repair consists of the replacement of worn or damaged parts. Observe all safety precautions.
14.2.2.3 Assembly and Installation
Assemble the motor blower components in the reverse order of disassembly. Note the following:
1. Be sure that wheel (02, Figure 14-14) is locked and properly positioned on the shaft of motor (03). The wheel should not contact the housing.
2. Be sure all mounting hardware and electrical connections are tight.
BD120149 Mechanical Systems Manual Hoist/Pulldown Machinery
The pulldown gearcase assembly is a triple-reduction-type unit. The input pinion is direct-coupled to the pulldown DC drive motor. Power is transmitted from the input pinion to the gear on the quill pinion-gear set, which rotates on its own bearings on the shipper shaft. The quill pinion drives the low-speed gear that is splined to the low-speed pinion. The low-speed pinion drives the main gear that is keyed to the shipper shaft. The pulldown brake is mounted to the low-speed pinion. The pulldown gearcase can be serviced in place providing suitable lifting and handling equipment is available to remove heavy components.
14.2.3.1 Removal
The rotary machinery carriage should be positioned at deck level to permit convenient access to the pulldown gear-case and resting, or supported on the deck. Refer to Figure 14-15 and proceed as follows:
WARNING!
Inadvertent machine movement can cause serious injury, or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.Dropping or mishandling of heavy drill parts can cause severe injury or death.Always move heavy components using the auxiliary winch, or suitable lifting device, andslings for removal and installation. Provide support for components which may releaseor move any during maintenance.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance work.
2. Disconnect coupling (34). Refer to Subtopic 14.2.1.
3. Remove the pulldown brake if desired. Refer to Subtopic 14.2.7.
Figure 14-16: Legend for Figure 14-15
LEGEND01. Gearcase02. Cover03. Hex Hd Capscrew04. Dowel05. Locknut06. Base07. O-ring08. Cover Gasket09. Inspection Cover10. Breather Filter11. Lockwire12. Drilled Head Cap-
BD120149 Mechanical Systems Manual Hoist/Pulldown Machinery
5. Refer to Figure 14-17 and remove the spreader (03) from the mast to allow access to the pulldown machinery.
6. Remove bearing housings (01 and 31) from the mast.
7. Refer to Figure 14-15. Remove locknuts (23), capscrews (40), and conical washers (22) from the pulldown gearcase base.
8. Remove pulldown gearcase assembly (01).
14.2.3.2 Disassembly
The machinery carriage should be resting or supported on the deck to permit convenient access to the pulldown gearcase. Disassembly can be accomplished with the gearcase on the drill.
WARNING!
Inadvertent machine movement can cause serious injury, or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
Hoist/Pulldown Machinery BD120149 Mechanical Systems Manual
WARNING!
Dropping or mishandling of heavy drill parts can cause severe injury, or death. Alwaysmove heavy components using the auxiliary winch, or suitable lifting device, and slingsfor removal and installation. Provide support for components which may release ormove any during maintenance.
Follow general maintenance instructions provided in Appendix A. Refer to Figure 14-15 and proceed as follows:
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance work.
2. Remove the pulldown brake. Refer to Subtopic 14.2.7.
3. Drain the gearcase.
4. Remove lockwire (41) and capscrews (42). Pull seal housing (39) and shims (36, 37, and 38).
5. Remove capscrews (03) and locknuts (04). Remove cover (02) and gasket (07).
6. Lift the entire shipper shaft (with gears, spacers, and bearings) from gearcase base (06). Remove this unit to an appropriate area for repair. Support the shaft and components on suitable blocking to permit disassembly. Remove parts as required. Pinion (22) and gear (18) are keyed and held together with snap ring (17).
7. Remove lockwire (28) and capscrews (27). Remove end cover (60) and shims (57, 58, and 59).
8. Remove lockwire (12) and capscrews (52). Remove seal housing (51): O-ring (50), and seals (49 and 48).
9. Support gear (43). Push pinion (55), with bearing (56 and 47), from the base. Remove bearings and spacer (54).
10. Remove pinion (55) from gear (43).
11. Remove the coupling halve from input pinion (32).
12. Remove lockwire (28) and capscrews (27). Remove the input pinion seal housing (29), O-ring (30), bearings (31 and 33) with ring (24), and seals (25 and 26).
13. Remove lockwire (12) and capscrews (23). Remove ring (24) and seals (25 and 26).
14. Remove seal housing (29), O-ring (30), and bearings (31 and 33).
14.2.3.3 Cleaning, Inspection and Repair
Clean and inspect parts as described in Appendix A of this manual. Repair consists of the replacement of worn or damaged parts. Observe all safety precautions.
14.2.3.4 Assembly
Assemble parts in the reverse order of disassembly. Refer to Figure 14-15 and note the following:
1. Shim low-speed pinion (55) for 0.13 to 0.25 mm (0.005" to 0.010") axial endplay, using shims (57,58, and 59).
BD120149 Mechanical Systems Manual Hoist/Pulldown Machinery
2. Shim shipper shaft (15) for 0.025 to 0.075 mm (0.001" to 0.003") axial preload using shims (36, 37, and 38).
3. When installing seals in housing (29), the lip (spring side) on inner seal (25) must face inward and the lip on outer seal (26) must face outward. Fill the cavity between the seals with grease.
14.2.3.5 lnstallation
Install components in the reverse order of removal. Refer to Figure 14-12 and note the following:
1. Align coupling (34) as described under PULLDOWN MOTOR on page 12-6.
2. Be sure breather/filter (10: Figure 12-10) and stopcock (39, Figure 12-51 are installed properly,
3. Fill the pulldown gearcase with oil.
14.2.4 Pulldown Pinions R5544D1
The pulldown drive pinions are mounted to the ends of the shipper shaft, which is driven by the pulldown motor and gearcase. The idler pulldown pinions are mounted on shafts on the rotary gearcase. Grease to lubricate the pull-down and idler pinion bearings and the gear racks is provided by the automatic lubrication system.
14.2.4.1 Pinion Maintenance
The machinery carriage should be positioned at deck level to permit convenient access to the pulldown pinions, and resting on the drill bit or otherwise supported to prevent falling.
WARNING!
Inadvertent machine movement can cause serious injury, or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
Refer to Figure 14-17 and proceed as follows:
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance work.
Hoist/Pulldown Machinery BD120149 Mechanical Systems Manual
14.2.5 Idler Pinions R7560D3
The idler pinions should be repaired or replaced if the splines are worn excessively, or if rotation is not true. The mast should be lowered to its horizontal position to repair or replace the drive pinions. Refer to Figure 14-17 and proceed as follow:
WARNING!
Inadvertent operation of the drill during service, inspection, or maintenance on themachine can cause severe bodily injury, or death. Use lockout and tagout procedures toprevent accidental operation of the drill.
1. Lock out and tag the drill operator controls to prevent inadvertent start-up during maintenance procedures.
2. Remove snap ring (40) and bearing retainer (41) from one idler pinion (44).
3. Remove second snap ring (42) from idler pinion shaft (47), and remove pinion (44) from the shaft. Remove a third snap ring (40), spacer (46), and bearing (43) from pinion (44).
4. Remove capscrews (08), and lockwashers (10) from the rotary gearcase. Remove idler shaft retainer (55) and shims (12, 13 and 14). Record the number of shims used.
5. Withdraw idler shaft (47) from the gearcase.
6. Repeat steps 2 through 5 for the other idler pinion.
7. Clean, inspect and repair parts as described in Appendix A.
8. Assemble and install parts in the reverse order of removal. Use shims (12, 13 and 14), as needed, so that the shoulder on idler shaft (47) is tight against the gearcase.
9. Before operating the hoist/pulldown system, initiate a manual lubrication cycle to be sure that the pinions are adequately greased.
14.2.6 Guide Rollers
14.2.6.1 Roller Adjustment
WARNING!
Rotary Carriage Rollers must be maintained within specified parameters at all times. Fail-ure to keep rollers properly adjusted could cause the drive and idler pinions to disen-
BD120149 Mechanical Systems Manual Hoist/Pulldown Machinery
WARNING!
Inadvertent machine movement can cause serious injury, or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance work.
2. Refer to Figure 14-20 and remove the Guide Roller Assemblies from the rotary carriage as follows:
A. Remove capscrews (01) and lockwashers (02) from the rotary gearcase.
B. Remove guide roller pin retainer (06) and shims (03, 04, 05). Record the number of shims used.
C. Withdraw roller pin (07) with roller assembly (08) from the gearcase.
D. Remove spacer (09) and bushing (10).
E. Repeat steps A through D for the other guide rollers.
BD120149 Mechanical Systems Manual Hoist/Pulldown Machinery
1. Remove nuts (07) and capscrews (06) from roller pins (04). Remove roller pins (04), rollers (03) and thrust washers (05).
2. Remove capscrews (06), washers (11) and bumper (10).
3. Remove capscrews (08) and eccentric bushings (02).
Cleaning, Inspection and Repair
Clean and inspect parts as described in Appendix A. Repair consists of the replacement of worn or damaged parts. Observe all safety precautions.
Assembly
Assemble the rollers in the reverse order of disassembly. Refer to Figure 14-21.
1. Position eccentric bushing (13) so that the eccentric is closest to rollers (03).
2. Install one capscrew (08) and locknut (09) to attach the eccentric bushing until the guide rollers are installed.
Installation
Refer to Figure 14-20 and proceed as follows:
1. Lubricate the guide rollers at installation.
2. Insert idler pin (07) through roller assembly (08), spacer (09) and bushing (10).
3. Mount roller assembly and pin to the mounting thrust washer on the gear case or the bearing housing (refer to Figure 14-17)
4. Re-install shims (03, 04, 05) that were removed during the removal operation and assemble and install retainer (06) using cap screws (01) and washers (02).
14.2.6.4 Lower Guide Roller Assembly R54362F3
The lower carriage roller assemblies are mounted on bearing housings and the rotary gearcase. The clearance between the rollers and mast legs can be adjusted to maintain proper pinion contact with the pulldown racks.
14.2.6.5 Removal
The mast should be positioned in the down or lowered position so the weight of the carriage is resting on the pin-ions. Refer to Figure 14-17 and proceed as follows:
WARNING!
Inadvertent machine movement can cause serious injury, or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance work.
Hoist/Pulldown Machinery BD120149 Mechanical Systems Manual
2. Remove capscrews (08) and lockwashers (10) from the rotary gearcase. Remove guide roller pin retainer (54) and shims (12, 13 and 14). Record the number of shims used.
3. Withdraw roller pin (17) with roller assembly (38) from the gearcase. Remove spacer (16) and bushing (15).
4. Repeat preceding steps 2 through 3 for the other guide rollers.
Hoist/Pulldown Machinery BD120149 Mechanical Systems Manual
2. Remove capscrews (06), washers (11) and bumper (10).
3. Remove capscrews (08) and eccentric bushings (02).
Cleaning, Inspection and Repair
Clean and inspect parts as described in Appendix A. Repair consists of the replacement of worn or damaged parts. Observe all safety precautions.
Assembly
Assemble the rollers in the reverse order of disassembly. Refer to Figure 14-21.
1. Position eccentric bushing (13) so that the eccentric is closest to rollers (03).
2. Install one capscrew (08) and locknut (09) to attach the eccentric bushing until the guide rollers are installed.
Installation
Refer to Figure 14-17 and proceed as follows:
1. Lubricate the guide rollers at installation.
2. Insert idler pin (14) through each guide roller (07) and thrust washer (13), and mount on gearcase (47) or hous-ing (01 or 22).
3. Assemble and install keeper plate (11) with mounting hardware in the reverse order of removal. Use shims (12) as needed so that there is minimum clearance between the guide roller and thrust washer.
Hoist/Pulldown Machinery BD120149 Mechanical Systems Manual
14.2.7.1 Inspection
The machinery carriage should be positioned at deck level to permit convenient access to the pulldown brake and resting on the drill bit, or otherwise supported, to prevent falling. Proceed as follows:
1. Inspect the brake and lines for hydraulic leaks and disc contamination.
2. Listen for unusual noise or clatter when the brake is turning (released). This may indicate brake unbalance or excessive wear.
3. Check for heat buildup after the brake has been free-running for a period of time. Excessive heat could indicate insufficient clearance.
4. Visually inspect the area near the brake for friction pad particles, which would indicate a problem.
BD120149 Mechanical Systems Manual Hoist/Pulldown Machinery
14.2.7.2 Checking Lining Wear
Lining wear is checked by measuring piston movement. Refer to Figure 14-24 and proceed as follows:
WARNING!
Inadvertent machine movement or operation can cause serious injury, or death. Whennecessary to operate the blasthole drill while making an adjustment or performing acheck, obtain the assistance of a second person who is thoroughly familiar with themachine. Have the assistant at the control panel to be sure that nothing is actuated thatmay be hazardous to you or the machine.
1. Lower the carriage to provide convenient access to the pulldown brake. The carriage must be resting on the drill bit, or other suitable support.
Figure 14-24: Pulldown Brake Wear Check
01
A
B
C
02
0304
LEGEND01. Piston02. Drive Plate
03. Stud Nut04. Shims
A: Brake Set PositionB: Brake Released PositionC: Piston Stroke
Hoist/Pulldown Machinery BD120149 Mechanical Systems Manual
2. With the brake set, measure and record how far the piston protrudes from the drive plate (Dimension A).
3. With the brake released, measure and record how far the piston protrudes from the drive plate (Dimension B).
4. The difference between Dimension A and Dimension B is the piston stroke. If the piston stroke exceeds 6.6 mm (0.260"), proceed as follows:
A. Release the brake.
B. Back off the stud nuts evenly and in steps until sufficient gap exists between the drive plate and the housing to slide the drive plate back approximately 1.6 mm (1/16").
C. Spread a shim at the split line and remove it by slipping the shim over the drive plate.
D. Tighten the stud nuts to93.5 to 108 Nm (70 to 80 ft-lbs).
E. Engage the brake. Check for approximate 4 mm (0.16") stroke.
CAUTIONBefore removing the second and third shims, remove the brake discs and inspect forequal wear on the lining surfaces. If wear is unequal, interchange the positions of thebrake discs within the brake as an attempt to equalize wear. When all shims have beenremoved and piston travel approaches 6.6 mm (.260"), the brake must be replaced.
SAFETY FIRST
Only qualified technicians should rebuild these brakes. P&H Mining Equipment recommendsthat brakes be returned to the nearest P&H MinePro Services facility for rebuild.
Hoist/Pulldown Machinery BD120149 Mechanical Systems Manual
The rotary machinery carriage should be positioned at deck level to permit convenient access to the brake and resting on the drill bit, or otherwise supported, to prevent falling. Disassemble to the extent necessary to make repairs.
WARNING!
Inadvertent machine movement can cause serious injury, or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
CAUTION!
High-pressure oil could cause the free lines to “whip” or spray hot oil, causing injury. Besure the hydraulic system is not pressurized before loosening or removing connections.
WARNING!
Dropping or mishandling of heavy drill parts may cause personal injury, or death. Alwaysmove heavy components using the auxiliary winch, or other suitable lifting device, andslings for removal and installation. Provide support for components that may release ormove during any maintenance.
1. Disconnect, lock out, and tag the power source that feeds the system to prevent power from being applied while service is being performed.
2. Remove the setscrew and disconnect the flexible shaft from the end of the resolver shaft. Refer to Figure 14-23.
3. Refer to Figure 14-25. Remove cover screws (11), lockwashers (12), and cover (13).
4. Refer to Figure 14-23 Remove the shaft plate screws and resolver shaft.
5. Refer to Figure 14-25. Remove capscrews (14) from piston (16).
NOTICE
Do not remove stud nuts (01) while capscrews (14) are out. This will release brake spring pres-sure and make assembly more difficult.
6. Pull piston (16) from drive plate (07). Two threaded bores in the piston facilitate piston removal.
7. Remove O-ring (17) and seal (21 and 22) from the piston. Remove O-rings and seals carefully to avoid scratching or marring sealing surfaces, which could cause leakage and brake malfunction.
8. Remove ring (20) and O-rings (18 and 19).
9. Back off hex nuts (01) incrementally and uniformly to release spring pressure. Remove nuts and withdraw drive plate (07) and remove shims (08).
BD120149 Mechanical Systems Manual Hoist/Pulldown Machinery
10. Remove pressure plate (09), discs (06), center plate (10) and wear ring (05) from housing (04).
WARNING!
Dropping or mishandling of heavy drill parts can cause personal injury, or death. Alwaysmove heavy components using the auxiliary winch, or other suitable lifting device, andslings for removal and installation. Provide support for components that may release ormove during any maintenance.
To remove the entire assembled brake, remove nuts (01), support the brake with a suitable lifting device, and pull the unit from the pulldown gearcase. Remove lock pins (02).
14.2.7.4 Cleaning, Inspection and Repair
Clean and inspect parts as described in Appendix A of this manual. In particular, inspect brake discs for damaged linings. Inspect plates for gouging of brake surfaces. Repair consists of the replacement of worn or damaged parts. Observe all safety precautions.
14.2.7.5 Assembly
Assemble the brake in the reverse order of disassembly. Note the following:
1. Clean the brake hub splines and brake disc splines. Apply a light coating of hydraulic oil to the splines. Refer to Figure 14-23.
2. Refer to Figure 14-25. Install the same number of shims (08) as removed. If new brake discs (06) have been installed, use three shims.
3. When installing drive plate (07), tighten hex nuts (01) uniformly and in a pattern to compress the brake springs (15). Torque the stud nuts to 93.5 - 108 Nm (70 - 80 ft-lbs). Apply Loctite, or equivalent sealing agent, to the stud nuts.
CAUTIONDo not permit outer O-rings or seals to become pinched when installing the ring and pis-ton. If damaged, the O-rings or seals will not seal properly, causing leakage and malfunc-tion.
4. Before installation, lubricate new O-rings and seals with a light coating of clean hydraulic oil.
Hoist/Pulldown Machinery BD120149 Mechanical Systems Manual
14.2.8 Pulldown Resolver 75Z1252D6
14.2.8.1 Removal
The machinery carriage should be positioned so it is resting on the deck. Refer to Figure 14-26 and proceed as fol-lows:
WARNING!
Inadvertent machine movement can cause serious injury, or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out and
Figure 14-26: Pulldown Resolver
LEGEND01. Resolver Assembly02. Hex Head Capscrew03. Tapped Plate04. Rubber Shim05. Resolver Bracket06. Socket Head Set Screw07. Hub (welded in place)08. Drilled Head Capscrew09. Tie Wire10. Resolver Clamp
BD120149 Mechanical Systems Manual Hoist/Pulldown Machinery
tag the operator controls to prevent inadvertent machine start-up during maintenancework.
Proceed as follows:
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance work.
2. Remove the hex socket capscrews in coupling (14).
3. Loosen nuts (12), and remove resolver (13).
4. Remove coupling (14) and shaft (15).
5. If cable (16) needs to be replaced, proceed as follows:
A. Remove the setscrew in the bushing on the flexible shaft cable at the resolver end.
B. Refer to Figure 12-9. Remove the setscrew and disconnect the flexible shaft cable from the brake end.
C. Remove setscrew (06) and withdraw cable (16).
D. Remove the cable from bushing (17) and conduit (18).
E. Remove bushing (17) and conduit (18) if replacement is required.
6. Remove bracket clamp (lo), bracket (05), plate (03), and shim (04) if necessary.
7. Remove related connecting parts for the cable that are on the pulldown brake as required. Refer to PULL-DOWN BRAKE on page 12-1.
14.2.9 Cleaning, Inspection and Repair
Clean and inspect parts as described in Appendix A of this manual. Repair consists of the replacement of worn or damaged parts. Observe all safety precautions.
1. Examine the coupling for stretching, bending, and twisting distortion. Replace damaged coupling.
2. Check for continuity across the resolver stator windings S1- S3 (terminals 2 and 5) and S2-S4 (terminals 4 and 6) and rotor winding R1-R2 (terminals 1 and 2) with an ohmmeter. Replace the resolver if there is an open or dead short across any winding.
14.2.10 Assembly and Installation
Assemble and install parts in the reverse order of removal. Refer to Figure 14-26 and note the following:
1. After installing shaft (15) in cable (16), and tightening the cable setscrew, install coupling (14) on shaft (15).
2. Position resolver (13) in clamp (10) so the resolver keyway is in line with the case connector. Slide the resolver into the coupling so there is approximately ¼" (6.4 mm) between the resolver and coupling. Tighten the cou-pling capscrews to10.8 to 13.6 Nm (8 to 10 ft-lbs)
3. Inspect the coupling to be sure it is not distorted. Apply Loctite, or equivalent sealant, to the coupling cap-screws.
BD120149 Mechanical Systems Manual Hoist/Pulldown Machinery
14.3 TroubleshootingProblem Probable Cause Remedy
Erratic Hoist/Pulldown Operation Electrical malfunction Investigate control and power cir-cuits for cause of incorrect opera-tion.
Insufficient Hoist/Pulldown Power Pulldown brake not fully released Check operation of brake.
Mechanical failure of gearcase Inspect the pulldown gearcase for interference, damaged components or other malfunction.
Incorrect voltage to drive motor Investigate control and power cir-cuits for cause of incorrect voltage.
Faulty drive motor If motor control and power circuits are functioning properly, inspect motor for evidence of overheating or other damage.
No Hoist/Pulldown Power No voltage to drive motor Check for tripped circuit breaker in power or control circuits. Investi-gate cause of power interruption.
Motor blower inoperative Check blower operation. Failure could cause motor overheating and shutdown.
Faulty drive motor If motor does not run, inspect rotary motor for signs of overheating and burnout.
Broken drive coupling Check condition on coupling.
Failure of pulldown gearcase Check gearcase oil level and inspect magnetic plug for evidence of inter-nal failure.
Hoist/Pulldown Operation Stalls Pulldown brake does not release Inspect hydraulic lines and connec-tions to brake.
Check hydraulic system.
Pinions jammed or damaged Clean any debris or other material from racks.
Inspect pinions for damage.
Electrical malfunction Investigate control and power cir-cuits for cause of lack of power and repair any deficiencies.
Pulldown Brake does not hold Worn linings Remove shim
Replace brake discs
Damaged or broken springs Replace springs
Pulldown Brake does not release No hydraulic pressure to brake Inspect hydraulic lines for loose connections (leaks) and breaks.
Pipe Handling Equipment BD120149 Mechanical Systems Manual
14.1.1 Pipe Racks
The pipe rack forms a long vertical cradle to handle a single length of drill pipe. Refer to Figure 14-1. The pipe rack is connected to inside mast members at the top and bottom by swing arms that allow the rack to be lowered from the retracted (stored) position to the drill centerline and vice versa. Movement of the pipe rack is accomplished by extension or retraction of a hydraulic cylinder that is attached between the mast and lower arm. The pipe section is held in the pipe rack by a pipe holder at the bottom and by a swing gate at the top. Two spring-loaded pipe wrenches or pawls in the pipe holder grab the outside surface of the pipe to hold the pipe during disconnection from the rotary head before returning the pipe to its stored position. The upper swing gate is opened or closed by a hydraulic cylinder. Operation of the racks is controlled by the operator through the PLC. Limit switches signal the PLC to indicate operational conditions of the pipe rack; that is, the pipe is in the pipe holder, the rack is retracted, and the gate is closed. The deck wrench units each consist of a housing, a sliding body with spring-loaded pawl, and a hydraulic cylinder that provides clamping power.
14.1.1.1 Left Pipe Rack 100J6766F6
The left pipe rack is a parallelogram-style pipe rack that is 11.3 meters (37 feet) in length. The rack is hydraulically controlled to move inward or outward. A mechanical mechanism is used to lock the drill pipe into place while stored. A hydraulic holdback system prevents the pipe rack from drifting into the drill string area when the drill is operating.
14.1.1.2 Right Pipe Rack R4081F1
The right pipe rack is a parallelogram-style pipe rack that is 8.4 meters (27.5 feet) in length. The rack is hydrauli-cally controlled to move inward or outward. A mechanical mechanism is used to lock the drill pipe into place while stored. A hydraulic holdback system prevents the pipe rack from drifting into the drill string area when the drill is operating.
14.1.2 Deck Wrench GH5007463
The deck wrench allows the operator to hold the pipe string while tools or pipe sections are being connected or dis-connected. It consists of a pair of hydraulically actuated rams mounted on the drilling platform. Each ram is located on opposite sides of the drill hole, just off of centerline.
BD120149 Mechanical Systems Manual Pipe Handling Equipment
14.1.3 Breakout Wrench R46448F1
The breakout wrench is used to loosen a pipe joint that is tighter than the joint at the rotary coupling. Refer to Fig-ure 14-3.
The breakout wrench is permanently mounted to the mast structure, and is operated by a set of hydraulically actu-ated cylinders. These cylinders operate in conjunction with each other to make the breakout wrench operation smooth and simple.
The breakout wrench is stored in the retracted position. The breakout wrench is fitted with inserts for gripping the drill pipe sections. These inserts are interchangeable, based on the drill pipe diameter being handled.
14.2 Pipe Handling Equipment Maintenance
NOTICE
Apply standard torque to fasteners unless otherwise specified. Refer to Appendix A for generalmechanical maintenance procedures, and to Appendix B for general hydraulic componentmaintenance procedures. It is advisable to replace all seals and O-rings whenever hydraulic
BD120149 Mechanical Systems Manual Pipe Handling Equipment
14.2.1 Pipe Racks
The two pipe racks are identical except for their length. The left-hand pipe rack (100J6766F6) is 11.3 meters (37 ft) long, while the right-hand pipe rack (R4081F1) is 8.4 meters (27.5 ft) in length.
BD120149 Mechanical Systems Manual Pipe Handling Equipment
14.2.1.1 Pipe Wrenches and Liners
Adjustment
Check engagement of the wrenches with pipe to be sure that the wrenches grab when pipe is being disconnected. If not, loosen the locknut and adjust the setscrew at the front of the pot to obtain correct holding action. The set-screw bears against the wrenches to set the closed position of the wrenches. Tighten locknut after adjustment. The pipe wrenches are installed in the pipe holder. The liners are installed in the pipe holder and pipe gate. Refer to the LinkOne electronic part manual for parts information.
Figure 14-6: Pipe Wrenches and Liners
02 03 02 04
05
06
01
07
08
01
BD0546a01
07
LEGEND01. Wrench02. Wrench Pin03. Setscrew and Nut04. Wrench Seat
Pipe Handling Equipment BD120149 Mechanical Systems Manual
14.2.1.2 Pipe Rack Gate
Removal
Refer to Figure 14-4 and proceed as follows:
WARNING!
The rotating drill or its associated moving components can entrap and crush people,resulting in severe injury, or death. Do not enter the drill string and mast area while thedrill is operating. Shut down the machine before performing inspections, service, ormaintenance. Establish a procedure to guard against inadvertent equipment operationor movement while conducting inspections. Use lockout and tagout procedures prior toconducting maintenance or service.
1. Disconnect, lock out and tag the power source that feeds the system to prevent power from being applied while service is being performed.
WARNING!
Falls from elevated mast can cause severe injury or death. Always use fall protectiondevices, such as the Saf-T-Climb system, when climbing the mast ladder. Do not attemptto perform maintenance or service from the ladder with the mast elevated. Lower themast or use appropriate work platforms to perform maintenance or service to the mastor mast components.
BD120149 Mechanical Systems Manual Pipe Handling Equipment
WARNING!
Dropping or mishandling of heavy drill parts may cause severe personal injury, or death.Always move heavy components using the auxiliary winch or other suitable lifting deviceand rigging for removal and installation. Provide support for components which mayrelease or move during any maintenance.
Removal And Disassembly
The pipe rack should be in the drilling position to perform repairs which allows better access to components. It also eliminates the possibility of the rack dropping from the stored position. Remove components selectively for repair or replacement. Refer to Figure 13-6 and proceed as follows:
WARNING!
The rotating drill or its associated moving components can entrap and crush peopleresulting in severe injury or death. Do not enter the drill string and mast area while thedrill is operating. Shut down the machine before performing inspections, service, ormaintenance. Establish a procedure to guard against inadvertent equipment operationor movement while conducting inspections. Use lockout and tagout procedures prior toconducting maintenance or service.
1. Disconnect, lock out, and tag the power source that feeds the system to prevent power from being applied while service is being performed.
2. Refer to Subtopic 14.2.1.8, for service instructions for cylinder (29).
3. Remove cotter pins (20) and sleeve pins (21). Withdraw gate arm (01) and remove gate support (02) and assembled sleeve (19).
4. Remove pivot pin (24) to detach assembled sleeve (19) with link (18) and bar (22).
5. Tie or otherwise support the upper end of the rack.
6. Remove capscrews (15) and lockwashers (16) to detach upper rack pin (17).
7. Loosen locknuts (14) and capscrews (07), remove retaining rings (06), and push out upper pin (05). Remove upper arm (04).
14.2.1.3 Cleaning, Inspection and Repair
Clean and inspect components in accordance with the general cleaning and inspection procedures in Appendix A of this manual. Repair consists of the replacement of all worn or damaged components. Refer to the LinkOne elec-tronic parts manual for component identification.
14.2.1.4 Assembly and Installation
Install the components in the reverse order of removal. Refer to Figure 13-6. Note the following instructions.
1. Refer to Subtopic 14.2.1.8, for service instructions for the gate cylinder (29).
Pipe Handling Equipment BD120149 Mechanical Systems Manual
2. After installation, check gate operation. Gate arm (01) should fully close and limit switch (26) should trip with the cylinder extended. Adjust the clevis on the cylinder rod to achieve these conditions.
3. If a new gate link and sleeve assembly are to be installed, the clearance between the gate arm bearing and the sleeve should be 0.060" (1.5 mm). Refer to Figure 14-7. This dimension is set at assembly of the parts when the sleeve assembly and gate arm are installed and clamped to dimension. Then the sleeve and arm can be drilled to allow insertion of the roll pin. Hole size is ½" (12.7 mm).
4. Start the drill and operate to verify operation of the gates and latches.
14.2.1.5 Pipe Holder and Swing Arm
WARNING!
Dropping or mishandling of heavy drill parts may cause severe personal injury, or death.Always move heavy components using the auxiliary winch or other suitable lifting deviceand rigging for removal and installation. Provide support for components which mayrelease or move during any maintenance.
Removal and Disassembly
The pipe rack should be in the drilling position to perform repairs which allows better access to components. It also eliminates the possibility of the rack dropping from the stored position. The location and arrangement of the pipe holder (pot), lower swing arm and related parts are shown on Figure 14-4. Remove components selectively for repair or replacement. Refer to Figure 14-4 and proceed as follows:
WARNING!
The rotating drill or its associated moving components can entrap and crush peopleresulting in severe injury or death. Do not enter the drill string and mast area while thedrill is operating. Shut down the machine before performing inspections, service, ormaintenance. Establish a procedure to guard against inadvertent equipment operationor movement while conducting inspections. Use lockout and tagout procedures prior toconducting maintenance or service.
1. Disconnect, lock open, and tag the power source which feeds the system to prevent power from being applied while service is being performed.
CAUTION!
High-pressure hydraulic or air systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits beforeloosening fittings or connections. Wear appropriate face, ear, and body protectivedevices while venting air or hydraulic systems.
2. Remove the wrenches. Refer to Subtopic 14.2.1.1.
3. Remove the limit switch. Refer to Subtopic 14.2.2.
BD120149 Mechanical Systems Manual Pipe Handling Equipment
4. Tie or otherwise hold the bottom of the rack in position
5. Remove capscrews (15) and lockwashers (16) to detach pins (36 and 42).
6. Loosen hex nuts (45) and capscrews (40), remove retaining rings (43), and push out pin (42). Remove arm (46).
7. Refer to Subtopic 14.2.1.6, for service instructions for the cylinder (35).
Cleaning, Inspection and Repair
Clean and inspect components in accordance with the general cleaning and inspection procedures described in Appendix A of this manual. Repair consists of the replacement of all worn or damaged components. Refer to the LinkOne electronic parts manual for component identification.
Assembly and Installation
Refer to Figure 14-4 and install the components in the reverse order of removal. Note the following instructions:
1. Refer to Subtopic 14.2.1.6, for service instructions for cylinder (35).
2. Confirm that all grease fittings (23) are installed.
3. Confirm that the mounting and air and hydraulic connections are secure.
4. Start the drill and check operation of the racks and confirm that all functions work properly.
Pipe Handling Equipment BD120149 Mechanical Systems Manual
14.2.1.6 Pipe Rack Swing Cylinder
The pipe rack swing cylinder is a double-acting hydraulic cylinder with “rod eye and clevis type” mounting provi-sions.
Removal
The pipe rack should be in the drilling position to perform repairs which allows better access to components. It also eliminates the possibility of the rack dropping from the stored position. Refer to Figure 14-4 and proceed as follows:
WARNING!
Inadvertent operation of the blasthole drill during maintenance on the machine couldcause severe bodily injury and/or death. Lock out and tag the drill operating controls toprevent accidental operation.
1. Lock out and tag the drill operator controls to prevent inadvertent startup during maintenance procedures.
Figure 14-8: Pipe Rack Swing Cylinder
LEGEND01. Seal Kit02. O-ring03. Back-Up Ring04. Wear Ring05. Rod Seal
06. Rod Seal07. Rod Wiper08. Back-Up Ring09. O-ring10. Piston Seal11. Wear Ring
BD120149 Mechanical Systems Manual Pipe Handling Equipment
CAUTION!
High-pressure hydraulic systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits beforeloosening fittings or connections. Wear appropriate face, ear, and body protectivedevices while venting air or hydraulic systems.
2. Tag and disconnect the hydraulic hoses from swing cylinder (35). Cap or plug hydraulic fittings to prevent con-tamination of the hydraulic system.
3. Support swing cylinder (35). Remove capscrews (15) and lockwashers (16) and withdraw pins (36). Remove the cylinder.
Disassembly
Refer to Figure 14-8 and proceed as follows:
1. Loosen and back out the cylinder head with a spanner wrench.
2. Remove the cylinder rod with head assembly and piston assembly from cylinder body.
3. Remove the piston and cylinder head assembly from the cylinder rod.
4. Remove and discard O-rings (02) and back-up ring (03) from the head.
5. Remove and discard wear rings (04), and seals (05 and 06) and wiper (07) from inside of the head.
6. Remove and discard wear ring (11), seal (10), O-ring (09), and back-up rings (08) from the piston.
Cleaning, Inspection and Repair
Clean and inspect the hydraulic cylinder components in accordance with the general cleaning and inspection pro-cedures in Appendix B of this manual. None of the components are repairable, and must be replaced if worn or damaged. It is advisable to replace all parts in the seal kit whenever the unit is disassembled. Refer to the LinkOne electronic parts manual for component identification.
Assembly
Lubricate all seals, O-rings, back-up rings and rod wiper with hydraulic oil prior to installation. Refer to Figure 14-8 and proceed as follows:
1. Install new wear O-rings (02) and back-up ring (03) on the head.
2. Install new wear rings (04), seals (05 and 06) and wiper (07) inside of the head.
3. Install new wear ring (11) and seal (10) on the piston.
4. Install new O-ring (09), and back-up rings (08) in the piston.
5. Install the assembled piston and cylinder head on the cylinder rod.
6. Install the cylinder rod with head assembly and piston assembly into the cylinder body.
Pipe Handling Equipment BD120149 Mechanical Systems Manual
7. Install the cylinder head with a spanner wrench.
14.2.1.7 Installation
Refer to Figure 13-6 and proceed as follows:
1. Support swing cylinder (35) in position on the pipe rack and clevis.
2. Insert cylinder pin (36) into rack clevis and the head end of cylinder (35). Install capscrew (15) and lockwasher (16) to secure the pivot pin.
3. Insert a second pivot pin (36) on the rod end of cylinder (35) as described in preceding step 2.
4. Connect the tagged hydraulic hoses to cylinder.
5. Start up the drill hydraulic system and bleed the hydraulic system at the cylinder.
6. Start the drill and confirm operation of the rack lower and retract action.
14.2.1.8 Pipe Rack Gate Cylinder
The pipe rack should be in the drilling position to perform repairs which allows better access to components. It also eliminates the possibility of the rack dropping from the stored position. Refer to Figure 14-4 and proceed as follows:
1. If necessary, lower the affected pipe rack to the drilling position.
WARNING!
Inadvertent operation of the blasthole drill during maintenance on the machine couldcause severe bodily injury and/or death. lock out and tag the drill operating controls toprevent accidental operation.
2. Lock out and tag the drill operator controls to prevent inadvertent startup during maintenance procedures.
CAUTION!
High-pressure hydraulic systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits beforeloosening fittings or connections. Wear appropriate face, ear, and body protectivedevices while venting air or hydraulic systems.
3. Tag and disconnect the hydraulic hoses from gate hydraulic cylinder.
4. Plug and/or cap all hose assemblies and hydraulic fittings to prevent contamination of the hydraulic system.
5. Support cylinder (29). Remove the pivot pin from the cylinder clevis and the head end of cylinder. Remove the attaching capscrews to detach the cylinder. Unscrew the clevis.
BD120149 Mechanical Systems Manual Pipe Handling Equipment
14.2.1.9 Cleaning, Inspection and Repair
Clean and inspect the hydraulic cylinders in accordance with the general cleaning and inspection procedures in Appendix B of this manual. Replace faulty cylinders.
14.2.1.10 Installation
The location and method of attachment is shown on Figure 13- 6. Assemble the cylinder and related hardware in the reverse order of removal.
1. Support gate cylinder (29) in position on the pipe rack
2. Connect the tagged hydraulic hoses to the cylinder.
3. Start up the drill hydraulic system and bleed the hydraulic system at the cylinder.
4. Start the drill and check the operation of the rack gate and/or latch.
14.2.2 Limit Switches
There are three limit switches mounted on each pipe rack. If a fault or malfunction occurs that is related to the limit switch functions, isolate the cause and locate the switch. Refer to Figures 14-4, and 13-10.
Figure 14-9: Pipe Holder Limit Switch
LEGEND01. Socket Head Capscrew02. Lock Washer03. Limit Switch04. Mounting Base
05. Spring06. Plunger07. Roll Pin08. Trip Bar09. Roll Pin
Pipe Handling Equipment BD120149 Mechanical Systems Manual
Inspect the applicable switch for loose mounting and loose or disconnected wires. Repair any faulty condition. If the wiring is good, inspect the switch for damage, distortion and wear. For the pot switch also examine the spring (Item 05, Figures 14-9,) and plunger (06). Replace all worn or damaged parts.
WARNING!
Inadvertent operation of the blasthole drill during maintenance on the machine couldcause severe bodily injury and/or death. Lock out and tag the drill operating controls toprevent accidental operation.
1. Lock out and tag the drill operator controls to prevent inadvertent startup during maintenance procedures.
2. Disconnect, lock out, and tag the power source which feeds the system to prevent power from being applied while service is being performed.
3. Tag and disconnect the wiring from the limit switch.
4. Remove the mounting hardware and related parts to detach the switch.
5. Check the on-off switch functions with an ohmmeter while actuating the switch manually. Replace a switch that does not operate properly.
6. Install a new switch with the same hardware and related parts.
7. Connect the wiring to the limit switch.
8. Start the drill and check operation of the limit switch.
BD120149 Mechanical Systems Manual Pipe Handling Equipment
14.2.3 Deck Wrench GH5007463
The deck wrench units each consist of a housing, a sliding body with spring-loaded pawl, and a hydraulic cylinder that provides clamping power.
14.2.3.1 Removal
Refer to Figure 14-10 and proceed as follows:
WARNING!
Inadvertent operation of the blasthole drill during maintenance on the machine couldcause severe bodily injury, or death. Lockout and tag the drill operating controls to pre-vent accidental operation.
1. Lock out and tag the drill operator controls to prevent inadvertent startup during maintenance procedures.
Pipe Handling Equipment BD120149 Mechanical Systems Manual
CAUTION!
High-pressure hydraulic or air systems can spray with extreme force and noise causingsevere injury. Slowly release pressure or vent circuits before loosening fittings or con-nections. Wear appropriate face, ear, and body protective devices while venting air orhydraulic systems.
2. Tag and disconnect the hydraulic hoses from the deck wrenches.
3. Remove the hydraulic fittings from the deck wrenches.
4. Tag and disconnect the lubrication hose assemblies from the deck wrenches.
5. Plug and/or cap all hose assemblies and hydraulic fittings to prevent contamination of the hydraulic system.
6. Remove cotter pins (13) and withdraw anchor pin (12) to free each deck wrench.
14.2.3.2 Disassembly
Refer to Figure 14-10 and proceed as follows:
1. Remove capscrews (1) and lockwashers (2). Separate retainers (3) and remove from the cylinder rod.
2. Withdraw housing (07) with pawl (11), spring (10), cylinder (06), and roll pin (09) from the working end of wrench housing (05).
3. Drive out roll pin (09), and remove pawl (11) and spring (10).
4. Tag and disconnect the hydraulic hoses from the deck wrenches.
5. Remove cylinder (06) from body (07).
6. Remove grease fittings (04), if necessary to replace.
14.2.3.3 Cleaning, Inspection and Repair
Clean and inspect the deck wrench components in accordance with the general cleaning and inspection proce-dures provided in Appendix A of this manual. Repair consists of replacement of all worn or damaged components. Refer to the LinkOne electronic parts manual for component identification.
14.2.3.4 Assembly
Refer to Figure 14-10 and proceed as follows:
1. Install new grease fittings (04) if necessary.
2. Position hydraulic cylinder (06) in body (07).
3. Place spring (10) and pawl (11) in body (07). Align the mounting holes on the pawl and the body, and install roll pin (09) to secure.
4. Install body (07) with pawl (11), spring (10), cylinder (06) and roll pin (09) into housing (05).
Pipe Handling Equipment BD120149 Mechanical Systems Manual
14.2.4 Deck Wrench Cylinders GH5010453
The deck wrench cylinders are double acting hydraulic cylinders, which are ported through the rod end. One cylin-der is located inside each wrench slide assembly. Refer to Subsection 14.2.3 for removal and installation proce-dures.
14.2.4.1 Disassembly
Refer to Figure 14-11 and proceed as follows:
1. Use a spanner wrench to loosen cylinder head (02); back it out, free of barrel (05).
2. Pull the entire piston and piston rod assembly out of barrel (05). Pull the assembly straight out, very carefully, to avoid scoring the cylinder bore.
3. Remove locknut (04) and the slide piston assembly off piston rod (01).
Figure 14-11: Deck Wrench Cylinder
LEGEND01. Piston Rod02. Cylinder Head03. Piston04. Locknut05. Barrel06. Service Kit07. Rod Wiper
08. Rod Seal09. O-ring10. Backup Ring11. O-ring12. Wear Ring13. Seal Assembly14. O-ring
BD120149 Mechanical Systems Manual Pipe Handling Equipment
4. Remove and discard O-ring (14) from inside of piston (03).
5. Remove two wear rings (12) and seal assembly (13) from the piston (03). Use care to avoid damage to the pis-ton land areas during disassembly.
6. Remove cylinder head assembly off piston rod (01).
7. Remove backup ring (10) and O-ring (11) from the outside of cylinder head (02).
8. Remove rod wiper (07), rod seal (08), and O-ring (09).
14.2.4.2 Cleaning, Inspection and Repair
Clean and inspect the hydraulic cylinder components in accordance with the general cleaning and inspection pro-cedures described in Appendix B of this manual. None of the components are repairable, and must be replaced if worn or damaged. Replace all seals and rings using available service kit. Refer to the LinkOne electronic parts manual for component identification.
14.2.4.3 Assembly
Refer to Figure 14-11 and proceed as follows:
1. Lubricate and install rod wiper (07), rod seal (08), and O-ring (09).
2. Install cylinder head (02) on piston rod (01).
3. Lubricate and install backup ring (10) and O-ring (11) on the outside of cylinder head (02).
4. Lubricate and install new O-ring (14) the inside of piston (03). Install piston with O ring on piston rod (01).
5. Lubricate and install two wear rings (12) and seal assembly (13) on piston (03). Use care to avoid damage to the piston land areas during assembly.
6. Install locknut (04) on piston rod (01).
7. Lubricate the bore of barrel.
8. Install the entire piston and piston rod assembly into barrel (05). Insert the assembly, very carefully, to avoid scoring the cylinder bore.
9. Install cylinder head (02) into the barrel, and torque securely with a spanner wrench.
14.2.4.4 Cleaning, Inspection And Repair
Clean and inspect components in accordance with the general cleaning and inspection procedures described in Appendix A of this manual.
Pipe Handling Equipment BD120149 Mechanical Systems Manual
14.2.5 Breakout Wrench R46448F1
The breakout wrench, the P&H SureWrench II™, is used to assist in the separation of pipe joints. Refer to Figure 14-12 .
WARNING!
The rotating drill string or its associated moving components can entrap and crush per-sonnel, resulting in severe injury or death. Do not enter the drilling platform and/or mastarea while the drill is operating. Notify the operator to shut down the drill and use lock-out/tagout procedures before conducting maintenance or service. When working in thedrilling and/or mast area while power is supplied to the drill, establish a procedure tomaintain communications between the work crew and the person controlling the drilloperation and shut down.
BD120149 Mechanical Systems Manual Pipe Handling Equipment
Step 1: Mount wrench to mast.
Step 2: Add proper jaws and dies to match diameter of drill pipe. Refer to Subtopic 14.2.5.2.
Step 3: Swing the breakout wrench into position to clamp around the pipe.
Step 4: Loosen the bolts on the breakout wrench mounting bracket.
Step 5: Using the hydraulics, clamp the drill pipe with the wrench.
Step 6: Tighten the bolts on the mounting brackets to secure the position of the wrench.
Step 7: Swing the wrench in and out to check the final alignment. If better alignment is needed, repeat steps 3 through 7.
14.2.5.2 Jaw and Die Chart
CAUTIONHaving unequal die lengths will result in the dies aligning incorrectly against the drillpipe. The hydraulic force applied to the jaws as they are rotated can be sufficient tocause the teeth to chip, resulting in slippage and premature wear on the dies.
Use the jaws and dies that correspond to the pipe diameter. Refer to Table 14-1.
14.2.5.3 Worn pins, bores, bushings, bushing guides, slots and pivots
As the working parts wear, the clamping and breaking performance will suffer. Wearing parts cause the Sure Wrench geometry to be distorted when clamping around a drill pipe as designed. As a result, the dies will not main-tain the required perpendicularity to the drill pipe. Thus, the dies will encounter point loading, which will result in the dies slipping and chipping teeth instead of biting into the drill pipe as the jaws are rotated.
Pipe Handling Equipment BD120149 Mechanical Systems Manual
14.2.6 Hydraulic Circuit Inspection and Adjustments
Table 14-2 shows tools, supplies, and parts required for the procedures that follow..
The procedures to adjust the hydraulic pressure (clamping force) will require two individuals with prior knowledge of the P&H drill. It is essential that everyone working on this adjustment understand all aspects of the procedure before work begins.
CAUTIONRemove dirt build-up from in and around the hydraulic fittings before repairs or adjust-ments are made to limit contamination from entering the system.
* 1 ea. 0-5000 psi gage
1 ea. 5/32" allen wrench
1 ea. 9/16" open end wrench
1 ea. Spray Cleaner
2 ea. #8 JIC Cap, 44Z511D4
1 ea. #8 JIC Union, 44Q44D15
** 1 ea. #8 JIC Tee, 44Z487D6
** 1 ea. Test Gage Connector, 44Z2664D4
* Use pressure test kit provided with the drill.
** These components will remain with the sequence valve.
Pipe Handling Equipment BD120149 Mechanical Systems Manual
Refer to Figure 14-13 and inspect hoses, fittings, sequence valve and hydraulic cylinders for oil leaks on a regular basis. Repair or replace damaged components before continuing on with the following steps:
14.2.6.2 Pressure Test Setup
Turn off power to the drill. Refer to Figure 14-13 and proceed as follows:
CAUTION!
High pressure hydraulic systems can spray oil with extreme force, causing severe injury.Test system pressure before loosening fittings or connections. Check pressure at TestPorts GA7 and GB7 on Valve Bank 2. Pressure must be zero before loosening any fit-tings or connections. Wear appropriate face, ear, and body protective devices whenventing hydraulic systems.
Step 8: Refer to Letter A on Figure 14-13. Remove the hose that connects the break cylinder to the sequence valve “H” port. Temporarily cap the open end of the hose.
Step 9: Install the tee fitting to the male fitting on the open port of the sequence valve. Reconnect the hose to the tee fitting.
Step 10: Install the test gage connector to the branch port of the tee fitting. Install the 0-5000 psi gage.
NOTICE
Tee fitting and test gage connector will remain with the sequence valve.
Step 11: Refer to Letter B on Figure 14-13. Remove both break cylinder hoses. Cap the open ports on the cylinder. Connect the two hoses together using the union fitting.
Step 1: Start the drill. When the hydraulic oil reaches normal operating temperature, continue with the following steps.
Step 2: From the operator’s cab, press and hold the rocker switch that controls the Sure Wrench Jaw and Break motions. Observe the pressure reading on the test gage.
Step 3: Make the necessary adjustments by adjusting cartridge (02, Figure 14-13) on the dual sequence valve facing towards the front of the drill. Turning the adjustment clockwise will increase pressure; turning anti-clockwise will decrease the pressure.
NOTICE
There are two cartridges on the dual sequence valve. Be certain to adjust the cartridge that isfacing the front, not the cartridge that is facing the rear.
Step 4: Adjust cartridge (02, Figure 14-13) to 2400 psi.
Step 5: Turn power off; remove test gage.
Step 6: Reconnect hoses onto the Break Cylinder.
Step 7: Start the drill and operate the Sure Wrench. Check for oil leaks.
BD120149 Mechanical Systems Manual Pipe Handling Equipment
Pipe Rack Does Not Swing Properly
Binding mechanism lnspect upper and lower swing mechanisms for foreign mate-rials. Remove any debris.
Lubricate pivot pins.
lnspect for broken or binding arm pivot pins. Repair as required.
lnspect for distortion of arms and supports. Repair or replace parts as necessary.
Hydraulic cylinder circuit malfunction
lnspect hydraulic lines to swing cylinder for leaks and/or loose connections. Repair any defi-ciencies.
Investigate control circuits for cause of incorrect operation and repair any deficiencies. Refer to Section 3, Auxiliary Hydraulic System. for trou-bleshooting of the auxiliary hydraulic system.
Swing hydraulic cylinder malfunction
Repair or replace faulty cylin-der.
Pipe Rack Gate Does Not Operate Properly
Gate mechanism out of adjustment
Adjust mechanism linkage.
Binding gate mechanism. lnspect mechanism for broken or binding pivot pins, rods, levers and rod ends. Repair or replace parts as required.
lnspect for broken or deformed latch compression spring. Replace faulty spring.
Pipe Rack Pot Wrenches Do Not Hold Pipe
Binding wrenches or pivot pins
lnspect pot for foreign materi-als. Remove any debris.
Lubricate wrench pins.
lnspect wrench pins for galling. Replace damaged pins.
BD120149 Mechanical Systems Manual Water Injection System
Section 15
Water Injection System
15.1 Theory of Operation
The water injection system injects a metered amount of water to the bit air to help control dust from drilling opera-tions. The water flow is regulated and monitored by a control potentiometer and flow meter in the operator’s cab.
Figure 15-1: Water Injection System
0101
02 03
05
07
09
04
06
LEGEND01. 1000-Gallon Water Tank, Insulated02. Water Pump03. Variable Speed Motor04. Air Piloted Water Dump Valve
Water Injection System BD120149 Mechanical Systems Manual
The system consists of a 1000 gallon (3785 liter) water tank, motor-driven pump, flow sensor, check valve, direc-tional control valve, relief valve, and related lines and fittings. Refer to Figure 15-1.
NOTICE
The water injection system should not normally be operated in sub-freezing ambient conditions.
The pump, the air-piloted dump valve, and the relief valve are mounted in the water tank. Water from the pump is discharged through the relief valve, which is factory preset at 55 psi (3.8 bar). A multipoint level switch, consisting of three float switches, is mounted inside the water tank. The normally open switches close when the tank is filled with water, and send signals to the PLC as follows:
• High water level switch HWLS opens to indicate that the tank is less than ½ full.
• Quarter water level switch QWLS opens to indicate that the tank is less than ¼ full.
• Empty water level switch EWLS opens to indicate that the tank is empty.
BD120149 Mechanical Systems Manual Water Injection System
The GUI in the operator’s cab indicates the level of water in the tank as well as the flow rate to the bit. Refer to Fig-ure 15-3
The pump is operated from the cab by turning the water injection switch ON. Water flow is adjusted with the flow control knob. Refer to Figure 15-4
For the water injection pump to operate, bit air must be ON, bit air pressure must be at least 15 psi, the tank level must be above empty, and the drill must be in drill or hoist mode.
BD120149 Mechanical Systems Manual Water Injection System
15.2.1 1000 Gallon Water Tank R33238F1
CAUTIONNever weld to the water tank. The tank is lined with epoxy on the inside. Epoxy will burn,causing corrosion on the inside of the tank.
The water tank is mounted on the left-hand platform. It is a steel tank, lined with epoxy on the inside, and is heated and insulated. The tank holds the pump and motor assembly as well as associated components.
15.2.1.1 Installation and Removal
The tank is mounted to the left-hand platform by 12 hex head capscrews, nuts and washers. Torque fasteners as indicated in Appendix A of this manual.
15.2.2 Submersible Water Pump 37U152D3
The submersible water pump has an integral sealed electric motor, check valve and suction screen. The unit is not field repairable and must be replaced if failure occurs.
The pump rests at the bottom of the tank in a 15° angle support. The angle provides drainage when the tank is emptied to prevent trapped water from freezing and damaging the water pump. The water pump can produce 5 gpm @ 75 psi.
Figure 15-6: Legend for Figure 15-5
LEGEND01. 250 Watt Strip Heater02. Flat Washer03. Lock Washer04. Hex Head Capscrew05. Strip Heater Guard06. Hex Head Capscrew07. Strip Heater Spacer08. Slotted Pan Head Machine
Screw09. Lock Washer10. Heater Control Thermoswitch11. Hex Nut12. 1000 Gallon Tank, Insulated and
Water Injection System BD120149 Mechanical Systems Manual
15.2.2.1 Removal
Refer to Figure 15-5 and proceed as follows:
WARNING!
Hazardous voltage can cause burns, injury, or death. Disconnect, lock open, and tag thepower source which feeds this device to prevent power from being applied while inspec-tion and repairs are being performed. Before beginning repairs, try the operational con-trols to verify that the intended power source is disconnected.
1. Disconnect, lock open, and tag the power source which feeds the system to prevent power from being applied while service is being performed.
2. Tag and disconnect the wiring to the pump at the electrical junction box on the tank.
3. Disconnect the water discharge hose from the access cover on the tank.
4. Pull the lock pins that secure the access cover to the tank.
WARNING!
Some blasthole drill components are extremely heavy. Dropping or mishandling of theseparts can cause severe personal injury or death, and damage to the equipment. Alwayssupport heavy components using a suitable hoist or other means for removal, disassem-bly, assembly and installation. Provide appropriate support for any components whichare not supported by the machinery during any maintenance.
5. Attach a suitable hoist to the lifting chains attached to the access cover. Lift the cover, pump and related hose, valve, cradle, frame and fittings from the tank, tanking care not to damage parts in the process.
6. Remove the hose, electrical wiring and fittings from the pump. Use these parts to install the new pump.
7. Remove the pump caps and pump.
15.2.2.2 Repair
Clean and inspect parts as specified in Appendix A. Replace deteriorated hose, gasket and wiring.
15.2.2.3 Installation
Refer to Figure 15-5 and proceed as follows:
1. Install the new pump on the cradle with the pump caps. Be sure that the check valve is pointed straight up before locking the pump in the cradle.
2. Install the hose, electrical wiring and fittings on the pump. Use pipe thread sealant in threaded fittings.
3. Attach a suitable hoist to the lifting chains attached to the access cover. Lower the cover, pump and related hose, valve, cradle, frame and fittings into the tank, tanking care not to damage parts in the process.
BD120149 Mechanical Systems Manual Water Injection System
4. Position the access cover on the tank. Use a new cover gasket if necessary.
5. Install the lock pins to secure the cover.
6. Connect the water discharge hose to the access cover.
7. Connect the wiring to the pump at the electrical junction box on the tank.
8. Operate the system to verify proper operation.
15.2.3 Pressure Relief Valve R12410D1
15.2.3.1 Replacement
Refer to Figure 15-7 and proceed as follows:
CAUTION!
Pressurized water systems can spray with extreme force, causing severe injury. Shutdown the system and slowly release pressure or vent circuits before loosening any fit-tings or connections. Wear appropriate face, ear and body protective devices while vent-
Figure 15-7: Pressure Relief Valve
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BD0550a01
LEGEND01. Cap02. Spring03. Locknut
04. Outlet Port05. Poppet06. Valve Body07. Inlet Port
Water Injection System BD120149 Mechanical Systems Manual
ing pressurized water systems.Inadvertent operation of the blasthole drill duringmaintenance could cause severe bodily injury and/ or death. Lockout and tagout the drilloperating controls to prevent accidental operation.
1. Lockout and tagout the drill operating controls to prevent inadvertent start-up of the drill during maintenance activities.
2. Disconnect the water discharge hose from the access cover on the tank.
3. Pull the lock pins that secure right side of the access cover to the tank. Swing the cover open.
4. Remove the pressure relief valve and close nipple.
5. Check the pressure setting of the relief valve or its replacement on a test stand. The correct relief pressure set-ting is 80 psi (5.5 bar). Adjust as necessary. If a test stand is not available, check and adjust as specified in topic, Relief Valve Adjustment.
6. Install the relief valve and nipple.
7. Close and secure the tank cover. Connect the water discharge hose.
BD120149 Mechanical Systems Manual Water Injection System
15.2.3.2 Adjustment
The pressure relief valve is set to 55 psi (3.8 bar). The valve can be adjusted on a test stand or using a setup simi-lar to the one shown in Figure 15-8. To adjust the valve on the drill, proceed as follows:
1. Lock and tag out the drill and relieve pressure. Open the tank cover as described under Subtopic 15.2.3.1.
2. Assemble test components as shown in Figure 15-8.
3. Remove the elbow from the cover and install the test equipment. Place the free end of the hose in the tank, open the test valve.
Figure 15-8: Relief Valve Adjustment
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07 08 07 09 10
07
BD0551a01
LEGEND01. Pressure Relief Valve02. Water Tank Access Cover03. Reducer, 1.00" - .50"04. Pressure Gauge 0 - 150 psi
Water Injection System BD120149 Mechanical Systems Manual
NOTICE
To start the water pump without the main air compressor running, temporarily jumper the mainair pressure switch (MAPS) (item 7, Figure 6-55).
4. Turn ON the water injection system switch to start the water pump. Adjust water flow with the control potenti-ometer.
5. When water is flowing through the test equipment and back into the tank, partially close the test valve until the pressure gauge reads 80 psi (5.5 bar).
6. Confirm that the valve starts to vent at 80 psi (5.5 bar). Tighten the locknut after adjustment to retain the set-ting.
7. Check the pressure setting by opening and partially closing the test valve several times to be sure that the relief valve continues to vent at the setting.
8. Shut down the water injection system.
9. Remove the test equipment from the tank.
10. Remove the jumper from the MAPS.
15.3 Sensing Components
The sensing components such as the level switches, flow sensor and two-way valve should be inspected in place before service. If these parts do not function, check the electrical connections and lines to other electrical parts before replacement. Replace any faulty parts. The location and method of installation are shown on the applicable exploded view illustrations. After replacement check all joints and connections for security.
BD120149 Mechanical Systems Manual Water Injection System
15.4 Troubleshooting
The following table provides general troubleshooting information on the water injection system.
Problem Possible Cause Remedy
Pump does not run. No water in tank Check if tank empty light (red) is on. Add water to tank as required
Bit air off Turn on bit air
Drill in propel mode Place drill in hoist or drill mode
Insufficient bit air pressure Investigate cause of low bit air pressure. Correct deficiency
No power to pump Check power and control circuits to pump. Correct deficiency
Broken drive belt (if applicable Replace belt and adjust
Faulty bit pressure switch Check pressure switch and replace if faulty
Faulty pump or pump motor Replace pump or motor
Pump runs erratically Faulty relief valve Check relief valve setting and adjust as required. If valve will not hold setting, disassemble and clean valve. Repair or replace valve
Low voltage or control circuit mal-function
Check power and control circuits to pump. Correct deficiency.
Faulty pump or pump motor Remove and inspect pump and motor. Replace faulty pump or motor.
Tank will not vent Faulty check valve Inspect check valve and replace if faulty.
Faulty two-way valve Check two-way valve and replace if faulty.
Without reference to specific lubricant manufacturers’ products, this manual makes referenceonly to the appropriate P&H Mining Equipment lubricant specifications. P&H Mining Equipmentlubricant specifications are listed in their entirety under Subsection 16.8. Each P&H materialspecification pertaining to lubricants provides the equipment owner with the minimum require-ments for the lubricant. Conformance to these requirements does not constitute the only basisof acceptance. Lubricants must be judged further on their satisfactory field performance.
In order for equipment to perform properly, the lubricant supplier and the equipment owner must work together to determine if the type of lubricant being considered will meet P&H Mining Equipment lubricant requirements (that is, specifications and performance). The lubricant supplier must confirm that the lubricant meets specifications; the equipment owner must confirm that the lubricant is suitable for and performs in the operating environment.
16.1.2 Operating in Cold Conditions
Automatic lubrication systems can malfunction when the lubricant becomes too cold to flow smoothly or vent prop-erly. This can cause the system cycle to end before lube points are properly lubricated.
16.1.2.1 Possible Effects Of Excessively Cold Lubricant
• Improper venting after the cycle may prevent the injectors from reloading. If pressure is not vented back to the tank, the injector springs stay compressed and can not reload. The next cycle the injectors will not out-put any lube if they have not recharged. As a result, the lube points may not receive proper lubrication.
• Cold grease can make it difficult to pump the lubricant. A restriction to flow in one area can cause a local pressure drop to some components. The pressure switch on the lubrication control panel may reach the set point pressure before it is high enough to cycle all the injectors. The lube pump turns off prematurely before the lube points get the needed lubricant.
If cold weather problems occur, contact your P&H MinePro Services representative to assist in choosing which of the following solutions should be selected.
16.1.2.2 Possible Solutions
• Use a grease more appropriate for colder temperatures. Refer to the lubrication specifications in this section of this manual for details.
• Slow the lubrication pump to allow more time for the cold grease to move through the lube piping. Refer to Section 8, Automatic Lubrication System. for more details.
16.1.3 Viscosity
The viscosity is a critical parameter in determining film thickness under operating conditions. Too low viscosity will allow tooth surfaces to contact each other. Viscosity varies exponentially with operating temperature.
The viscosity grade selection is dependent on the maximum and minimum operating temperatures. If the extreme or peak operating sump temperatures are not known, measure the sump oil temperature during a period of extreme or peak ambient temperature, after working the machine continuously for at least ½ shift.
Maximum oil viscosity (and, therefore, its suitability for application in cold weather) is also temperature-dependent and is primarily determined by the pour point of the oil. Refer to minimum operating sump temperatures in Table 16-1.
NOTICE
The maximum sump temperatures are based on a minimum allowable viscosity of 400 cSt.Exceeding limits, especially the maximum limits, for even short periods can result in progres-sive surface deterioration. If maximum and minimum temperature limits cannot be met with anyone product, seasonal oil changes should be considered. In cold environments exceeding lowerlimits, drives should be run at no load to warm up the oil prior to operation. Sump temperaturesshould be monitored in extreme ambient conditions.
The channel point of an oil is about 8-14°F below the pour point. If the ambient temperature drops below the pour point, the oil will not flow through a pump. This condition is unacceptable, even though some lubrication of gearing might be possible if the gearing dips into oil in a sump. If the ambient temperature falls below the channel point, no lubrication is possible as the oil will become semi-solid and will be displaced (channeled) as the gearing dips into the sump. This condition will result in destruction of the gearing.
If it is desired to use a single grade of oil year round, users must be certain that at no time will either the maximum or minimum operating sump temperature be exceeded for the grade of oil being used.
The minimum operating sump temperature represents the pour point of the oil, but it is still possible to operate the machine if the ambient temperature drops below the pour point. Temperature below the pour point is mainly a con-cern if the machine is not operating. If a machine has been shut down for an extended period of time, and the ambi-ent temperature drops below the pour point during this time, observe carefully while the motions are run slowly under no load. Warm up the oil to the point where it will flow before putting the gearing under load. This task is crit-ical to avoid serious damage to gearing. If the sump temperature is still below the pour point, a lighter grade of oil should be used.
Oil selection will affect filter performance. When selecting filter elements, the viscosity, grade, and operating tem-perature must be considered. The viscosity of the oil will change with temperature. Normally, a 10 psi pressure drop is permitted across filters. To ensure that the filter element type and mesh is appropriate for the oil viscosity at the highest and lowest temperature, the oil temperature, oil viscosity at that temperature, and the flow through the filter must be known. Generally, the curves for filter elements are available from filter suppliers.
The selection of gearcase oils must be made on the basis of conformance to P&H Specification 497 or 474, on the minimum viscosity requirements of 400 cSt at maximum operating temperature, and on the pour point of the oil vs. the minimum ambient temperature.
16.1.4 ISO Grade
It is recommended that only oils with an ISO grade designation be used. If a type of oil other than an ISO grade is to be used, consult with the manufacturer. Oils of the same ISO grade will typically have similar viscosity and pour point parameters. If unsure, compare proposed oil’s properties with those listed in Table 16-1. If significantly differ-ent, consult the manufacturer regarding suitability.
NOTICE
If the lubrication service recommendations in this manual conflict with those of the originalequipment manufacturer, the original equipment manufacturer’s specifications take prece-dence.
CAUTIONGrease lubricants with different formulation bases are incompatible. Before using a dif-ferent grease, check to be sure that the base of the new grease is compatible with theoriginal. If not, all components in contact with the lubricant, including shafts and bear-ings, must be thoroughly purged of the old grease, removed from the system, andcleaned with solvent. Component failure will result if thorough cleaning is not done.
The automatic lubrication system supplies grease lubricant, Material Specification P&H 472 to specified lube points on the upper machinery, the crawlers, and each of the four leveling jacks. The NLGI grade of the grease must be appropriate for the prevailing ambient temperature range. P&H 472C is the preferred grade for all temperature ranges; however, at lower ambient temperature ranges, P&H 472A or 472B may be recommended by the lubrica-tion supplier.
Check the lubricant level at least weekly. Refill the reservoir as necessary.
The auto lube system is controlled by the programmable logic controller (PLC). Refer to Section 8, Automatic Lubrication System. for a complete description.
16.3 Oil Bath Lubrication
All gear drives, including the pump drive transmission, and some of the other rotating equipment on the blasthole drill, are lubricated through self-contained oil bath reservoirs. Most of the equipment units that have self-contained lubricant reservoirs lubricate their internal components by immersion in the oil bath, or by splashing lubricant from the surface of the oil bath. The equipment within this category includes the following:
The pulldown gearcase uses oil, Material Specification P&H 497. Viscosity is indicated by a letter, and should be selected according to expected extreme ambient temperatures. Refer to Table 16-2
Check oil level at the sight glass every week and add oil as required. Change oil as specified in Table 16-9 or as indicated by oil analysis.
The hydraulic pump drive transmission uses gear oil, Material Specification P&H 497. Viscosity is indicated by a letter, and should be selected according to expected extreme ambient temperatures. Refer to Table 16-3
Check oil level on the dipstick every month and add oil as required. Change oil as specified in Table 16-9 or as indi-cated by oil analysis.
The auxiliary winch gear reducer uses gear oil, Material Specification P&H 497. Viscosity is indicated by a letter, and should be selected according to expected extreme ambient temperatures. Refer to Figure 16-3.
Check oil level in the auxiliary winch gear reducer every month and add oil as required. Change oil as specified in Table 16-9 or as indicated by oil analysis.
Lubricate the auxiliary winch wire rope as required using Open Gear and Wire Rope Lubricant, Material Specifica-tion P&H 464.
The cable reel gear reducers use gear oil, Material Specification P&H 497. Viscosity is indicated by a letter, and should be selected according the expected extreme ambient temperatures. Refer to Table 16-5.
Check oil level at the level plugs every week and add oil as required. Change oil as specified in Table 16-9 or as indicated by oil analysis.
On either side of the frame, lubricate drum bearing grease fittings every week or after 40 hours of operation using extreme pressure grease, Material Specification P&H 472. P&H 472C is the preferred grade for all temperature
ranges; however, at lower ambient temperature ranges, P&H 472A or 472B may be recommended by the lubrica-tion supplier.
16.3.5 Propel Transmissions
The propel transmissions use gear oil, Material Specification P&H 497. Viscosity is indicated by a letter, and should be selected according to the expected extreme ambient temperatures. Refer to Table 16-6
Check oil level at the level plugs every week and add oil as required.Change oil as specified in Table 16-9 or as indicated by oil analysis.
The rotary gearcase and the air compressor have enclosed, dedicated oil lubrication systems.
16.4.1 Rotary Gearcase
The rotary gearcase is a sealed unit with a self-contained oil bath sump and gear-driven pump that circulates lubri-cating oil, under pressure, to the bearings and gears.
The rotary gearcase uses gear oil, Material Specification P&H 497. Viscosity is indicated by a letter, and should be selected according the expected extreme ambient temperatures. Refer to
Check oil level at the level plugs every week and add oil as required. Change oil as specified in Table 16-9 or as indicated by oil analysis.
The air compressor uses Dexron® ATF in all ambient temperatures. The capacity is 100 US Gallons (378.54 liters). Check the oil level at the T-Tank sight gauge each shift or after each 8 hours of operation. Change oil as specified in Table 16-9 or as indicated by oil analysis.
Figure 16-7: Lubrication, Air Compressor T-Tank
02
01
03 BD0557b01
LEGEND01. Fill Plug 02.Sight Gauge 03.Manual Drain Valve
Oil filters associated with the main air compressor are (refer to Figure 16-9):
• The Main Compressor Oil Filter (01), mounted on the compressor, is a replaceable-element filter that filters the majority of the oil returning to the compressor from the T-Tank.
Figure 16-8: Main Air System Oil Filter Locations
Figure 16-9: Compressor Oil Filter Locations
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03BD0729a0104
LEGEND01. Main Compressor Oil Filter (on compressor)03. Oil Removal Filters (T-Tank)04. Scavenger Oil Filter (on air control panel)
01
02
03BD0729a0104
LEGEND01. Main Compressor Oil Filter (on compressor)02. Compressor Bearing Oil Filter (on compressor)03. Oil Removal Filters (T-Tank)04. Scavenger Oil Filter (on air control panel)
• The Compressor Bearing Oil Filter (02), mounted on the compressor, is a spin-on filter that filters the oil used to lubricate the bearing on the air end.
• The two Oil Removal Filters (03) are an integral part of the T-Tank. They remove the oil vapor from the out-going pressurized air for return to the compressor.
• The Scavenger Oil Filter (04), mounted on the air control panel, is a spin-on filter that filters the oil returning through the scavenger lines from the Oil Removal Filters (03).
Check the condition of the Main Compressor Oil Filter and the two Oil Removal Filters every week or after 40 hours of operation. Refer to and check the filters as follows:
Check the Oil Separator Filters by observing the gauge on valve (01) while turning the handle first to one position and then the other. Follow the same procedure for the Main Compressor Oil Filter by using valve (02). In both instances, if the difference in pressure is greater than 8 psi, change the filter. Procedure to change the main oil filter follows this subtopic; for the procedure to change the separator filters, refer to Subsection 6.3.4.1.
WARNING!
Inadvertent machine movement can cause injury or death. Do not perform maintenancework on a machine without first disabling the operator controls. Lock out and tag theoperator controls to prevent inadvertent machine operation while performing manuallubrication tasks.
Lock out and tag out the operator controls to prevent inadvertent drill operation.
CAUTION!
Pressurized oil will spray with extreme force from the compressor main oil filter whenbeing loosened, and can cause severe injury. Slowly release air pressure or vent the T-Tank before loosening the filter canister. Wear appropriate face, ear, and body protectivedevices while opening the canister.
Change the Compressor Bearing Oil Filter and the Scavenger Oil Filter every month or after 160 hours of opera-tion. Remove the filter by rotating the filter body anticlockwise. To install an new filter, coat the gasket with ATF and rotate the new filter body clockwise to thread it onto the stem.
The main compressor oil filter has an indicator to help determine when the filter needs to be changed. Change the element in the main compressor filter after 160 hours of operation or when the filter indicator indicates in the CHANGE FILTER area (refer to
Refer to Figure 16-12 and change the element as follows:
Figure 16-11: Main Compressor Oil Filter Indicator
Inadvertent machine movement can cause injury or death. Do not perform maintenancework on a machine without first disabling the operator controls. Lock out and tag theoperator controls to prevent inadvertent machine operation while performing manuallubrication tasks.
1. Lock out and tag out the operator controls to prevent inadvertent drill operation.
2. Change the filter element if any of the following conditions exists:
• the filter indicator is in the red CHANGE FILTER position;
• the GUI has issued a fain compressor oil filter fault;
• it has been more than six months since the last filter element change; or
• the differential switch and gauge on the air control panel registers a difference of 8 psi or greater.
Figure 16-12: Changing Main Compressor Oil Filter
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BD0559a01
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LEGEND01. Spring02. Filter Element03. Seal04. Baffle05. Head O-ring06. Indicator O-ring07. Snap Ring08. Tee Handle O-ring09. Tee Handle10. Head Assembly11. Indicator Assembly12. Housing13. Flow Switch
Pressurized oil will spray with extreme force from the compressor main oil filter whenbeing loosened, and can cause severe injury. Slowly release air pressure or vent the T-Tank before loosening the filter canister. Wear appropriate face, ear, and body protectivedevices while opening the canister.
A. Vent any residual air from the T-Tank.
B. Remove the filter head (10) by rotating handle (09) anticlockwise until the head is free of the housing (12).
C. Hold the baffle (04) down and push down on the indicator assembly (11) to be sure it moves freely up and down within the baffle.
D. Remove the baffle (04) and check the bore for nicks. Smooth the bore if necessary and replace seal (03) if it is damaged.
E. Remove the element (02) from the housing (12). Remove the indicator assembly (11) from the element using a screwdriver between the indicator assembly and the element cap and carefully prying downward. Inspect the O-ring (06) and replace it if necessary.
F. Remove the O-ring (05) from the head (10) and replace it if necessary. Clean the O-ring area of the head, lubricate a new O-ring with oil and reinstall the O-ring in the head.
G. Install indicator assembly (11) into the new element(02). Place the element into housing (12) being sure the large diameter of spring (01) contacts the new element. Install the baffle (04).
H. Place the head (10) on the housing (12) and turn the handle (09) clockwise until it is hand tight. Do not exceed 20 ft-lb (26 Nm).
I. If leakage appears around the handle (09), remove the snap ring (07) and remove the handle from the head. Discard the O-ring (08) and reassemble the unit with a new O-ring.
The hydraulic tank uses Dexron® ATF. Check the sight gauge at the beginning of each shift or after 8 hours of operation. Replenish the oil level using the supplemental oil tank mounted near the air compressor.
Every week of operation, inspect the visual indicators on the suction filters and on the return filters. Also check the color of the desiccant in the breather cartridge. Change the filters and the breathers when indicated.
Drain, flush and refill the hydraulic system as specified in Table 16-9 or as indicated by oil analysis.
The stated capacity of the hydraulic tank is 125 US Gallons (482 liters); however, the placard next to the sight gauge is the final determiner of maximum and minimum oil levels, depending on the physical condition of the drill (mast up or down, jacks extended or retracted). Refer to Figure 16-14.
P&H Mining Equipment recommends that a sample of oil be drawn from the hydraulic tankannually. This sample should be about two quarts (two liters) and should be taken when the oilis warmed through normal operation. The sample should be analyzed by a qualified lubricationspecialist to determine whether it is suitable for continued use. The interval between oilchanges may be extended based upon the operating conditions and on the care used in han-dling oils and in keeping them clean during the handling process.
Figure 16-14: Hydraulic Tank Level Sight Gauge and Temperature Gauge
Inadvertent machine movement can cause injury or death. Do not perform maintenancework on a machine without first disabling the operator controls. Lock out and tag theoperator controls to prevent inadvertent machine operation while performing manuallubrication tasks.
16.6.1 General
16.6.1.1 Lube Points Without Fittings
Miscellaneous pins, levers and linkages that move but are not considered wear surfaces should be lubricated weekly or as required by administering a few drops of motor oil as indicated on Figure 16-8.
16.6.1.2 Lube Points with Grease Fittings
Lubrication points that are provided with grease fittings use extreme pressure lithium grease, Material Specification P&H 472. The preferred grade is a synthetic grade NLGI #1. A non-synthetic grade NLGI #2 is a suitable alterna-tive. A non-synthetic NLGI #1 or #0 may be required for proper dispensing at low temperatures or by centralized lubrication systems.
< 20°F(< -7°C)
+20 to 110°F(-7 to 43°C)
>110°F(>43°C)
SAE 10W SAE 15W40 SAE 30
Table 16-8: Lubrication, Miscellaneous Pins, Levers and Linkages
Every month of operation, lubricate slide areas with EP Grease (refer to Subtopic 16.6.1.2) and lubricate pins on the mast back brace with motor oil (refer to Subtopic 16.6.1.1).
Figure 16-16: Lubrication, Mast Back Braces
01
01
01
01
02
02
BD0562a01
LEGEND01. Pin (4 pins)02. Slide Area (6 slide areas)
CAUTIONUsing incorrect lubricants can cause substantial equipment damage. The material speci-fications listed in this manual are current at the time of publication, and are intended tobe used for reference only. Contact your local P&H MinePro Services representative forthe current specifications.
1.0 SCOPE
1.1 This specification covers open gear lubricants with highly fortified blends of viscous oils combined with addi-tives to form a stable, long lasting, high load carrying and wear resistant films that lubricate under boundary condi-tions.
1.2 Materials furnished under this specification are intended to lubricate open gears, racks, bushings, rails, rollers, dipper handles and walk mechanisms. These applications are subject to extreme contact pressures, reversing loads and peripheral speeds of up to 1,200 feet per minute/366 meters per minute, while operating under varied weather conditions.
Semi-Annually orEvery 1800-2000
Hours
04 Rotary Gearcase Change Oil Figure 16-6
12 Propel Transmission Change Oil Figure 16-5
112 Main Compressor Bearing Oil Filter Replace Figure 16-8
1.3 Materials furnished under this specifications are intended to be dispensed intermittently by centralized lubrica-tion systems of the single line parallel, single line progressive series, and/or dual line progressive construction.
1.4 This specification covers all grades of open gear lubricants that are usable from -50F/-46C to 120F/49C. The particular grade selected must perform in the specific temperature range in which it is utilized.
1.5 Materials furnished under this specification may be semi-fluid asphaltic or non-asphaltic, greases or pastes. Specific product selection will depend on climate, application, performance and regulatory requirements.
1.6 Materials furnished under this specification are not intended for use in moderate to high speed anti-friction bearings.
2.0 REFERENCE DOCUMENTS
2.1 ASTM D92/ISO 2592 - Flash Point, COC Method
2.2 ASTM D1404 - Deleterious Particles Test
2.3 ASTM D1743 - Rust Protection
2.4 ASTM D2266 - Four Ball Wear Test
2.5 ASTM D2596 - Four Ball EP Test
2.6 ASTM D4048 - Copper Strip Corrosion Test
2.7 Grease Pumpability, Lincoln Ventability (Ventmeter) test
3.0 PHYSICAL CHARACTERISTICS
3.1 These open gear lubricants must have excellent adhesive and cohesive qualities, must not chip or throw off, and must provide sufficient film thickness to prevent metal to metal contact between applications under all operat-ing conditions.
3.2 These open gear lubricants must have excellent water resistant and rust preventive qualities.
3.3 These open gear lubricants must have retarded dripping qualities for operation at various temperatures.
3.4 These open gear lubricants must be specifically formulated to protect surfaces, reduce wear, and provide nor-mal component service life under all anticipated operating conditions.
3.5 These material shall meet applicable safety, health and environmental regulations.
4.0 PERFORMANCE REQUIREMENTS
PROPERTY REQUIREMENT
Flash point, ASTM D92/ISO 2592, minimum F/C 175/79
Four ball EP test, ASTM D2596, weld point, minimum kgf,
(1) Consult lubricant system component manufacturer regarding any deviations from this requirement.
5.0 SPECIAL CONSIDERATIONS
5.1 The material furnished under this specification must be dispensable through the distribution lines of a central-ized lubrication system to the most remote application point, at the lowest anticipated operating temperature. It must not plate or plug components of the centralized lubrication system such as injectors, metering blocks or spray nozzles.
5.2 When the material furnished under this specification is formulated with solid film additives, particle size must not exceed 100 microns.
5.3 Should the material furnished under this specification contain a diluent to improve dispensability, special care must be exercised to insure its compatibility with all centralized lubrication system components, i.e., gaskets, o-rings, vent valves, etc.
5.4 Diluent containing lubricants furnished under this specification must conform to the performance requirements provided in Section 4.0 after the diluent has evaporated.
6.0 IDENTIFICATION AND PACKAGING
6.1 Containers must be clearly identified by the supplier with the following information:
6.1.1 Purchase Order Number
6.1.2 Supplier's Name and Product Trade Name
6.1.3 P&H Material Specification Number followed by a brief description:
6.1.3.1 P&H No. 464 - Asphaltic Type Open Gear Lubricant
or
6.1.3.2 P&H No. 464 - Paste Type Open Gear Lubricant
6.1.4 Material Safety Data Sheet (MSDS) - One (1) with each shipment
Four ball wear test, ASTM D2266, 60 minutes @ 40 kgf, maximum scar, mm
6.2 The lubricant furnished under this specification must be supplied in clean containers of the size(s) as specified on the purchase order.
7.0 INSPECTION AT PURCHASER'S WORKS
7.1 Acceptance of material furnished under this specification shall be subjected to confirmation by Customer's Quality Assurance Department.
7.2 The purchaser shall have the option of accepting or rejecting any material failing to meet the requirements of this specification.
8.0 ADDITIONAL CRITERIA OF ACCEPTANCE
8.1 Conformance to all specified requirements shall not constitute the sole basis of acceptance since all lubricants must be judged further on their satisfactory field performance Harnischfeger Corporation equipment.
8.2 Relubrication volume and frequency can directly affect the performance of a lubricant and the economies of operation. Consult the equipment shop manual and lubricant supplier for the relubrication volume, and frequency for each application.
8.3 The suitability of a lubricant is highly dependent upon environmental conditions. It is the consumer's responsi-bility to provide lubricant suppliers with the following:
8.3.1 Actual application and copy of this specification.
8.3.2 Environmental data - temperature range and weather conditions.
8.3.3 Type of centralized lubrication system(s).
8.4 It is the responsibility of the consumer to verify that lubricants conform to applicable environmental and safety codes governing their use and disposal.
CAUTIONUsing incorrect lubricants can cause substantial equipment damage. The material speci-fications listed in this manual are current at the time of publication, and are intended tobe used for reference only. Contact your local P&H MinePro Services representative forthe current specifications.
1.0 SCOPE
1.1 Material furnished under this specification is a multi-purpose aluminum complex soap grease lubricant. It is characterized by its excellent water resistance, thermal and shear stability, and compatibility with all other types of greases.
1.2 This grease contains a derivative of polytetrafluoroethylene as a solid lubricant additive. This additive has the registered trade name “LIQUILON”.
1.3 This grease is intended for lubricating components during assembly. It can be sued in equipment having grease fittings and in centralized distribution systems. (Note (a) under Paragraph 2).
2.0 PHYSICAL PROPERTIES
2.1 This lubricant must be an Aluminum Complex Soap Base, Multi-Purpose Extreme Pressure Grease containing “LIQUILON”. It must be formulated to resist oxidation and corrosion, oil separation, caking, and water washout.
2.2 Material furnished under this specification shall conform to the following physical requirements.
P&H Grade 469 469A
N.L.G.I. Consistency #2EP #1EP
Suggested Operating Temperature Range oF (a) 0 to +400 -15 to +400
Penetration at 77 oF Worked 60 Strokes 265-295 330-340
(a) Consult manufacturer's manual for correct consistency when used in centralized distribution systems.
2.3 Conformance to the above requirements shall not constitute the sole basis of acceptance since all lubricants must be judged further on their satisfactory field performance in Harnischfeger equipment.
3.0 PACKAGING
3.1 This grease lubricant is available in 400 lb. drums, 120 lb. kegs, 35 lb. pails, and hand gun cartridges. The con-tainer shall be specified on the purchase order to the supplier.
4.0 IDENTIFICATION
4.1 Containers must be clearly identified by the supplier with the following information:
4.1.1 Purchase Order Number4.1.2 Supplier's Name and Product Trade Name4.1.3 P&H Material Specification Number as specified by Purchase Order
5.0 INSPECTION AT PURCHASER'S WORKS
5.1 Acceptance of material furnished under this specification shall be subject to confirmation by Customer's Materi-als Engineering Department.
5.2 The Purchaser shall have the option of accepting or rejecting material that fails to meet any of the requirements of this specification.
5.3 In the event of rejection, the supplier will be notified, and the material will be returned at his expense.
CAUTION Using incorrect lubricants can cause substantial equipment damage. The material spec-ifications listed in this manual are current at the time of publication, and are intended tobe used for reference only. Contact your local P&H MinePro Services representative forthe current specifications.
1.0 SCOPE
1.1 This specification covers premium multipurpose, extreme pressure greases with essential properties and char-acteristics that make them suitable for use in diversified applications through a wide range of ambient tempera-tures. Both mineral and synthetic base oils may be used to formulate greases that comply with this specification.
1.2 Materials furnished under this specification are intended to lubricate bushings, plain and rolling element bear-ings, and miscellaneous items on Harnischfeger Corporation equipment requiring a grease.
1.3 Materials furnished under this specification may be applied by hand, hand pressure guns, pneumatic or electric pressure guns, or centralized lubrication systems of the single line parallel, single line progressive series, and/or dual line progressive construction.
1.4 P&H 472 (no suffix) from Issue No. 9 is the same as P&H 472C in this specification.
1.5 P&H 472D is primarily intended to lubricate bearings in Magnetorque Assemblies, and bearings and gears in hoists and cranes where long life of lubricant is demanded, and high temperature operation may be expected in both intermittent and continuous duty. Other product uses include high speed electric motor bearings; ball, roller and journal bearings - medium to high temperature and high temperature applications; bearings subject to water, steam, chemicals and contaminants; and bearings subject to heavy thrust or shock loads.
2.0 REFERENCE DOCUMENTS
2.1 ASTM D217/ISO 2137 - Determination of Cone Penetration2.2 ASTM D445/ISO 3104, D 2161 - Kinematic Viscosity2.3 ASTM D566/ISO 2176 - Determination of Dropping Point2.4 ASTM D942 - Oxidation Stability, Oxygen Bomb Method2.5 ASTM D1264 - Water Washout Resistance2.6 ASTM D1404 - Deleterious Particles Test2.7 ASTM D1743 - Rust Protection2.8 ASTM D1831 - Roll Stability Test2.9 ASTM D2265 - Determination of dropping point over a wide temperature range2.10 ASTM D2509 - Timken EP Test2.11 ASTM D2596 - Four Ball EP Test2.12 ASTM D4048 - Copper Strip Corrosion Test2.13 DIN 51 802/IP220, EMCOR Rust Protection Test2.14 Grease Pumpability, Lincoln Ventability (Ventmeter) Test
3.1 These lubricating greases shall be manufactured with a lithium 12-hydroxystearate, lithium complex, or other thickeners provided care is taken by the end user to avoid grease incompatibility in Harnischfeger equipment. Thickeners such as clay base, polyurea or calcium may result in incompatibilities. Always consult lubricant suppli-ers before changing types or brands of greases.
3.2 These lubricating greases must contain extreme pressure additives, and be formulated to resist oxidation, cor-rosion, separation, and water washout.
3.3 These lubricating greases must have chemical and mechanical stability to maintain consistency and perfor-mance characteristics throughout their intended service life.
3.4 The NLGI grade of the grease must be appropriate for the prevailing ambient temperature range. A lithium complex synthetic grease which meets the requirements of P&H 472B is the preferred grade for all temperature ranges. A lithium complex non-synthetic grease which meets the requirements of P&H 472C is a suitable alterna-tive. At lower ambient temperature ranges, a lithium complex non-synthetic grease which meets the requirements of P&H 472A or P&H 472B may be recommended by the lubrication supplier.
3.5 These materials shall meet applicable safety, health, and environmental regulations.
4.0 PERFORMANCE REQUIREMENTS
P&H Grade 472A 472B 472C 472D
NLGI grade (1) 0 1 2 2
Worked penetration ASTM D217/ISO 2137 @ 60 strokes, 25C/77F
355-385 310-340 265-295 265-295
Dropping point, ASTM D566/ISO 2176 or ASTM D2265, Min., C/F
Not Applicable 177/350 177/350 260/500
Base fluid viscosity, ASTM D445/ISO 3104; D2161, Min. mm2/s @ 40C
5.1 Containers must be clearly identified by the supplier with the following information:
5.1.1 Purchase Order Number
5.1.2 Suppliers Name and Product Trade Name
5.1.3 P&H Material Specification Number followed by a letter which will indicate a particular consistency grade in accordance with the following:
5.1.3.1 P&H Number 472A - NLGI #0 EP
5.1.3.2 P&H Number 472B - NLGI #1 EP
5.1.3.3 P&H Number 472C - NLGI #2 EP
5.1.3.4 P&H Number 472D - NLGI #2 EP
5.1.4 Material Safety Data Sheets (MSDS) - One (1) with each shipment.
5.2 The lubricant furnished under this specification shall be supplied in clean containers of the size(s) as specified on the purchase order.
6.0 INSPECTION AT PURCHASER'S WORKS
6.1 Acceptance of material furnished under this specification shall be subjected to confirmation by purchaser's Quality Assurance Department.
6.2 The purchaser shall have the option of accepting or rejecting any material failing to meet the requirements of this specification.
7.0 ADDITIONAL CRITERIA OF ACCEPTANCE
7.1 Conformance to all specified requirements shall not constitute the sole basis of acceptance, since all lubricants must be judged further on their satisfactory field performance in Harnischfeger Corporation equipment
Deleterious particles, ASTM D1404, Max. number of scratches
(1) The preferred grade is NLGI #2. However, an NLGI #1 or #0 may be required for proper dis-pensing at low temperatures, or by centralized lubrication systems. See section 7.3
(2) This is applicable for use only in centralized lubrication systems.
(3) Consult lubrication system component manufacturer regarding any deviations from this require-ment.
Table 16-12: Performance Requirements, Material Specification P&H 472
7.2 Relubrication volume and frequency can directly affect the performance of a lubricant and the economies of operation. Consult the equipment shop manual and lubricant supplier for the proper relubrication volume and fre-quency for each application.
7.3 The suitability of a lubricant is highly dependent upon environmental conditions. It is the consumer's responsi-bility to provide lubricant suppliers with the following:
7.3.1 Actual application and copy of this specification.
7.3.2 Environmental data - ambient temperature range and weather conditions.
7.3.3 Type of centralized lubrication system(s).
7.4 It is the responsibility of the consumer to verify that lubricants conform to applicable environmental and safety codes governing their use and disposal.
NOTICE
The preferred grade is a synthetic grade NLGI #1. A non-synthetic grade NLGI #2 is a suitablealternative. A non-synthetic NLGI #1 or #0 may be required for proper dispensing at low tem-peratures or by centralized lubrication systems. See Section 7.3
CAUTION Using incorrect lubricants can cause substantial equipment damage. The material spec-ifications listed in this manual are current at the time of publication, and are intended tobe used for reference only. Contact your local P&H MinePro Services representative forthe current specifications.
1.0 SCOPE
1.1 This specification covers premium gear oils produced from synthetic or semi-synthetic base stocks and com-pounded with extreme pressure additives for high load carrying ability.
1.1.1 Materials furnished to Issue No. 3 of this specification had a single flash point requirement whereas this issue now covers a variety of ambient temperatures.
1.2 Materials furnished under this specification are intended to lubricate gears, bushings, plain and rolling element bearings, sprockets, chain drives, and other components enclosed in oil-tight housings, and operating under high speed, high torque, high shock load, and/or high speed, low torque conditions. WARNING: Do not use oils contain-ing EP additives or other friction modifiers in applications containing internal mechanical load brakes, backstops or clutches. Additionally, certain EP formulations may not be compatible with bronze gears as found in worm gear cases.
1.3 Materials furnished under this specification may be used in sump (splash), circulating, or total-loss applications.
1.4 Materials furnished under this specification may be used as replacements for P&H specification 496 or 498 gear oils, when extremes in ambient temperatures require seasonal changes to different viscosities. Consult Har-nischfeger Corporate Engineering or Service prior to making such a substitution.
1.5 Materials furnished under this specification are intended for use in applications where MIL-L-2105 (latest issue) and/or API Service GL-5 gear oils are a requirement.
1.6 Materials furnished under this specification are not intended for use in applications where bulk oil operating temperatures routinely range from 77C/170F to 107C/225F.
2.0 REFERENCE DOCUMENTS
2.1 ASTM D92/ISO 2592 - Flash Point, COC Method
2.2 ASTM D97/ISO 3016 - Pour Point
2.3 ASTM D130/ISO 2160 - Copper Strip Corrosion Test
2.8 ASTM D2422/ISO 3448 - ISO Viscosity Classifications
2.9 ASTM D2711 - Demulsibility
2.10 ASTM D2782 - Timken EP Test
2.11 ASTM D2783 - Four Ball EP Test
2.12 ASTM D2893 - Oxidation Stability
2.13 DIN 51 354 - FZG Test
3.0 PHYSICAL CHARACTERISTICS
3.1 These gear oils must be formulated with full synthetic or semi-synthetic base fluids.
CAUTIONNumerous types of synthetic and semi-synthetic fluid formulations may be applicable tothis specification, some of which may be chemically incompatible. Therefore, to avoidequipment damage, different brands or types of synthetic or semi-synthetic fluidsshould not be intermixed such as during system top-off, without consulting the lubricantsupplier(s).
3.2 These lubricants may not contain viscosity or viscosity index enhancers that are subject to breakdown under extended shearing conditions.
3.3 These lubricants must have chemical and physical stability to maintain viscosity and performance characteris-tics throughout their intended service life.
3.4 Any EP or other friction modifiers used in the formulation of these lubricants must be fully oil soluble, and/or be in a stable colloidal suspension.
3.5 These materials shall meet applicable safety, health and environmental regulations.
4.0 P&H IDENTIFICATION NUMBER AND VISCOSITY GRADE
P&H No. 474A, ISO VG 32, AGMA 0 EPP&H No. 474B, ISO VG 46, AGMA 1 EPP&H No. 474C, ISO VG 68, AGMA 2 EPP&H No. 474D, ISO VG 100, AGMA 3 EPP&H No. 474E, ISO VG 150, AGMA 4 EPP&H No. 474F, ISO VG 220, AGMA 5 EPP&H No. 474G, ISO VG 320, AGMA 6 EPP&H No. 474H, ISO VG 460, AGMA 7 EPP&H No. 474I, ISO VG 680, AGMA 8 EPP&H No. 474J, ISO VG 1000, AGMA 8A EPP&H No. 474K, ISO VG 1500, AGMA 9 EP
(1) Esters having a lower viscosity index and meeting all other requirements of this specification may be used in specific applications where proper viscosity at operating temperature has been verified.
(2) Polyglycols which will not pass the demulsibility test, but meet all other requirements of this specification, may be used in specific applications where there is no danger of water contamination.
6.0 IDENTIFICATION AND PACKAGING
6.1 Containers must be clearly identified by the supplier with the following information:
6.1.1 Purchase Order Number
6.1.2 Supplier's Name and Product Trade Name
6.1.3 P&H Material Specification Number followed by a letter which will indicate a particular viscosity grade in accordance with the following:
6.1.3.1 P&H No. 474A, ISO VG 32, AGMA 0 EP
6.1.3.2 P&H No. 474B, ISO VG 46, AGMA 1 EP
6.1.3.3 P&H No. 474C, ISO VG 68, AGMA 2 EP
6.1.3.4 P&H No. 474D, ISO VG 100, AGMA 3 EP
6.1.3.5 P&H No. 474E, ISO VG 150, AGMA 4 EP
6.1.3.6 P&H No. 474F, ISO VG 220, AGMA 5 EP
6.1.3.7 P&H No. 474G, ISO VG 320, AGMA 6 EP
Demulsibility,
ASTM D2711
Must be within these lim-its: (2)
Max % water in oil after 5 hr test
1.0
Max cuff after centrifug-ing
2.0 ml
Min total free water col-lected during entire test (start with 90 ml water)
60.0 ml
Four ball EP test, ASTM D2783
Weld load, Min. kgfLoad wear index, Min.
kgf
250
55
Timken EP test, ASTM D2782
Min. OK value, kg/lbs 27/60
FZG test, DIN 51 354 with A/8.3/90C
parameters, Min. fail stage > 12
Table 16-14: Additional Performance Requirements, Material Specification P&H 474
6.1.4 Material Safety Data Sheet (MSDS) - One (1) with each shipment.
6.2 The lubricant furnished under this specification shall be supplied in clean containers of the size(s) as specified on the purchase order.
7.0 INSPECTION AT PURCHASER'S WORKS
7.1 Acceptance of material furnished under this specification shall be subjected to confirmation by customer's Quality Assurance Department.
7.2 The purchaser shall have the option of accepting or rejecting any material failing to meet the requirements of this specification.
8.0 ADDITIONAL CRITERIA OF ACCEPTANCE
8.1 Conformance to all specified requirements shall not constitute the sole basis of acceptance, since all lubricants must be judged further on their satisfactory field performance in Harnischfeger Corporation equipment.
8.2 Lubricant change frequency, or relubrication volume and frequency, can directly affect the performance of a lubricant and the economies of operation. Consult the equipment shop manual, and lubricant supplier for the proper change frequency, or relubrication volume and frequency, for each application.
8.3 The suitability of a lubricant is highly dependent upon environmental conditions. It is the consumer's responsi-bility to provide lubricant suppliers with the following:
8.3.1 Actual application and copy of this specification.
8.3.2 Environmental data - ambient temperature range and weather conditions.
8.3.3 Type of centralized lubrication system(s), including pump, filtration and reservoir data, when applicable.
8.4 It is the responsibility of the consumer to verify that lubricants conform to applicable environmental and safety codes governing their use and disposal.
Gear Oil - Single Viscosity Grade, Extreme Pressure (EP)
Ver 07, 02-93
CAUTIONUsing incorrect lubricants can cause substantial equipment damage. The material speci-fications listed in this manual are current at the time of publication, and are intended tobe used for reference only. Contact your local P&H MinePro Services representative forthe current specifications.
1.0 SCOPE
1.1 This specification covers premium single grade gear oils produced from refined mineral oil base stocks, and compounded with extreme pressure additives for high load carrying ability. Synthetic lubricants are not covered in this specification.
1.2 Materials furnished under this specification are intended to lubricate gears, bushings, plain and rolling element bearings, sprockets, chain drives and other components enclosed in oil-tight housings, and operating under high speed, high torque, high shock load, and/or high speed, low torque conditions.
WARNING!
Use of oils containing EP additives or other friction modifiers in applications containinginternal mechanical load brakes, backstops or clutches could cause equipment failure,resulting in death or severe personal injury. Do not use oils containing EP additives orother friction modifiers in applications containing internal mechanical load brakes, back-stops or clutches. Additionally, certain EP formulations may not be compatible withbronze gears as found in worm gear cases.
1.3 Materials furnished under this specification may be used in sump (splash) circulating, or total loss applications.
1.4 When extremes in ambient temperatures may dictate seasonal changes to different viscosity grades, or where MIL-L-2105 oils are required, P&H specification 496 or 498 gear oils may be suitable substitutions for these single grade EP gear oils. Consult Harnischfeger Corporation Engineering or Service prior to making such a substitution.
1.5 The designations 497A and 497B are being reserved for lighter viscosities than ISO VG 68 if required in the future. P&H 497A, B, and C from Issue No. 6 do not match the same designations in this specification.
1.6 Materials furnished under this specification are not intended for use in applications where MIL-L-2105 (latest issues), and/or API Service GL-5 gear oils are a requirement.
2.6 ASTM D665/ISO 7120, Latest Issue: Rust Test2.7 ASTM D2270/ISO 2909, Latest Issue: Viscosity Index2.8 ASTM D2422/ISO 3449, Latest Issue: ISO Viscosity Classifications2.9 ASTM D2711, Latest Issue: Demulsibility2.10 ASTM D2782, Latest Issue: Timken EP Test2.11 ASTM D2783, Latest Issue: Four Ball EP Test2.12 ASTM D2893, Latest Issue: Oxidation Stability2.13 DIN 51 354, Latest Issue: FZG Test
3.0 PHYSICAL CHARACTERISTICS
3.1 These gear oils must be manufactured from highly refined mineral oil base stocks.
3.2 These lubricants may not contain viscosity or viscosity index enhancers that are subject to breakdown under extended shearing conditions.
3.3 These lubricants must have chemical and physical stability to maintain viscosity, and performance characteris-tics throughout their intended service life.
3.4 Any EP or other friction modifiers used in the formulation of these lubricants must be fully oil soluble, and/or be in a stable colloidal suspension.
3.5 These materials shall meet applicable safety, health and environmental regulations.
6.1.4 Material Safety Data Sheet (MSDS) - One (1) with each shipment
6.2 The lubricant furnished under this specification shall be supplied in clean containers of the size(s) as specified on the purchase order.
7.0 INSPECTION AT PURCHASER'S WORKS
7.1 Acceptance of material furnished under this specification shall be subjected to confirmation by purchaser's Quality Assurance Department.
7.2 The purchaser shall have the option of accepting or rejecting any material failing to meet the requirements of this specification.
8.0 ADDITIONAL CRITERIA OF ACCEPTANCE
8.1 Conformance to all specified requirements shall not constitute the sole basis of acceptance, since all lubricants must be judged further on their satisfactory field performance in Harnischfeger Corporation equipment.
8.2 Lubricant change frequency, or relubrication volume and frequency, can directly affect the performance of a lubricant and the economies of operation. Consult the equipment shop manual, and with the lubricant supplier for the proper change frequency, or relubrication volume and frequency, for each application.
8.3 The suitability of a lubricant is highly dependent upon environmental conditions. It is the consumer's responsi-bility to provide lubricant suppliers with the following:
8.3.1 Actual application and copy of this specification.
8.3.2 Environmental data - ambient temperature range and weather conditions.
8.3.3 Type of centralized lubrication system(s), including pump, filtration and reservoir data, when applicable.
8.4 It is the responsibility of the consumer to verify that lubricants conform to applicable environmental and safety codes governing their use and disposal.
CAUTIONUsing incorrect lubricants can cause substantial equipment damage. The material speci-fications listed in this manual are current at the time of publication, and are intended tobe used for reference only. Contact your local P&H MinePro Services representative forthe current specifications.
1.0 SCOPE
1.1 This specification covers a petroleum resistant sealing compound properly formulated to have oil sealant quali-ties.
2.0 APPLICATION
2.1 This sealing grease is intended for use in certain applications which require the use of a suitable sealant.
2.2 This sealing grease is primarily used as an oil seal on shafts, hubs and other keyway assemblies. The com-pound need not serve primarily as a lubricant but should not interfere with lubrication.
2.3 This sealing grease may also be used in other applications (as an oil seal) that are satisfied by a compound of this type.
3.0 PHYSICAL PROPERTIES
3.1 The material furnished under this specification shall conform to the following characteristics, requirements and conditions:
3.1.1 Insoluble in petroleum oil and petroleum by-products.
3.1.2 Have shelf life in excess of one year.
3.1.3 Must retain insolubility and exhibit no dispersal in mineral oil when in contact with agitated or flowing oil within a temperature range of -20oF to +225oF.
3.1.4 Must retain the properties of a high viscosity paste without hardening in application to machinery with rotating parts and adjacent moving surfaces.
3.2 The above mentioned properties are not a complete description of the product required and stated only as ref-erence material for descriptive purposes. Conformance to the physical properties shall not constitute the sole basis of acceptance or application.
4.0 GENERAL INFORMATION
4.1 The accepted symbol used in the petroleum products industry to designate this standard is S.C.
5.1 Sealing grease used for this purpose shall be supplied in cartons containing clean, one pound cans; unless oth-erwise specified on the Purchase Order.
6.0 IDENTIFICATION
6.1 Containers must be clearly identified by the supplier with the following information:
6.1.1 Purchase Order Number
6.1.2 Supplier's Name and Trade Name
6.1.3 P&H Material Specification Number
7.0 REJECTION
7.1 The purchaser shall have the option of accepting or rejecting material that fails to meet any of the requirements of this specification.
8.0 SUPPLIERS AND TRADE NAMES
8.1 General Electric Supply Co.G.E. Sealing Grease D6AD2
CAUTION Using incorrect lubricants can cause substantial equipment damage. The materialspecifications listed in this manual are current at the time of publication, and areintended to be used for reference only. Contact your local P&H MinePro Services repre-sentative for the current specifications.
1.0 SCOPE
1.1 Multi service lubricants specified herein are partially or fully synthetic premium quality semifluid EP greases or polymer/gel thickened which are specifically formulated to provide the necessary load carrying and wear resisting characteristics required in a variety of applications found in large surface mining equipment in continuous opera-tion.
1.2 These lubricants are intended to lubricate open gears, racks, bushings, rails, rollers, handles, walk mecha-nisms, multi-row slewing bearings, and low to moderate speed plane and rolling element bearings. These applica-tions are subject to extreme contact pressures reversing loads that may dwell at zero velocity while loaded, gear peripheral speeds over 2000 feet per minute/610 meters per minute, and bearing speeds approaching 1000 rpm.
1.3 Lubricants furnished under this specification are intended to be dispensed intermittently from centralized lubri-cation systems of the single line parallel, single line progressive, and/or dual line progressive construction at the ambient operational temperature at which the equipment operates.
1.4 Lubricants furnished under this specification are not intended to lubricate electric motor bearings, Magna-torque® clutches, and other applications where there may be service requirements of the lubricant that differ from or are beyond those described in this specification. Depending upon the consistency of semi-fluid products, they may not be appropriate for use in couplings or with labyrinth seals.
2.0 REFERENCE DOCUMENTS
2.1 ASTM D92/ISO 2592 - Flash Point, COC Method
2.2 ASTM D445/ISO 3104/D2161 - Standard Test Method for Kinematic Viscosity
2.9 US Steel Lubrication Manual - Grease Mobility Test
2.10 US Steel Lubrication Manual - Timken Retention Test
2.11 US Steel Lubrication Manual - Lincoln Ventmeter Test
3.0 PHYSICAL CHARACTERISTICS
3.1 Multi service lubricants specified herein must have the necessary adhesive and cohesive properties to resist chipping, throw off, and run off, and provide the necessary film thickness and lubricating properties to prevent metal to metal contact between application intervals under all operating conditions.
3.2 These lubricants must be specifically formulated to protect surfaces from wear, have excellent water resisting and rust preventing properties, and have the necessary properties to provide exceptional service life of the compo-nents which they lubricate under all operating conditions.
3.3 Multi service lubricants specified herein must be dispensable through the distribution lines of a centralized lubri-cation system to the most remote application point at the lowest anticipated operating temperature. They must not plate or plug components of the centralized lubrication system such as injectors, metering blocks, lines, or spray nozzles.
3.4 When a lubricant furnished under this specification is formulated with a diluent to improve dispensibility, the lubricant must meet the performance requirements of section 4.0 both before and after the diluent has evaporated.
3.5 Materials specified herein must meet the performance requirements of section 4.0 when tested with samples taken from production batches of the lubricant.
3.6 Materials specified herein shall meet all applicable safety, health, and environmental regulations.
* Note for diluent containing lubricants: Although the flashpoint requirement applies to the mixture of diluent and lubricant, it should be noted that the flashpoint of a diluent alone (i.e. the flashpoint of the diluent when it is not mixed with the lubricant) may be considerably lower than the flashpoint of the mixture of lubricant and diluent.
** Note: While 300 cSt is the minimum viscosity required for most climates, it may be necessary to formulate prod-ucts with slightly lower base oil viscosity for use in arctic conditions. In such cases, these products should only be applied within their intended temperature range.
5.0 IDENTIFICATION AND PACKAGING
5.1 Containers must be clearly marked by the supplier with the product name and, if appropriate, the grade (i.e. “arctic”, “heavy”, “summer”, etc.)
5.2 Identification must remain legible upon outdoor storage of the containers.
5.3 If appropriate, a shelf life should be clearly marked on the container.
5.4 Any special considerations regarding the storage of the product such as protection of container openings, elim-ination of water build up, etc. should be clearly communicated to the end user.
5.5 Material Safety Data Sheets (MSDS) must be supplied to the end user for each product delivered.
6.0 ADDITIONAL CRITERIA OF ACCEPTANCE
Property Test Method Requirement
Flash point ASTM D92/ISO 2592 130°C (266°F) minimum*
6.1 Conformance to all specified requirements shall not constitute the sole basis of acceptance since all lubricants must be judged further on their satisfactory field performance on the type and model equipment which they are intended to lubricate.
6.2 Relubrication volume and frequency can directly affect the performance of a lubricant and the economies of operation. Consult the equipment shop manual and lubricant supplier for the relubrication volume and frequency for each application.
6.3 The suitability of a lubricant is highly dependent upon environmental conditions. It is the consumer’s responsi-bility to provide the lubricant supplier(s) with the appropriate application data, material specification(s), environ-mental data such as temperature and weather conditions, and type of centralized lubrication system.
6.4 It is the responsibility of the consumer to verify that lubricants conform to applicable environmental and safety codes governing their use and disposal.
BD120149 Mechanical Systems Manual Preventive Maintenance
Section 17
Preventive Maintenance
17.1 General
This section outlines the maintenance procedures that should be performed on the drill at regular intervals to ensure optimum performance. Each maintenance item is listed in one of the maintenance check sheets provided in this section. Specific descriptions of each maintenance or lubrication item are provided. Use these descriptions in conjunction with the maintenance check sheets to ensure that each item is performed at the prescribed time inter-val.
17.2 Lubrication
Preventive Maintenance means performing inspections and services that are necessary to keep the drill operating at peak performance. Lubrication is an essential component of Preventive Maintenance. The breakdown of lubrica-tion services that must be performed are covered in detail in Section 16, Lubrication., and there are lubrication ser-vice checklists starting at Topic 16.7. Those procedures are incorporated in the recommended Preventive Maintenance procedures by reference.
17.3 Bolt Lubrication
Unless otherwise specified, all capscrews, bolts, and nuts used to secure or attach major components and assem-blies should be lubricated with an anti-seize thread lubricant when repairs or replacements are made. Lubricant should be applied to the threads of fasteners and to the friction-bearing surface of bolt heads, nuts, and washers. Additionally, the threaded connections of all drill pipe joints, rotary head coupling- to-pipe, and drill bit-to-stabilizer connections must be lubricated with a silicone thread lubricant.
17.4 Bolts And Bolt Torques
Recommended bolt torques are listed in Tables 17-1, through 17-3. Unless otherwise specified, these torque val-ues apply to all component mounting bolts that attach structural members of all machinery. At least bi-annually, all mounting and attachment bolts and capscrews should be checked using a torque wrench to ensure compliance with Table 17-1. Heavy duty mounting hardware as described in this manual is equivalent to SAE grade 5 hardware or equal. English to metric conversion factors are presented in Table 17-2.
Preventive Maintenance BD120149 Mechanical Systems Manual
C
17.4.1 Bolt Torques -- American Standard Coarse Thread Screw, Stud,
or BoltDiameter(inches)
Grade 2(ft.-lbs)
Studsonly
Grade 4(ft.-lbs)
Grade 5(ft.-lbs)
Grade 7(ft.-lbs)
Grade 8(ft.-lbs)
oarse ThreadsUNC & 8UNC
1/4 6 10 9 11 12
5/16 11 20 17 21 25
3/8 20 36 31 38 44
7/16 32 58 50 61 70
1/2 49 90 75 93 106
9/16 70 130 109 135 154
5/8 97 180 150 185 212
3/4 172 315 266 330 380
7/8 170 505 430 530 610
1 250 760 650 800 910
1-1/8 355 1,075 800 1,130 1,290
1-1/4 500 1,520 1,120 1,590 1,820
1-3/8 660 1,990 1,470 2,090 2,390
1-1/2 870 2,640 1,950 2,770 3,160
1-3/4 1,370 4,160 3,080 4,370 49,90
2 2,060 6,250 4,630 6,570 7,500
2-1/4 3,020 9,140 6,770 9,600 10,970
2-1/2 4,130 12,500 9,250 13,130 15,000
2-3/4 5,590 16,950 12,540 17,800 20,400
3 7,390 22,390 16,570 23,500 26,900
3-1/4 9,520 28,850 21,350 30,290 34,600
3-1/2 12,030 36,450 26,970 38,300 43,800
3-3/4 14,940 45,300 33,500 47,600 54,400
4 18,280 55,400 41,000 58,200 66,500
The above values assume dry “As Received” threads. The use of thread lubricant (oil, grease, etc.) will lower recommended torque values by approximately 25%. Type of lubricant used can cause significant variation.
Table 17-1: Recommended Torque Values for American Standard Threads (Coarse Threads)
BD120149 Mechanical Systems Manual Preventive Maintenance
17.4.2 Bolt Torques -- American Standard Fine Thread Screw, Stud,
or BoltDiameter(inches)
Grade 2(ft.-lbs)
Studsonly
Grade 4(ft.-lbs)
Grade 5(ft.-lbs)
Grade 7(ft.-lbs)
Grade 8(ft.-lbs)
Coarse ThreadsUNC & 8UNC
1/4 6 11 9 11 13
5/16 12 22 18 23 26
3/8 22 39 33 41 47
7/16 34 62 52 65 74
1/2 53 95 81 100 114
9/16 75 136 115 142 163
5/8 105 190 162 200 228
3/4 183 332 282 350 400
7/8 180 530 450 560 635
1 260 790 670 830 945
1-1/8 380 1,150 850 1,200 1,380
1-1/4 525 1,600 1,180 1,680 1,910
1-3/8 710 2,150 1,590 2,260 2,580
1-1/2 930 2,820 2,090 2,960 3,380
1-3/4 1,500 4,540 3,360 4,770 5,450
2 2,270 6,860 5,080 7,210 8,240
2-1/4 3,260 9,860 7,300 10,360 11,830
2-1/2 4,500 13,630 10,100 14,310 16,360
2-3/4 6,030 18,260 13,500 19,170 21,910
3 7,860 23,800 17,600 25,010 28,600
3-1/4 10,040 30,400 22,500 32,000 36,500
3-1/2 12,600 38,200 28,200 40,100 45,800
3-3/4 15,500 47,100 34,800 49,400 56,500
4 18,900 57,300 42,400 60,100 68,700
The above values assume dry “As Received” threads. The use of thread lubricant (oil, grease, etc.) will lower recommended torque values by approximately 25%. Type of lubricant used can cause significant variation.
Table 17-2: Recommended Torque Values for American Standard Threads (Fine Threads)
BD120149 Mechanical Systems Manual Preventive Maintenance
17.4.5 Special Bolt Tightening Requirements
Any special bolt tightening requirements that differ from standard torque values are identified within the appropriate assembly and installation instructions of this manual.
17.5 Maintenance Schedule Check Sheets
The actual operating environment of the drill governs the maintenance schedule. The check sheets on the follow-ing pages indicate the areas of the drill to be checked and the suggested intervals at which they should be checked. The order in which the items are listed is suggested only and does not constitute the order of perfor-mance. Maintenance items may be performed in any order desired within a given time interval.
The following suggested schedule check sheets are based on average operating conditions. The type of work being done, the type and hardness of the materials being drilled, and the ground and weather conditions are all factors that must be considered when establishing a maintenance schedule for this drill. The suggested schedule is given for hours of operation and calendar intervals.
Any changes in the established schedule check sheets should be preceded by a complete re-evaluation of drill operation. Carefully study previous maintenance check sheets and records before making changes in, or extend-ing, the maintenance check intervals.
17.6 Using The Maintenance Schedule Check Sheets
The maintenance schedule check sheets are designed as a preventive maintenance guide until adequate experi-ence is obtained to establish a schedule to meet a specific operating environment and machine. Detailed proce-dures for each check sheet operation are provided following the check sheets. The check sheets can be reproduced on any copy machine.
Maintenance personnel should indicate on the sheet that the required check has been completed, and that the drill will be ready for continued operation until the next scheduled check is due. Completed check sheets should be retained as a permanent part of the drill maintenance records for future reference.
.The following topics describe the maintenance procedures to be performed on this blasthole drill. Each topic cov-ers a specific time period. Detailed maintenance instructions are provided for the individual lubrication and service points listed on the corresponding maintenance check sheets. The maintenance person may use the following pro-cedures in conjunction with the maintenance check sheets to ensure that all service and lubrication points are cor-rectly serviced at the appropriate time interval. The lubrication charts and figures shown in the Lubrication Section provide general locations of the individual service points and list the type of lubricant which should be used for each component. Refer to these charts for the location of lubrication points on this drill. The location of service points other than lubrication points are described in the following paragraphs as applicable.
Unexpected machine movement can cause severe personal injury or death. Shut downthe machine before performing inspections, service or maintenance. Establish a proce-dure to guard against inadvertent equipment operation or movement while conductinginspections. Use lockout and tagout procedures prior to conducting maintenance or service.
√ ITEMS TO BE VERIFIED REF COMMENTS
Note and record any faults on the GUI Fault Log Subsec-tion 17.7.1
Fill water tank Subsec-tion 17.7.2
Inspect machine for damage and leaks Subsec-tion 17.7.3
Unexpected machine movement can cause severe personal injury or death. Shut downthe machine before performing inspections, service or maintenance. Establish a proce-dure to guard against inadvertent equipment operation or movement while conductinginspections. Use lockout and tagout procedures prior to conducting maintenance or service.
Unexpected machine movement can cause severe personal injury or death. Shut downthe machine before performing inspections, service or maintenance. Establish a proce-dure to guard against inadvertent equipment operation or movement while conductinginspections. Use lockout and tagout procedures prior to conducting maintenance or service.
√ ITEMS TO BE VERIFIED REF COMMENTS
Perform “A” Maintenance Checks
Inspect hydraulic system components Subsec-tion 17.8.1
Check Cable Reel Oil Level Subsec-tion 17.8.2
Inspect Breakout Wrench Subsec-tion 17.8.3
Inspect Mast Racks and Pinions Subsec-tion 17.8.4
Inspect Rotary Machinery Subsec-tion 17.8.5
Inspect Bailing Air System Components Subsec-tion 17.8.6
Unexpected machine movement can cause severe personal injury or death. Shut downthe machine before performing inspections, service or maintenance. Establish a proce-dure to guard against inadvertent equipment operation or movement while conductinginspections. Use lockout and tagout procedures prior to conducting maintenance or service.
Unexpected machine movement can cause severe personal injury or death. Shut downthe machine before performing inspections, service or maintenance. Establish a proce-dure to guard against inadvertent equipment operation or movement while conductinginspections. Use lockout and tagout procedures prior to conducting maintenance or service.
√ ITEMS TO BE VERIFIED REF COMMENTS
Repeat “a” and “b” maintenance checks
Inspect mast back braces and slides Subsec-tion 17.9.1
Inspect mast Subsec-tion 17.9.2
Inspect auxiliary winch sheave Subsec-tion 17.9.3
Clean main compressor and hydraulic oil cooler Subsec-tion 17.9.4
Unexpected machine movement can cause severe personal injury or death. Shut downthe machine before performing inspections, service or maintenance. Establish a proce-dure to guard against inadvertent equipment operation or movement while conductinginspections. Use lockout and tagout procedures prior to conducting maintenance or service.
Preventive Maintenance BD120149 Mechanical Systems Manual
17.7 “A” Maintenance Checks
The “A” Maintenance Checks should be performed daily, or at the beginning of each work shift. Park the drill on level ground or use the jacks to level the drill prior to the inspection. If an item is found to be incorrect, the problem must be corrected prior to start-up to ensure satisfactory operation of the drill.
17.7.1 Note and Record Any Faults on GUI Fault Log
The Graphical User Interface (GUI) provides a fault log that indicates conditions that need attention. To access the GUI fault log, proceed as follows:
Touch the MAINTENANCE block on the GUI Main Page (Figure 17-3)
Preventive Maintenance BD120149 Mechanical Systems Manual
17.7.2 Fill Water Tank
The optional water tank is located on a platform at the left, rear outer side of the drill. At the start of each work shift or after each 8 hours of operation, fill the tank with water. The tank should be filled to approximately 1 inch (25 cm) from the bottom lip of the access cover.
17.7.3 Inspect Machine For Damage And Leaks
Make a complete and thorough visual inspection of the mast, jacks, lower frame, and underside of the drill, looking for leaks, loose connections, or any other unsatisfactory conditions. Ensure that problems found during inspection are corrected prior to continued drill operation. If repairs are necessary, refer to the applicable section of this man-ual, for detailed instructions. Additional specific inspection procedures are outlined elsewhere in this manual for various time intervals. This topic is intended to locate potentially hazardous conditions before they result in equip-ment damage or personal injury.
17.7.3.1 lnspect Air Lines For Leaks
Visually inspect each air system hose and pipe for leaks, abrasion, damage, kinks, or other signs of wear or decay. Report any problems. Damaged hoses and piping must be replaced prior to continued operation of the drill.
17.7.3.2 lnspect Hoses And Hydraulic Lines
Visually inspect each hydraulic and lubrication hose, and tubing for abrasion, damage, kinks, or other signs of wear or decay. Report any problems which are found. Damaged hoses and piping must be replaced prior to continued operation of the drill.
17.7.3.3 lnspect Hydraulic Fittings For Leaks
Refer to Appendix B and inspect all hydraulic and lubrication connections as described, and if necessary use the appropriate tightening sequence to secure the connection.
17.7.3.4 lnspect Dust Curtain
Weekly, or every 40 hours of operation, inspect the condition of the dust curtain. Visually inspect the curtain for damage caused by flying rocks and debris. Operate the dust curtain through a full cycle to ensure that it operates correctly. Repair or replace damaged dust curtains prior to continued drill operation.
17.7.4 Check Hydraulic Tank Oil Level
The hydraulic tank is located in the lubrication room on the right front corner of the machine. With the drill on level ground, check the oil level by reading the oil level sight glass, located on the side of the tank. The legend along side of the sight glass indicates the correct minimum and maximum permissible oil levels for the following positions of the mast and drill leveling jacks:
BD120149 Mechanical Systems Manual Preventive Maintenance
MIN. MAST UP AND JACKS RETRACTED
MIN. MAST DOWN AND JACKS EXTENDED
MIN. MAST UP AND JACKS EXTENDED
CAUTIONAdding unfiltered oil can introduce contaminants that can damage the hydraulic systemand its components. Always filter oil that is added to the hydraulic tank.
Fill the hydraulic oil tank as needed, using either the Wiggins Quick Fill system or by adding filtered oil directly to the hydraulic tank. Refer to Topic 16.5.
NOTICE
P&H Mining Equipment recommends that a sample of oil be drawn from the hydraulic tank atleast annually. The sample should be about two quarts and should be taken when the oil iswarmed through normal operation. The sample should be analyzed by a qualified lubricationspecialist to determine whether it is suitable for continued use. The interval between oilchanges depends upon operating conditions, on the care used in the handling of oils, andcleanliness during the handling process.
BD120149 Mechanical Systems Manual Preventive Maintenance
17.7.5 Check Main Air Compressor Oil Reservoir Level
The main air compressor oil reservoir (T-Tank) contains the lubricant for the compressor components, including the screws, bearings, and gears. The reservoir is located on a platform on the left side of the drill, outside the machin-ery house. Check the oil level in the main air compressor oil reservoir as follows:
1. With the drill parked on level ground, check the reservoir oil level at the sight glass on the reservoir T-tank.
CAUTIONOperating the air compressor with insufficient oil can cause severe damage to the com-pressor lobes. Never operate the main air compressor when the oil level is below theLOW mark. Add oil of the type specified in the Lubrication Section any time the oil levelfalls below the LOW mark.
2. Wait for the main air system pressure to completely vent through the muffler.
Preventive Maintenance BD120149 Mechanical Systems Manual
CAUTION!
Pressurized oil will spray with extreme force from the reservoir when opening the fillerplug and can cause severe injury. Shut down the air compressor and allow air pressurevent before opening the filler plug. Wear appropriate face, ear, and body protectivedevices while venting the main air system and/or opening the filler plug.
3. Add oil to the main compressor oil tank by opening the filler plug, located on top of the tank. Add oil to the full mark on the sight gauge. Use the type specified in the Lubrication Section.
4. Install the filler plug. Use pipe thread sealant and tighten securely to prevent leakage.
17.7.6 lnspect Operator Cab Air Filter
The operator cab is pressurized with filtered air for operator comfort. To ensure that air entering the operator cab is satisfactorily filtered, the filter assembly must be visually inspected on a daily basis.
• Visually inspect the operator cab air filters in the machinery house for dirt and contamination. If the filters are fitted with a restriction indicator, visually check the indicator. When the indicator or visual inspection reveals the need to change the filters, install a new filters.
• Visually inspect the air recirculation filter behind the panel in the ceiling of the operator’s cab. Replace the fil-ter when it has accumulated a thin layer of dust.
17.7.7 lnspect Drill Pipe Sling
The pipe sling is located approximately half-way up the mast. It is a rigid structural framework and cable that serves to catch a loose pipe section and keep it from falling free of the mast should it separate from the rotary head coupling. Visually inspect the pipe sling components for damage, cracks, or missing hardware. All mounting hard-ware should be properly torqued. Replace any damaged or missing sections and/or hardware.
17.7.8 lnspect Auxiliary Winch Rope
The auxiliary winch used to raise and lower tools on the mast assembly utilizes a steel wire rope. Care of this wire rope is critical to the safe operation of the winch. Visually inspect the wire rope using the following procedure:
17.7.8.1 Daily Inspection
Visually inspect the winch rope at the start of each shift. This inspection is general, for the purpose of discovering gross damage, such as:
• Distortion
• Corrosion
• Broken or cut strands.
• Excessive broken wires.
Presence of these conditions will prompt further inspection or rope replacement.
BD120149 Mechanical Systems Manual Preventive Maintenance
17.7.8.2 250-Hour Inspection
A periodic detailed rope inspection will show damage over the entire rope. All individual outer wires in the strands of the rope are inspected, and any deterioration resulting in significant loss of original strength will be a factor in determining whether further use of the rope would constitute a hazard.
A full written report of rope condition should be made by the inspector. This report must be dated, signed, and kept on file where it is readily available to designated personnel.
The monthly inspection should be aimed at determining the degree of deterioration at the worst lay, since this will determine the suitability for continued service. By definition, a rope lay is the axial distance along the rope in which one strand makes one complete turn around the rope. These visual observations should be concerned with discov-ering damage, such as listed below:
1. Reduction of rope diameter below normal due to loss of core support, internal or external corrosion or wear of outside wires.
2. A number of broken outside wires and the degree of distribution or concentration of such broken wires.
3. Worn outside wires.
4. Corroded or broken wires at the end connections
5. Corroded, cracked, bent, worn, or improperly applied end connections.
6. Distortion of the rope, such as kinking, crushing, unstranding, birdcaging, main strand displacement, or core protrusion.
7. Evidence of improper lubrication. When such damage is discovered, the rope should be removed from service and replaced.
17.7.9 lnspect Winch
The winch is mounted inside the machinery house at the base of the mast, and is used for hoisting of drill pipe, drill bits, and other accessory tools and equipment. At the beginning of every shift, inspect the winch for loose mounting hardware, frame cracks, loose or leaking hydraulic hoses and fittings, and incorrectly spooled cable. Also confirm that the cable clamps attaching the hook to the cable are securely tightened.
17.7.10 Check Rotary Gearcase Oil Level
The rotary gearcase is mounted to the lower end of the rotary carriage. This double-reduction gear reducer drives the rotary head coupling, the drill bit, and the pipe string. Use the following procedure to check the rotary gearcase oil level at the start of each shift, or each 8 hours of operation (see Figure 17-3):
1. With the mast in the vertical position, lower the rotary carriage to the bottom of the mast and shut down opera-tion of the drill.
WARNING!
Inadvertent machine movement can cause injury or death. Do not perform maintenancework on a machine without first disabling the operator controls. Lock out and tag theoperator controls to prevent inadvertent machine start-up during maintenance.
Preventive Maintenance BD120149 Mechanical Systems Manual
2. Lock out and tag the operator controls to prevent inadvertent start-up of the machinery. Follow the lockout and tagout procedures outlined at the front of this manual.
3. Ensure that the machine is level, or as near level as possible. Check the oil level by inspecting the dipstick, located on the top surface of the rotary gearcase.
CAUTIONOperating the rotary machinery when the rotary gear case has been overfilled with oilwill cause overheating and will damage gearcase components. Never operate the rotarygearcase when the oil level is below the LOW level or above the FULL level.
BD120149 Mechanical Systems Manual Preventive Maintenance
4. .The oil level must be maintained between the upper and lower windows in the sight glass. Add oil of the type
specified in the Section 16, Lubrication. through the vent pipe on top of the gearcase housing.
5. Recheck the oil level after adding oil. If oil appears in the upper sight glass, drain enough oil from the gearcase to maintain the oil level between the upper and lower sight glasses.
6. Securely reinstall the vent cap.
Figure 17-8: Rotary Carriage
BD0870b01
01
02
LEGEND01. Inspection Cover with Breather: Fill gear
case through this port.
02. Oil Level Sight Gauge: Oil should appear to fill the lower glass; the upper glass should appear empty.
Preventive Maintenance BD120149 Mechanical Systems Manual
17.7.11 Check Pulldown Gearcase Oil Level
The pulldown gearcase is mounted at the upper level of the rotary carriage assembly. The torque output from this gear reducer drives the rotary carriage assembly up and down the mast. Use the following procedure to check the pulldown gearcase oil level at the start of each shift, or after each 8 hours of operation (see Figure 17-3):
1. Lower the rotary carriage to the bottom of the mast, and shut down operation of the drill.
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine startup during maintenance.
2. Lock out and tag the operator controls to prevent inadvertent start-up of the machinery. Follow the lockout and tagout procedures outlined at the front of this manual.
3. Ensure that the drill is level, or as nearly level as possible. View the oil level on the sight gauge located on the right rear side of the pulldown gearcase.
CAUTIONOperating the pulldown gearcase after it has been overfilled with oil will cause overheat-ing and will damage gearcase components. Never operate the pulldown gearcase whenthe oil level is either below the LOW level or above the FULL level on the sight gauge.
4. The oil level must be maintained between the LOW and FULL level markings on the sight gauge. As neces-sary, add oil of the type specified in Section 16, Lubrication. through the breather on top of the pulldown gear-case housing. Use care to avoid over-filling of the gearcase.
5. Apply pipe thread sealant to the male threads of the breather pipe, and install the breather pipe securely.
6. The hydraulic oil supply to operate the autolube grease pump comes from the low-pressure hydraulic system. Pressure is limited by a pressure reducing valve (the bottom valve in the first stack on the low pressure hydrau-lic valve bank). Check the pressure to confirm that the pressure is set at 220 psig (15.2 bar). The oil supply pressure gauge is located near the grease pump on top of the grease supply reservoir.
17.7.13 lnspect Deck Wrenches
1. Inspect the pawls, bodies, and housings for cracks, wear, corrosion, and distortion.
2. Check for broken or weak springs.
3. Check for worn, broken, or missing hardware items.
4. Check the hydraulic and lubrication hoses and fittings for wear and leaks.
BD120149 Mechanical Systems Manual Preventive Maintenance
6. Refer to the Pipe Handling Section for repair procedures.
17.7.14 Inspect Pipe Racks
To ensure safe and satisfactory pipe rack operation, and correct positioning of the drill pipes, inspect the condition of each pipe rack weekly.
1. Before shutting down the drill, move the pipe racks in and out to confirm correct operation.
2. Lower the mast and shut down operation of the drill.
17.7.15 Inspect Crawler
1. Check for cracked or broken shoes
2. Check for excessively worn upper or lower rollers
3. Check both axles for wear, cracks, and loose or damaged mounting hardware
4. Check for smooth mesh between shoe and tumbler lugs
17.7.16 lnspect Jack Shoes And Retaining Pins
The leveling capability and stability of the drill depends on the integrity of the jack shoe assemblies. Inspect these assemblies weekly for cracked gussets, loose or broken retainer pin, and missing retainer pin capscrew and lock-washer.
17.8 “B” Maintenance Checks
The “B” Maintenance Checks should be performed every week, or after 100 hours of operation, whichever occurs first. If an item is checked and found to be incorrect, the problem must be corrected prior to machine start-up to ensure satisfactory operation of the drill. Refer to the maintenance check sheets and complete all “A” Maintenance Checks before proceeding with the “B” Maintenance Checks.
17.8.1 lnspect Hydraulic System Components
Visually inspect each hydraulic component for damage and leaks. Operate each control valve and solenoid and check for correct component operation. Repair or replace any damaged or malfunctioning hydraulic component. Inspect, but do not limit the inspection to the following components:
Preventive Maintenance BD120149 Mechanical Systems Manual
• Cylinders, pins, and bushings.
• Hydraulic motors.
17.8.2 Check Cable Reel Drive Reducer Oil Levels
The trail cable reel (optional equipment) is mounted across the front of the drill and stores the trail cable. The cable reel is driven through the use of gear reducers, driven by a hydraulic motor, and provides the rotary motion to rotate the cable drum and the level-wind assembly.
Refer to Figure 17-9 and proceed as follows:
WARNING!
Working on or near the cable reel while the drill is operating is hazardous and can resultin injury or death. Shut down operation of the drill, and lock out and tag the operatorcontrols prior to working on or near the cable reel. Follow the lockout and tagout proce-dures outlined in this manual.
1. Lock out and tag the operator controls to prevent inadvertent movement during maintenance activities.
2. Remove the oil level plug, and check the oil level. The oil should reach up to the lower edge of the level plug opening. The oil level plug on the planetary gear reducer is located on the hydraulic motor end of the gear reducer. There are plugs located at the three o'clock and nine o'clock positions. The breather/filler cap is mounted on the same end of the reducer at the twelve o'clock position.
CAUTIONOperating the cable reel when the gear reducer has been overfilled with oil will causeoverheating of the gear reducer components resulting in component damage. Neveroperate the cable reel when the oil level is below or above the lower edge of the levelplug opening.
BD120149 Mechanical Systems Manual Preventive Maintenance
3. If the oil is below the lower edge of the level plug opening, add oil, of the type specified in the Lubrication Sec-tion, through the reducer breather opening.
WARNING!
Inadvertent operation of the drill while working on or near the mast structure can resultin injury or death. Lower the rotary carriage to the bottom of the mast, shut down drilloperation, lock out and tag the operator controls prior to working on or near the maststructure. Follow the lockout and tagout procedures outlined at the front of this manual.
4. Lock out and tag the operator controls to prevent inadvertent start-up of the machinery. Follow the lockout and tagout procedures outlined at the front of this manual.
Preventive Maintenance BD120149 Mechanical Systems Manual
• Hydraulic cylinders for oil leaks, wear, or damage.
• Pipe rack structure for damage.
• Pipe rack for correct operation.
• Linkages for looseness, wear, or damage.
Repair or replace worn or damaged pipe rack components. Refer to the applicable topic in this manual for repair instructions regarding the pipe rack.
17.8.3 lnspect Breakout Wrench
1. Inspect for cracked, broken, or distorted arm or hinge pins.
2. Inspect for missing die teeth, die retainers, shims, and pins.
3. Confirm that the arms move freely on the hinge pins.
17.8.4 lnspect Mast Racks and Pinions
Inspect the condition of the mast racks and pinions once weekly. Proceed as follows:
1. Lower the rotary carriage to the bottom of the mast, lower the mast to the stored position, and shut down oper-ation of the drill.
WARNING!
Working on or near the mast structure while the drill is operating is hazardous and canresult in the injury or death of personnel. Lower the rotary carriage to the bottom of themast, lower the mast to the stored position, shut down drill operation, lock out and tagthe operator controls prior to working on or near the mast structure. Follow the lockoutand tagout procedures outlined at the front of this manual.
2. Lock out and tag the operator controls to prevent inadvertent start-up of the machinery. Follow the lockout and tagout procedures outlined at the front of this manual.
3. Inspect the gear racks and pinions for excessive wear, fractured or missing gear teeth, and other signs of dam-age which could effect the operation of the rotary carriage or pulldown system. Repair or replace any damaged rack segments or pinions. Refer to the applicable topic in this manual for repair instructions or procedures.
17.8.5 lnspect Rotary Machinery
Visually inspect the condition of the rotary machinery. Check for cracks, wear, or damage. Repair or replace any worn or damaged components.
1. Lower the rotary carriage to the bottom of the mast.
BD120149 Mechanical Systems Manual Preventive Maintenance
WARNING!
Inadvertent machine operation while working on or near the mast structure can result inthe injury or death. Lower the rotary carriage to the bottom of the mast, shut down drilloperation, lock out and tag the operator controls prior to working on or near the maststructure. Follow the lockout and tagout procedures outlined at the front of this manual.
2. Lock out and tag the operator controls to prevent inadvertent movement during maintenance activities.
3. Inspect for the following:
• Pulldown motor bolts for correct torque.
• Pulldown motor coupling for correct torque.
• Pulldown gearcase for secure mounting.
• Pulldown gearcase for oil leaks.
• Resolver for secure mounting.
• Hoist brake for assembly for secure mounting.
• Main rotary gearcase shaft for end play.
• Swivel for leaks.
• Rotary motor bolts for correct torque.
• Rotary gearcase for oil leaks.
• Rotary head side frames for cracks.
• Motor blowers for operation and cleanliness.
• Drill pipe coupling damper for correct clearances.
• Drill pipe coupling for thread wear or damage.
• Condition of hoses and cables.
Refer to the applicable sections of this manual for detailed instructions on inspection and adjustment of the rotary machinery.
17.8.6 Inspect Bailing Air System Components
Visually inspect the condition of the bailing air system components. Check for cracks, wear, or damage. Repair or replace any damaged components. Inspection should include but not be limited to the following bailing air system components:
Preventive Maintenance BD120149 Mechanical Systems Manual
• Check the GUI to confirm functioning of the main air pressure transducer (MAPT), the bailing air pressure transducer (BAPT), the main air temperature transducer (MATT), and the compressor oil temperature trans-ducer (COTT).
• Confirm functioning of the bailing air pressure gauge.
• Check all oil hoses and connections for leaks, wear, cracks, or damage.
BD120149 Mechanical Systems Manual Preventive Maintenance
17.8.7 Check Crawler Belt Tension
Refer to Figure 17-10 and check crawler belt tension as follows:
1. Raise the drill until the crawler belt is free of the ground.
2. Measure the distance from the bottom of the side frame nearest the mid-point of the crawler to the top of the crawler pad where the roller normally contacts the pad.
3. Normally this distance will be from 12 to 14 inches (300 to 360 mm). If the distance exceeds 14 inches, adjust-ment is required.
Preventive Maintenance BD120149 Mechanical Systems Manual
17.8.8 Check Hydraulic Charge Filter
Each main hydraulic system is equipped with a pressure filter which is inserted between the output of the control pressure charging pump and the input to the system control valves. The charge filters are located on a support bracket above the pump drive transmission. Check the filters as follows:
BD120149 Mechanical Systems Manual Preventive Maintenance
4. Inspect the filter unit for visible damage, leaking seals, or leaking fittings. If the GUI filter indicator shows that the element has become fouled (or, alternatively, after 6 months or 1000 hours of operation has passed), the element should be replaced. Refer to and replace the charge filter elements as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine startup during maintenance.
5. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
6. Turn off the Handwell valve and be sure that no pressure exists in any of the main hydraulic system circuits.
7. Remove the bleed plug located on bottom of the filter.
BD120149 Mechanical Systems Manual Preventive Maintenance
15. Check the filters for visible damage, leaking seals, and leaking connections.
16. If the filter indicators are in the red zone, or after six months or 1000 hours of operation the filter elements must be replaced. Replace the hydraulic return line filter elements as follows:
17.8.9.1 Disassembly.
Disassemble the return line filters for replacement of filter elements as follows (see Figure 17-1 1):
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lockout andtag the operator controls to prevent inadvertent machine startup during maintenance.
17.8.10 Check Main Compressor Oil Filter Indicator
To ensure unrestricted flow of oil to the main compressor, the oil filter assembly must be serviced at regular inter-vals.
The main compressor oil filter is flange mounted to the oil return port on the main compressor. The compressor must be running and the oil at operating temperature for the indicator to read accurately. Check the indicator with a bright light to be certain of the indicator position. Some lubricants will obscure the indicator.The element must be replaced when one of the following conditions exists:
BD120149 Mechanical Systems Manual Preventive Maintenance
• Replace the main air compressor oil filter as follows:
Figure 17-15: Main Air Control Panel
CIPS MAPS
SUB PILOT
VALVE OPENS
AT 58 PSI
TANK FILTER
COMP. FILTER
COPS
BAPT
BACS
01
02
03
04
05
06 07
08
09
101112A
B
C
E
D
G
F
H
MAPT
BD0509a01
LEGEND01. Bit Air Pressure Transducer02. directional flow control Valve03. Bit Air Control Solenoid04. Main Air Pressure Transducer05. Electrical Panel06. Compressor Inlet Pressure Switch07. Main Air Pressure Switch
08. Subtractive Pilot Valve09. T-Tank Oil Separator Pressure
Preventive Maintenance BD120149 Mechanical Systems Manual
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lockout andtag the operator controls to prevent inadvertent machine startup during maintenance.
1. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
CAUTION!
Pressurized oil will spray with extreme force from the compressor main oil filter whenbeing loosened, and can cause severe injury. Slowly release air pressure or vent the T-tank before loosening the filter canister. Wear appropriate face, ear, and body protectivedevices while opening the canister.
2. Vent any residual air pressure from the T-tank. The T-tank will vent through the main air system muffler when the main air compressor is not running.
3. Remove the head assembly by rotating tee handle counter-clockwise until head assembly is free of housing.
4. Holding baffle down, push down on indicator assembly to ensure that it moves up and down freely within the baffle. Remove baffle, and check the bore for burrs or deep scratches. Carefully smooth out the bore, if required. Check seal for cuts or excess wear.
5. Remove element from housing assembly. Remove the indicator assembly from element by inserting a screw-driver between the indicator assembly and the element cap, and carefully prying downward. Inspect indicator O-ring for cuts or excessive wear and discard element.
6. Remove O-ring from head assembly, and inspect it for cuts or excessive wear. Wipe the O-ring area of head with a clean cloth, and, after covering the O-ring with oil, reinstall it in the head assembly.
7. Reinstall indicator assembly into new element. Place the element into canister, being sure the large diameter of spring contacts the new element. Install baffle.
8. Place head assembly onto housing assembly and rotate tee handle clockwise until it is hand tight; do not exceed 20 ft-lbs (26 N.m).
9. Start the compressor. If leakage appears at the top of the canister, replace O-ring (02). If this does not stop the leakage, the canister may be nicked or distorted by over-torquing, and the canister should be repaired or replaced.
10. If leakage appears around tee handle (08), remove snap ring (lo), and, then, remove the tee handle from head assembly (01). Remove and discard O-ring (09). Wipe the tee handle and the 0 - ring groove. Oil and install a new O-ring, then insert the tee handle into the head assembly, and replace the snap ring.
BD120149 Mechanical Systems Manual Preventive Maintenance
17.8.11 Check Main Compressor Oil Separator Element
11. The main compressor oil separator is equipped with inner and outer filter elements. The separator includes a system for measuring the pressure differential between the inlet and outlet ports of the oil separator. When the differential pressure exceeds 8 psi (0.5 bar), the oil separator element needs to be replaced.
Refer to Figure 17-16 and replace the filter elements inside the oil separator as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lock out andtag the operator controls to prevent inadvertent machine start-up during maintenancework.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
Figure 17-16: T-Tank (on Left Hand Platform)
01
02
03
04
07
08
11 10
09
BD0501b01
05
06
05
LEGEND01. Sight Tube02. Fill Plug03. Oil Separators04. Main Air Pipe05. Sling Lift Point
06. Union07. Safety Relief Valve08. Air Pilot Valve09. Air/Oil Reservoir10. Compressor Oil Temperature Probe11. Shutoff (Drain) Valve
Preventive Maintenance BD120149 Mechanical Systems Manual
CAUTION!
High pressure hydraulic or air systems can spray with extreme force and noise causingsevere injury. Shut down system and slowly release pressure or vent circuits beforeloosening fittings or connections. Wear appropriate face, ear, and body protectivedevices while venting air or hydraulic systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will vent through the main air system muffler when the main air compressor is not running and the controls are de-energized.
3. Thoroughly clean the air-oil separator flange and fittings to remove any dirt that could fall into the T-Tank when the separator cover and other fittings are opened.
4. Tag and remove the hose assembly on top of the oil separator cover that connects to the scavenger tubes.
Technician Tip
It is not necessary to remove the fittings or interconnecting tubing from the oil separator cover.
5. Tag and remove the upstream pressure tap hose assembly on top of the oil separator cover.
6. Remove hose from the safety relief valve.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can injure personnel and/or damage equipment. Use suitable slings and hoisting equipment to stabilize and liftheavy objects.
7. Attach suitable hoisting equipment to the main air pipe assembly, and carefully take up the slack.
8. Remove nuts, lockwashers, and capscrews that attach main air pipe flange to the oil separator cover, and lift the main air pipe assembly from the T-Tank.
9. Remove and discard gasket.
10. Attach a suitable hoist to oil separator cover, remove capscrews and lockwashers from the separator cover, then lift the separator cover and attached inner separator element from the T-Tank. Lift the cover straight up when removing it from the T-Tank to avoid damaging the separator element.
11. Remove outer separator element from the T-Tank. Discard the element in a suitable container, and cover the T-Tank opening to prevent entry of dirt.
12. Remove capscrews, lockwashers, retainer, and inner separator element from oil separator cover. Discard the element in a suitable container.
13. Clean away any deposits from inside the T-Tank and from the mounting surfaces of oil separator cover.
14. Inspect scavenger tubes for signs of deterioration or plugging. Replace as necessary.
BD120149 Mechanical Systems Manual Preventive Maintenance
15. Inspect the insert (Item 10, Figure 6-45) to be sure it is positioned correctly. The cut-out at the bottom must face the front of the drill away from the 6" inlet pipe.
CAUTION!
Staples on the filter elements are required to eliminate static electricity, which couldcause the oil to flash, resulting in personal injury and/or property damage. Do notremove staples from the gaskets.
16. Install a new gasket between the inner separator element and the T-Tank tower.
17. Install new inner separator element to oil separator cover assembly with retainer, capscrews, and lockwashers. Position inner scavenger tube so that it rests on the bottom plate of the inner element.
18. Install a new outer separator element into the top of the T-Tank. Align the holes in the element cover with those of the T-Tank flange.
CAUTION!
Lifting heavy components with inadequate hoisting apparatus can injure personnel and/or damage equipment. Use suitable slings and hoisting equipment to stabilize and liftheavy objects.
19. Attach suitable lifting equipment to separator cover assembly, and position on top of outer element flange on the T-Tank. Be sure outer scavenger tube is correctly positioned at the bottom of the outer element. Position the holes in the separator cover to align with the holes in the outer element flange.
20. Install oil separator cover to the T-Tank flange with capscrews and lockwashers. Torque the capscrews evenly in a crisscross pattern to uniformly compress the outer element flange.
21. Attach suitable lifting equipment to air inlet nozzle, and position the flange above the mating flange on top of separator cover assembly.
22. Install main air pipe to separator cover assembly with capscrews, lockwashers, nuts, and a new gasket. Do not tighten the nuts at this time.
23. Align the opposite end of air pipe with manifold and couple with union. Tighten the union securely, then uni-formly tighten the nuts at the flange end of the air inlet nozzle.
24. Install the hose assembly to the scavenger tube fitting on top of oil separator cover.
25. Install the upstream pressure tap hose assembly on top of oil separator cover.
26. Check the level of compressor oil in the T-Tank, and fill as necessary.
17.8.12 Check Main Compressor Air Intake Filters
The main compressor is equipped with two filter systems, one at each intake. Each filter system has two filters in series (see Figure 17-14); a primary filter element, and a safety filter element. The air drawn into the main com-pressor passes through both filters. To ensure that the compressor retains its maximum output capacity, the air intake filters must be periodically cleaned.
Preventive Maintenance BD120149 Mechanical Systems Manual
Inspect the filter assembly weekly. Visually inspect the main compressor intake filter(s) for dirt and contamination. The filters are fitted with restriction indicator fittings. Check the GUI fault log to determine the need for cleaning.
Refer to the Main Air Section of this manual for removal and replacement procedures.
NOTICE
The safety element is not designed to be cleaned. For maximum compressor protection, installa new safety filter every third primary element cleaning (or replacement). Replace the main aircompressor air intake filter elements as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lockout andtag the operator controls to prevent inadvertent machine startup during maintenance.
1. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
2. Loosen the band clamp which secures air cleaner cover, and remove the cover.
Figure 17-17: Main Compressor Air Cleaner Assembly
BD120149 Mechanical Systems Manual Preventive Maintenance
3. Remove wing nut and washer, and pull primary element from the air cleaner assembly.
4. Remove wing nut, and pull safety element from the air cleaner assembly.
5. If the filter body requires cleaning, loosen the band clamps which secure housing and cup to primary body, and separate the air cleaner assembly.
6. Clean or replace the primary element, and replace the safety element as required.
7. Refer to Figure 17-17 and assemble the air cleaner with clean or new elements.
17.8.13 Check Auto Lube Grease Reservoir Level
Weekly or every 40 hours of operation, check the level of the grease lubricant in the automatic lubrication system grease reservoir. Remove the cover of the grease reservoir and visually check the lubricant level. Refill the reser-voir as necessary to maintain adequate lubrication.
Continued drill use will provide a history of grease consumption, which may dictate varied grease reservoir level checks. If unsure of the lubricant level, shut down operation of the drill and check the reservoir level.
17.8.14 lnspect Trail Cable
Proceed as follows.
WARNING!
Hazardous voltage can cause injury or death. Disconnect electric power to the tail cableat the power substation and use lockout and tagout procedures prior to visual inspec-tion or handling of the tail cable. Use qualified inspection personnel equipped withappropriate devices for testing, handling, and personal protection.
• Power is fed to the blast hole drill via the trail cable power conductor cable. It is imperative that this cable not be damaged, or cut. Visually inspect the tail cable to ensure that it is not damaged, crushed, or cut. Replace the trail cable if it is damaged.
17.9 “C” Maintenance Checks
The “C” Maintenance Checks should be performed monthly, or every 160 -250 hours. If an item is found to be incorrect, the problem must be corrected prior to start-up to ensure satisfactory operation of the drill.
Refer to the maintenance check sheets and complete “A” and “B” Maintenance Checks before proceeding with the “C” Maintenance Checks.
Preventive Maintenance BD120149 Mechanical Systems Manual
WARNING!
Cracks in the back brace pivot anchors will result in the pivot anchors separating fromthe drill frame, or from the mast chords, resulting in the collapse of the mast. Collapse ofthe mast may result in injury or death. Visually inspect the pivot points of the backbraces, and make repairs immediately if cracks are found.
The back braces restrain movement of the mast during drilling operations. These tubular braces absorb a large amount of the vibration from the drilling operation and as a result are common points for the development of struc-tural cracks. Visually inspect the pivot points of the back braces for cracks.
SAFETY FIRST
Although cracks are most commonly found at the upper mast anchor point, each pivot shouldbe carefully checked. If any doubt exists as to the presence of a crack, test the crack usingchemical or magnetic crack detection methods.
If cracks are found, refer to the Mast Section of this manual, and repair the back braces. Inspect the slide surfaces of the back brace locking sleeves for wear or damage. If the slides are excessively worn or damaged, repair the slides and/or sleeves as described in Mast Section of this manual.
17.9.2 lnspect Mast
Visually inspect the structural condition of the mast. Check for cracks, wear, or damage. Repair or replace the com-ponents of the mast, mast bracing, or lacing as revealed through this inspection.
WARNING!
Working on or near the mast structure while the drill is operating is hazardous and canresult in injury or death. Lower the rotary carriage to the bottom of the mast, shut downdrill operation, lock out and tag the operator controls prior to working on or near themast structure.
Follow the lockout and tagout procedures outlined at the front of this manual. Inspect for the following:
• Mast chords, for cracks or kinks.
• Lacings, for cracks or kinks.
• Mast hoist cylinder pins and retainers for wear or looseness.
• Ladders, platforms, and handrails for looseness.
• Hoist cylinder rods, pins, and seals for damage or wear.
• Hydraulic connections and cylinders for leakage.
• Pivot pins, anchors, and retainers for wear and looseness.
BD120149 Mechanical Systems Manual Preventive Maintenance
Refer to the Mast Section of this manual for detailed instructions on inspection of the mast.
17.9.3 lnspect Auxiliary Winch Sheaves
Proceed as follows.
WARNING!
Working on or near the mast structure while the drill is operating is hazardous and canresult in injury or death. Lower the rotary carriage to the bottom of the mast, shut downdrill operation, lock out and tag the operator controls prior to working on or near themast structure. Follow the lockout and tagout procedures outlined at the front of thismanual.
As wire rope passes over sheaves, the sheaves become worn. Inspect the condition of the winch sheaves monthly to ensure that the sheaves are not excessively worn. Measure the sheave groove wear pattern using a sheave gauge. Replace the sheaves as revealed through this inspection. Refer to the Mast Section of this manual for repair instructions regarding the winch sheaves. The mast must be lowered to facilitate inspection of the sheaves.
17.9.4 Clean Main Compressor and Hydraulic Oil Cooler
To ensure satisfactory cooling of the main compressor oil, the main compressor oil cooler must be periodically cleaned. At least monthly, or every 160 hours of operation, clean the oil cooler radiators as follows:
1. Shut down operation of the main air compressor and cooler.
WARNING!
Working on or near rotating machinery while in operation is hazardous and can result ininjury or death. Shut down operation of the drill, and use lockout/tagout proceduresprior to working on or near rotating machinery.
2. Lock out and tag the electrical controls to the main air compressor pressor and cooler to prevent inadvertent start-up during service activities.
3. Remove the machinery house access covers to access to the main compressor oil cooler radiator.
CAUTION!
Pressurized steam used for cleaning can cause injury. Exercise care and caution whenusing pressurized steam to clean machinery components. Wear protective clothing,gloves, and face shield when operating a pressurized steam cleaner.
4. Use a pressurized steam cleaner to flush dirt and contaminants from the fins of the main compressor oil cooler radiator. Ensure thorough cleaning of the entire radiator.
Preventive Maintenance BD120149 Mechanical Systems Manual
5. After the radiator has been thoroughly cleaned, use compressed air to blow the remaining dirt, contaminants, and water from the oil cooler fins.
6. Clean any dirt, contaminants, and water from the floor of the machinery house.
7. Reinstall any access covers which were removed to permit cleaning of the oil cooler.
17.9.5 Inspect Main Frame
Visually inspect the structural condition of the drill framework. Check for cracks, wear, or damage. Repair or replace the components of the frame as revealed through this inspection.
Inadvertent machine operation during maintenance activities can cause injury or death. Shut down the drill before performing inspections, service, or maintenance. Establish a procedure to guard against inadvertent equipment operation or movement while conducting inspections. Use lockout and tagout procedures prior to conducting main-tenance or service.
1. Lock out and tag the operator controls to prevent inadvertent movement of the machine during maintenance activities.
2. Inspect the following:
• Entire structural frame.
• Jack flanges and flange bolts.
• Stairways, ladders, and platforms.
• Machinery house framing.
• Jack assemblies/jack shoes.
• Machinery house panels.
• Machinery house doors.
• Water tank (optional equipment).
• Dust collector chutes (optional equipment).
17.9.6 Inspect Crawler Frames
Visually inspect the structural condition of each crawler side frame. Check for cracks, wear, or damage. Repair or replace the components of the crawler frames as revealed through this inspection.
WARNING!
Working on or near rotating machinery while in operation is hazardous and can result inthe injury or death of personnel. Shut down operation of the drill, and use lockout/tagoutprocedures prior to working on or near rotating machinery.
BD120149 Mechanical Systems Manual Preventive Maintenance
Inspect the following components:
• Entire structural crawler side frame.
• Track shoes.
• Crawler links.
• Idler rollers.
• Top guide rollers.
• Bottom guide rollers
• Main axle mounting bolts.
• Equalizer axle mounting pins.
• Track pins and retainers.
• Take-up adjustment assemblies.
• Drive tumblers.
17.9.7 Check Auxiliary Winch Oil Level
Monthly, check the auxiliary winch gearcase oil level as follows:
1. Shut down operation of the drill.
WARNING!
Working on or near rotating machinery while in operation is hazardous and can result in theinjury or death of personnel. Shut down operation of the drill, and use lockout/tagout proceduresprior to working on or near rotating machinery.
2. Use lockout and tagout procedures to prevent inadvertent start-up during service activities.
3. Remove the oil level plug from the end opposite the hydraulic motor, and check the winch gearcase oil level. The oil should reach up to the lower edge of the level plug opening.
CAUTIONOperating the winch when the gearcase has been overfilled will cause overheating of thegearcase components resulting in component damage. Never operate the winch whenthe oil level is below or above the lower edge of the level plug opening.
4. The oil level must be even with the lower edge of the level plug opening. If the oil is below the lower edge of the level plug opening, add oil, of the type specified in the Lubrication Section through the gearcase breather open-ing.
Preventive Maintenance BD120149 Mechanical Systems Manual
5. Clean and securely reinstall the breather.
6. Apply pipe thread sealant to the level plug, and install securely.
17.9.8 Inspect Cable Reel Components
Visually inspect the condition of the optional cable reel components. Check for cracks, wear, or damage. Repair or replace the components of the cable reel as revealed through this inspection.
WARNING!
Working on or near rotating machinery while in operation is hazardous and can result inthe injury or death of personnel. Shut down operation of the drill, and use lockout/tagoutprocedures prior to working on or near rotating machinery.
1. Lock out and tag the operator controls to prevent inadvertent movement of the machine during maintenance activities.
2. Inspect the following:
• Hydraulic motor. for leaks
• Drive chain for wear and tension.
• Chain sprockets for wear.
• Right angle gear reducer for leaks.
• Cable reel structure, for cracks
Refer to the applicable section of this manual specific to this drill for detailed instructions on correct inspection of and/or adjustment of the cable reel machinery.
17.9.9 Clean/Flush Water Tank
Flush and clean the optional water tank periodically to remove dirt, sediment, and contaminants accumulated over time. Monthly, drain, clean, and flush the water tank. Refill the tank with fresh water.
17.9.10 Check Pump Drive Transmission Oil Level
The pump drive transmission mounted on the front end of the main power unit, drives the two main hydraulic pumps and one auxiliary hydraulic pump. Monthly, check the oil level in the pump drive transmission using the fol-lowing procedure:
BD120149 Mechanical Systems Manual Preventive Maintenance
WARNING!
Working on or near rotating machinery while in operation is hazardous and can result ininjury or death. Shut down operation of the drill, and use lockout/tagout proceduresprior to working on or near rotating machinery.
2. 2. Shut down, lock out, and tag the electrical controls to the drill to prevent inadvertent start-up during service activities.
3. 3. Check the pump drive transmission oil level using the dip stick.
4. 4. If the oil level is low, add oil to bring the level even with the full mark on the dip stick. (See the Lubrication Section, for lubricant specifications). Add oil through the oil filler plug located on top of the reducer housing.
CAUTIONOperating the pump drive transmission when it has been overfilled will cause overheat-ing of the pump drive transmission components resulting in component damage. Neveroperate the pump drive transmission when the oil level is either too full or too low.
17.9.11 Change Main Compressor Bearing Oil Filter
A spin-on type oil filter (located on the motor-end face of the compressor) is used to filter the bearing oil as it passes through the main air compressor. This filter removes dirt and abrasives from the circulated oil before it reaches the bearings.
The filter is disposable, and is equipped with a relief valve that opens in the event the element becomes dirty enough to block the flow of oil. Replace this filter each time the main oil filter element is replaced. Use only the replacement filter shown in the parts list; others may not have sufficient burst pressure strength.
Replace the main compressor bearing oil filter as follows:
WARNING!
Working on the main air system while the compressor is in operation is hazardous andcan result in injury or death. Shut down the main air compressor, and use lockout/tagoutprocedures prior to starting any service on the machinery.
1. Lock out and tag the high-voltage main circuit breaker switch to prevent operation of the main air compressor drive motor during system service.
WARNING!
Pressurized oil will spray with extreme force from the compressor bearing oil filter whenbeing loosened, and can cause severe injury. Slowly release air pressure or vent the T-tank before loosening the filter canister. Wear appropriate face, ear, and body protectivedevices while removing the filter from the compressor housing.
Preventive Maintenance BD120149 Mechanical Systems Manual
2. Vent any residual air pressure from the T-tank. The T-tank will vent through the main air system muffler when the main air compressor is not running.
3. Spin off the old filter and discard. Apply a film of oil to the filter gasket, then spin on the new filter. Tighten the fil-ter firmly by hand to prevent oil leaks. Be sure the filter sealing surfaces are clean before installing the new fil-ter.
NOTICE
When changing this filter between oil changes, add one quart of compressor oil to the system toreplace that retained in the old filter (see the Lubrication Section for specifications of the com-pressor oil to use).
17.9.12 Check Propel Transmission Oil Level
The propel transmissions are mounted at the front of each crawler assembly. Each propel transmission is driven by a hydraulic motor and together with the transmission. serves as the drive mechanism to propel the drill. Monthly, check the oil level in the propel transmissions using the following procedure:
1. Rotate the transmission until the level/fill plug and drain plug are positioned as shown in Figure 17-15.
BD120149 Mechanical Systems Manual Preventive Maintenance
WARNING!
Working on or near rotating machinery while in operation is hazardous and can result ininjury or death. Shut down operation of the drill, and use lockout/tagout proceduresprior to working on or near rotating machinery.
3. Shut down, lock out, and tag the electrical controls to the drill to prevent inadvertent start-up during service activities.
4. Remove the propel transmission oil level/fill plug.
5. Check that the oil level is up to the bottom of the oil level plug hole.
6. If the oil level is low, add oil to bring the level even with the bottom of the oil level plug hole (see the Lubrication Section for lubricant specifications). Add oil through the oil level/fill plug.
7. Apply pipe thread sealant to the oil level/fill plug, and install the plug securely.
CAUTIONOperating the propel transmission when it has been overfilled will cause overheating ofthe propel transmission components resulting in component damage. Never operate thepropel transmission when the oil level is either too full or too low.
17.9.13 Clean/inspect Machinery House Blowers And Filters
The following paragraphs describe the inspection and maintenance procedures that should be followed when ser-vicing the machinery house blowers and impingement filters that provide pressurized air to the machinery house.
An electric-motor-driven blower provides air under slight positive pressure to the machinery house. The fan is located in the upper section of the mast. Air is drawn from atmosphere and blown through filter assemblies into the machinery house. Air flows through the house and is exhausted to atmosphere through openings in the house. This ensures that cooling air within the house is clean and fresh.
The blowers maintain a slight positive pressure within the machinery house, causing air to flow outward through any house openings, thus helping to keep dirt out.
The blowers and motors are installed in-line within sheet metal housings that attached to impingement type filters. These filters separate dust and entrained particles from the input air stream and allow the resulting clean air to enter the machinery house while dropping the separated particulate out of the machine through tubes at the bottom of the air cleaners, as shown in Figure 17-17.
Inspect the ventilation system as follows:
1. Check for large debris in air inlet passages and remove when found.
2. Check blower motor mounting for security.
3. Check that the blower blades are tight and set at the same angle.
Preventive Maintenance BD120149 Mechanical Systems Manual
4. Check the filters for accumulated dirt and debris. A light coating of dust on the cells is normal and will not impair operation or efficiency of the filters. However, the cell blades may accumulate a thicker deposit of sur-face dirt due to the sticky character of some types of dust, or the presence of oil mist or similar vapor in the out-side air. When the accumulated deposit reaches a thickness of 118 inch (3.2 mm), the cell blades should be cleaned. In addition to the 160-hour inspection, a more detailed inspection should be made twice annually. Check that the blower blades are clean and set at the proper pitch
Use the following procedure to clean the filter elements:
1. Gain access to the filters by removing the sheet metal which encloses them.
2. Refer to Figure 17-22 and loosen the nuts which hold the blade pack clamp bars in place. Then rotate the clamp bars 90 degrees and remove the bullnose strips.
3. Refer to Figure 17-22 and pull each of the blade packs out of the cell.
4. Thoroughly clean the blade packs in a detergent or other similar non-oily solution.
NOTICE
If the cleaning process removes paint from the blades, they should be repainted prior to installa-tion.
5. After cleaning and drying the filter blade packs, coat the outside surfaces of the channels to which the blades are welded and the inside surfaces of the channels into which each blade pack slides with grease. This grease lubricates the edge of the blade pack for easier installation and serves as a seal to prevent air and dirt bypass.
6. Check bleed ducts for dirt buildup and clean if necessary. The only maintenance possible on the motor/blower assemblies is blower replacement, motor replacement, or replacement of the blower and motor unit as an assembly.
NOTICE
When ordering replacement parts for the blower/motor assembly always give all information onthe blower data plate.
Preventive Maintenance BD120149 Mechanical Systems Manual
17.9.14 Inspect Rotary Carriage Rollers
Check the clearance of the carriage rollers monthly, or more often if there is extended use of the drill on a daily basis. The carriage rollers are mounted on eccentric shafts to permit adjustment of roller position, and to maintain proper pulldown pinion engagement due to roller wear. The 16 mounting holes in the shaft flanges permit adjust-ment in increments equivalent to the 22.5" difference in the location of the mounting holes.
WARNING!
Inadvertent machine movement or operation can cause injury or death. When necessaryto operate the blasthole drill while making an adjustment or performing a check, obtainthe assistance of a second person who is thoroughly familiar with the machine. Have theassistant at the control panel to be sure that nothing is actuated that may be hazardousto you or the machine.
17.9.14.1 Roller Adjustment
The mast should be positioned in the down, or lowered, position. Refer to Figure 17-21 and proceed as follows:
1. Lower the mast so that the pinion shrouds are resting on the rack shrouds.
2. Remove the four socket head capscrews from the eccentric bushing.
3. Turn the eccentric bushing until a gap of 1/8" (.125"; 3mm) is obtained between all of the rollers and the back of the mast chord.
Follow steps 1 through 3 for all three remaining roller carriers.
BD120149 Mechanical Systems Manual Preventive Maintenance
17.9.15 Check And Adjust Water Pump Drive Belt
The water pump (see Figure 17-21) is mounted on a bracket at one end of the water supply tank. It is protected from the environment by a louvered enclosure. The pump is V-belt driven by an independently-mounted electric motor. The tension of the V-belt should be checked at least once monthly, and adjusted as needed. Adjust the drive belt tension as follows:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lockout andtag the operator controls to prevent inadvertent machine startup during maintenance.
1. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
2. Remove the pump enclosure.
3. Loosen, but do not remove, the motor mounting hardware.
4. Loosen the adjustment locknuts.
5. Turn the belt tensioning screws as required until there is 112 inch (13 mm) deflection of the belt at a point mid-way between the sheaves. Adjust the screws evenly so the motor sheave remains parallel to the belt.
The “D” Maintenance checks should be performed every 500 hours, or quarterly. If an item is checked and found to be incorrect, the problem must be corrected prior to start-up to ensure satisfactory operation of the drill.
Repeat “A”, “B” and “C” Maintenance Checks before proceeding with the “D” Maintenance Checks, refer to the maintenance check sheets and complete all of the “A”, “B”, and “C” Maintenance Checks.
17.10.1 Replace Oil Line Scavenger Filter Element
The oil line scavenger filter is located on the main air control panel. This filter cleans oil scavenged from between the two oil separator elements. Replace the filter as follows:
WARNING!
Inadvertent machine movement can cause injury or death. Do not perform maintenancework on a machine without first disabling the operator controls. Lock out and tag theoperator controls to prevent inadvertent machine startup during maintenance.
Preventive Maintenance BD120149 Mechanical Systems Manual
1. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
WARNING!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Uselockout and tagout procedures to guard against inadvertent hydraulic system ormachine start up during service or maintenance. Allow the hydraulic system to coolbefore maintenance or repair. Slowly release pressure or vent circuits before discon-necting hydraulic lines. Wear appropriate face and body protective devices while care-fully loosening any connection or fitting.
2. Be sure that no air or hydraulic pressure exists in the main air system.
3. Loosen and remove the filter housing from the body.
CAUTIONSmall amounts of contaminants in the air compressor recirculation system can causesignificant equipment damage. Clean dirt from the filter assembly before loosening thehousing.
4. Remove and discard the used filter element.
5. Check the filter seal for nicks and cuts. Replace as necessary.
6. Install a new filter element in the housing.
7. Lubricate the seal with hydraulic oil, and install the housing securely in the filter body.
17.10.2 Check Bolts, Mounting And Attachment Torques
It is recommended that all mounting and attachment bolts and capscrews be checked periodically for correct torque to ensure that all components remain securely mounted. This mounting bolt check should be made quarterly at first and adjusted as experience dictates. Refer to the bolt and capscrew torque values provided in Table 17- 1 for appli-cable bolt and capscrew torques.
The “E” Maintenance checks should be performed every 1000 hours, or semi-annually. If an item is checked and found to be incorrect, the problem must be corrected prior to start-up to ensure satisfactory drill operation. Refer to the maintenance check sheets and complete all of the “A”, “B”, “C”, and “D” Maintenance Checks.
17.11.1 Change Rotary Gearcase Oil
The rotary gearcase is mounted to the lower end of the rotary carriage. This double-reduction gear reducer drives the rotary head coupling, the drill bit, and the pipe string. Change the rotary gearcase oil as follows (see Figure 17-3):
BD120149 Mechanical Systems Manual Preventive Maintenance
1. Lower the rotary carriage to the bottom of the mast.
WARNING!
Working on or near rotating machinery while in operation is hazardous and can result ininjury or death. Lower the rotary carriage to the bottom of the mast; use lockout/tagoutprocedures to shut down the drill before performing service procedures.
2. Use lockout/tagout procedures to prevent inadvertent start-up during service procedures.
3. Open the gearcase bearing drain valve and remove the drain plug from the bottom of the gearcase, and drain the oil from the gearcase into a suitable container.
4. When the old oil is completely drained, close the gearcase bearing drain valve. Clean the drain plug, apply pipe thread sealant, and install it in the back of the gearcase.
5. Remove the vent cap from the top of the gearcase.
6. Add oil, of the type and amount specified in the Lubrication Section, through the fill pipe until oil reaches the FULL mark on the dipstick.
7. Clean and install the vent cap.
CAUTIONOperating the rotary machinery when the rotary gearcase has been overfilled will causeoverheating of the gearcase components resulting in damage to the gearcase compo-nents. Never operate the rotary machinery with the rotary gearcase oil level above theFULL mark on the dipstick.
17.11.2 Change Pump Drive Transmission Oil
The pump drive transmission provides the rotational power to drive the three main hydraulic pumps and one auxil-iary hydraulic pump. Every six months, or each 1000 hours of operation, change the pump drive transmission oil as follows (see Figure 17-22):
Preventive Maintenance BD120149 Mechanical Systems Manual
WARNING!
Working on or near rotating machinery while in operation is hazardous and can result ininjury or death. Lower the rotary carriage to the bottom of the mast; use lockout/tagoutprocedures to shut down the drill before performing service procedures.
1. Use lockout/tagout procedures to prevent inadvertent start-up during service procedures.
2. Open the gearcase drain valve and drain the oil from the gearcase into a suitable container. The outlet for the pump drive
transmission drain is located below the machinery deck.
3. When the old oil is completely drained, close the crankcase drain valve.
4. Remove the vent/fill cap.
5. Add oil, of the type and amount specified in the Lubrication Section, until oil reaches the full mark on the dip stick.
6. Clean and install the fill/vent cap.
CAUTIONOperating the pump drive transmission when the transmission has been overfilled willcause transmission components to overheat, resulting in damage to the transmission.Never operate the pump drive transmission with the oil level above the level plug.
BD120149 Mechanical Systems Manual Preventive Maintenance
17.11.3 Change Hoist/Pulldown Gear Reducer Oil
The hoist/pulldown gear reducer (see Figure 17-3) provides the torque required to power the rotary carriage assembly along the vertical length of the mast. Every six months, or 1000 hours of gearcase operation, use the fol-lowing procedure to change the oil in the reducer:
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lockout andtag the operator controls to prevent inadvertent machine startup during maintenance.
1. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
2. Using a suitable container to catch the used oil, remove the drain plug from the bottom of the reducer housing, and drain all of the oil.
3. Install the drain plug with pipe thread sealant.
4. 4. to the correct level, indicated on the sight gauge, with oil specified in the Lubrication Section of this manual.
5. Install the filler plug with pipe thread sealant.
17.11.4 Change Propel Transmission Oil
The propel transmission is equipped with a planetary drive gearcase, hydraulically driven, which functions to pro-vide rotary motion to drive the crawler belt and propel the drill. Use following procedure to change the oil in the pro-pel transmission once each year, or every 2000 hours of operation (see Figure 17- 15):
1. Rotate the transmission until the level/fill plug and drain plug are positioned as shown on Figure 17-15.
WARNING!
Unexpected movement of the propel system could result in injury or death. Use lockouttagout procedure to shut down the drill before starting propel transmission oil changeprocedures.
2. Shut down the drilling operations. Use lockout/tagout procedures to prevent inadvertent drill movement.
3. Remove the propel transmission drain and level plugs, and drain the oil into a suitable container.
4. Clean the oil drain plug. Apply a coating of pipe thread sealant, and install the drain plugs.
17.11.5 Change Hoist/Pulldown Gear Reducer Oil
The hoist/pulldown gear reducer (see Figure 17-3) provides the torque required to power the rotary carriage assembly along the vertical length of the mast. Every six months, or 1000 hours of operation, use the following pro-cedure to change the oil in the reducer:
Preventive Maintenance BD120149 Mechanical Systems Manual
WARNING!
Inadvertent machine movement can cause serious injury or death. Do not perform main-tenance work on a machine without first disabling the operator controls. Lockout andtag the operator controls to prevent inadvertent machine startup during maintenance.
1. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
2. Using a suitable container to catch the used oil, remove the drain plug from the bottom of the reducer housing, and drain all of the oil.
3. Install the drain plug with pipe thread sealant.
4. Remove the filler plug from the top of the reducer housing, and fill the reducer to the correct level, indicated on the sight gauge, with oil specified in the Lubrication Section of this manual.
5. Install the filler plug with pipe thread sealant.
17.11.6 Change Propel Transmission Oil
The propel transmission is equipped with a planetary drive gearcase, hydraulically driven, which functions to pro-vide rotary motion to drive the crawler belt and propel the drill. Use following procedure to change the oil in the pro-pel transmission once each year, or every 2000 hours of operation (see Figure 17- 15):
1. Rotate the transmission until the level/fill plug and drain plug are positioned as shown on Figure 17-15.
WARNING!
Unexpected movement of the propel system could result in injury or death. Use lockouttagout procedure to shut down the drill before starting propel transmission oil changeprocedures.
2. Shut down the drilling operations. Use lockout/tagout procedures to prevent inadvertent drill movement.
3. Remove the propel transmission drain and level plugs, and drain the oil into a suitable container.
4. Clean the oil drain plug. Apply a coating of pipe thread sealant, and install the drain plugs.
5. Add oil, of the type specified in Lubrication Section, through the level/fill plug opening until the level reaches the bottom of the fill/level plug hole.
6. Apply pipe thread sealant to the vent plug, and install the plugs.
17.12 “F” Maintenance Checks - Annual/2000Hours
The “F” Maintenance checks should be performed 2000 hours or annually. If an item is checked and found to be incorrect, the problem must be corrected prior to start-up to ensure satisfactory operation of the drill.
BD120149 Mechanical Systems Manual Preventive Maintenance
Repeat “A”, “B”, “C”, “D”, and “E” Maintenance Checks before proceeding with the “F” Maintenance Checks
17.12.1 Change Hydraulic System Oil
It is recommended that the hydraulic system oil be changed once each year, or every 2000 hours of operation. Drain, flush, and refill the hydraulic system. Refill the hydraulic system with the type and amount of oil specified in the Lubrication Section.
NOTICE
It is recommended that a sample of oil be drawn from the hydraulic tank annually. This sampleshould be about two quarts and should be taken when the oil is warmed through normal opera-tion. If possible, the sample should be analyzed by a qualified lubrication specialist to determinewhether it is suitable for continued use. The interval between oil changes depends upon theoperating conditions and on the care used in the handling oils and keeping the clean during thehandling process.
17.12.2 Change Auxiliary Winch Gearcase Oil
The auxiliary winch gearcase contains a planetary-type trans- mission inside the winch assembly. Annually, or every 2000 hours of operation, the oil in the auxiliary winch gearcase needs to be changed. Use the following pro-cedure to change the oil in the gearcase:
WARNING!
Working on or near the mast and/or winch during drilling operation is hazardous and canresult in injury or death. Lower the rotary carriage to the bottom of the mast and shutdown the drill using lockout/tagout procedures.
1. Lower the rotary carriage to the bottom of the mast, and shutdown the drill using lockout/tagout procedures to prevent inadvertent start-up of the drill.
2. Remove the oil drain plug from the end opposite the hydraulic motor, and drain the oil into a suitable container,
3. Clean the oil drain plug, apply a coating of pipe thread sealant, and install the drain plug.
4. Remove the oil fill and level plugs.
5. Add oil of the type specified in the Lubrication Section, through the gearcase fill plug opening until the level reaches the bottom of the level plug hole.
6. Apply pipe thread sealant to the fill and level plugs, and reinstall the plugs.
17.12.3 Change Cable Reel Gear Reducer Oil
The tail cable reel (optional equipment) is mounted across the front of the machinery house and serves to store the tail cable. The gear reducer, driven by a hydraulic motor, provides rotary motion to rotate the cable drum.
Annually, or every 2000 hours of operation, the oil in the cable reel gear reducer needs to be changed. Use the fol-lowing procedure to change the oil in the reducer:
Preventive Maintenance BD120149 Mechanical Systems Manual
1. Shut down the drilling operations, and power down the drill.
WARNING!
Working on or near the cable reel during drill operation is hazardous and can result ininjury or death. Shut down operation of the drill, and use lockout/tagout proceduresprior to working on or near the cable reel.
2. Lock out and tag the electrical controls to the auxiliary hydraulic system to prevent inadvertent start-up of the cable reel during service activities,
3. Remove the oil drain plug, and drain the oil into a suitable container.
4. Clean the oil drain plug. Apply a coating of pipe thread sealant, and install the drain plug.
5. Remove the oil level plug and the oil breather cap.
CAUTIONOperating the cable reel when the gear reducer has been overfilled will cause overheat-ing of the reducer components resulting in component damage. Never operate the cablereel when the oil level is either below or above the lower edge of the level plug opening.
6. Add oil of the type specified in the Lubrication Section, through the gearcase breather opening until the level reaches the bottom of the filler plug hole.
7. Apply pipe thread sealant to the fill level plug, and install the plug securely.
BD120149 Mechanical Systems Manual General Maintenance
Appendix A
General Maintenance
A.1 Removal – General
The following general rules apply to removal of most major components.
1. Always make sure that all controls are in the OFF position. Main and emergency power switches must be opened and locked in the open (OFF) positions. Place warning signs on these switches so that others do not turn on the power while you are working on the machine.
WARNING!
Unexpected machine operation could result in death or severe personal injury. Warningsigns must always be removed by the person who placed them - never by anyone else.
2. Lifting heavy components with inadequate hoisting apparatus can injure personnel and/or damage equipment. Use suitable rigging and hoisting equipment to stabilize and lift heavy objects.
3. Before performing any work on any system, consider the effect that the work may have on the system. Be sure that the machinery will not move as a result of the work being performed. Be sure the system is not under pres-sure. Be sure electrical power is disconnected.
A.2 Disassembly – General
1. Disassemble only what is required for specific repairs.
2. Never use a torch to assist in removing parts unless the parts to be heated are already damaged beyond repair, or the instructions recommend the use of heat for disassembly. Excessive heat may damage the part beyond repair.
3. Never use more force than necessary to dismantle an assembly. In most cases, a great deal of force is not required.
4. Handle parts carefully to prevent nicks or other damage while the parts are removed from the machine.
5. Tag all electrical leads and hydraulic lines before disconnecting them to ensure proper reconnections.
A.3 Inspection, Cleaning And Repair – General
The following general recommendations should be followed during routine cleaning, inspection and repair of most machine components.
General Maintenance BD120149 Mechanical Systems Manual
WARNING!
Gasoline, naphtha, and other highly flammable fluids will burn if ignited, and mayexplode if the fumes are ignited in a confined space, resulting in burns, severe bodilyinjury and/or death. Do not use these materials to clean, or for any other maintenanceprocedure. If necessary, use Toluol, Perchloroethylene, or other approved solvent.
1. Clean all parts thoroughly using kerosene, diesel oil, or a suitable commercial solvent. Never use a hot alkaline solution on finished parts or bearings.
2. Dry metal parts (except bearings) using low-pressure compressed air. Do not spin-dry bearings.
3. Inspect all gears as described under Subtopic A.5.7.
4. Inspect all bushings for wear, scoring or galling and replace when required.
5. If possible, replace all oil seals and O-rings, regardless of the reason for removal, even if no damage is appar-ent.
6. If possible, replace all gaskets. Be sure the new gasket is of the same material and thickness as the discarded gasket.
7. Inspect all anti-friction bearings as described under Subtopic A.5.1.
A.4 Assembly
The following general rules apply to assembly of any component.
1. When torque values are specified, be sure to use a torque wrench and tighten to the specified torque value. If a tightening sequence is specified, follow the sequence. If none is given, tighten evenly and alternately around the bolt circle.
2. Always pre-pack anti-friction bearings with suitable bearing grease before installation.
3. Install all bearings as instructed under Subtopic A.5.1.
4. Inspect all grease passages to be sure they are open and clean.
5. Smooth all nicks, burrs, or galled spots on shafts, bores, pins, gears and bushings. Pay particular attention to oil seal seating areas to ensure that shaft irregularities do not lead to seal wear and lubrication leaks.
6. Check the fit of keys in keyways. Shaft keyways have an interference fit which should not be altered.
BD120149 Mechanical Systems Manual General Maintenance
A.5 Maintenance Of Specific Components
A.5.1 Bearings
A.5.1.1 Removal
Most bearings are removed by means of a bearing puller or driver. In either case, the puller or driver should contact only the inner bearing race to prevent damage to the bearing. Inspection and repair. Inspect all bearings for wear, binding, excessive play, distorted races and roller wear or damage. Always replace worn or damaged bearings.
NOTICE
Some organizations make it a practice to replace all bearings in crucial applications whether ornot damage is apparent. The cost of the part is often minor in comparison with the cost of redo-ing the job should the part fail.
A.5.1.2 Installation
Prepack all anti-friction bearings with a good grade of bearing grease before installation. Many bearings require an interference fit between the inner race and the shaft on which the inner race is mounted. To obtain the required interference fit, the bearing must be heated, the shaft must be cooled, or a combination of both methods may be necessary. It is usually easiest to heat the bearing, and this is the method most commonly used. Use an oven, a bearing heater, or an oil bath for heating a bearing; do not use a torch. Once the bearing has been properly heated, it must be pressed into position on the shaft in one smooth and continuous operation. Do not allow the bearing to stop short of it's final position, since it will quickly “freeze” on the shaft and will then have to be removed and reheated before it can be properly installed.
CAUTIONNever use hot alkaline solutions on bearings (or other finished parts) because the alka-line solutions will score or damage finished surfaces.
CAUTIONNever spin dry bearings with compressed air since this will damage the bearings.
A.5.2 Couplings
Power transmission couplings are the usual means of connecting coaxial shafts so that one shaft can drive the other. For example, they may be used to connect an electric motor to a pump shaft or to connect two pieces of shafting together to obtain a longer shaft extension.
Couplings are manufactured in many types, styles and sizes. However, they can be classified into two groups: Rigid couplings (sometimes called solid couplings) and flexible couplings. Each is discussed below.
A.5.2.1 Rigid (Solid) Couplings
These couplings connect shaft ends together rigidly, making the shafts so connected into a single continuous entity. They are generally used when true alignment and a solid coupling are required, as with line shafting. Solid
General Maintenance BD120149 Mechanical Systems Manual
couplings are self-supporting and automatically align the shafts to which they are attached when the coupling halves on the shaft ends are connected. Solid couplings require the following for good service:
1. Coupling halves must be interference fits on shafts
2. After installation, all surfaces of the coupling must be checked for runout and surfaces found to be running out must be machined true. Checking of surfaces for runout is especially necessary if the coupling halves are assembled by driving or bumping rather than pressing.
Rigid couplings should not be used to connect shafts of independent units which must be aligned at assembly.
A.5.2.2 Flexible Couplings
Flexible couplings are used to connect two independently supported coaxial shafts so one can drive the other. For example, prime movers such as internal combustion engines and electric motors are usually connected to gear reducers and pumps by means of flexible couplings.
For this type of application, the flexible coupling is used because it is practically impossible to obtain perfect align-ment of the adjacent shafts. Also, there is usually wear occurring in the connected components and their shaft bearings, as well as movement from temperature changes and external forces such as vibration.
Therefore, to enable coaxial shafts to operate satisfactorily with slight misalignment, flexible couplings, depending on the design, may allow one or more of the following misalignments:
Angular Misalignment
Parallel Misalignment
Axial Movement (End Float)
Torsional Movement (Twisting)
Most flexible couplings are made up of three basic parts: two hubs mounted on the shaft ends to be connected, and a flexing element that transmits power from one hub to the other. Most flexible couplings fall into one of the fol-lowing categories:
Chain Couplings
A chain coupling is one having two sprockets with hubs for attachment to the shafts, connected by a length of dou-ble chain having links which mesh with the sprocket teeth. This type of coupling normally requires lubrication.
Gear Couplings
Gear couplings are made up of meshing internal and external gears or splines. Flexibility results from both the fit of the teeth and the special shaping of the teeth that permits them to pivot in relation to each other. This type of cou-pling normally requires lubrication.
Jaw and Slider Couplings
These couplings usually have two hubs which attach to the shafts. The hubs are connected by a sliding member which provides flexibility. The slider is connected to the hubs by jaws, keys, or splines. These couplings usually require lubrication.
BD120149 Mechanical Systems Manual General Maintenance
This is a very common type of coupling. The most commonly used resilient flexible materials are metal and rubber (or synthetic substitute). These couplings allow angular and parallel misalignment and end float. Those using rub-ber elements have more torsional flexibility than most other types of couplings. Most of these couplings do not need lubrication, except the ones using flexible metal elements.
A.5.3 Alignment
In preparing to align a coupling, it must be determined which unit is to be adjusted - the “driving” or the “driven” unit. Common practice is to position, level and secure the driven unit as required and then adjust the “driver” to align with it. The driven unit must be set with its shaft centerline slightly higher than the driver to allow for alignment shims.
Coupling alignment consists of bringing the centerlines of two coaxial shafts into alignment, rather than aligning the surfaces of the coupling. For example: If the coupling hub surfaces do not run true with the shaft centerline, align-ment of the untrue surfaces will result in misalignment of the shaft centerlines. True running surfaces are therefore a vital requirement if the alignment procedures that follow are to be successful.
There are two kinds of shaft misalignment: Angular Misalignment and Parallel Misalignment.
Note that misalignment of the shaft centerlines may occur in any plane within a full circle. Angular misalignment may be a tilt up, down, or to the side of one shaft in respect to the other. Parallel misalignment may be one shaft high, low, or to the side of the other. The usual method of correcting alignment is to check and adjust in the vertical and horizontal planes as illustrated in Figure A-4.
To align centerlines of coaxial shafts in both the vertical and horizontal planes requires four distinct operations: An angular and parallel alignment in the vertical plane and the same in the horizontal plane.
To do an alignment properly requires an organized procedure. Since adjustments are usually made by inserting shims at low support points, an important first step is to check the foundation of the unit to ensure that no rocking motion exists. If rocking does exist, eliminate it by shimming before proceeding. Tools best suited for coupling alignment are the straight edge, feeler gauge, and taper gauge. The taper gauge is just what it implies, a tapered piece of straight metal which allows direct reading instead of the “trial and error” type of reading obtained by a feeler gauge.
Two methods of coupling alignment are commonly used: the straightedge-feeler gauge method and the dial indica-tor method. Each method will be illustrated using specific measurements as examples after the following general explanation. In both methods, four alignments are performed in a specific order, although the final two steps are combined into one in the numbered procedure below.
NOTICE
Only when adjustments are performed in the correct order can a succeeding adjustment be per-formed without disturbing prior settings.
A.5.3.1 Vertical Face Alignment
To adjust vertical face alignment, it is necessary to tip the unit as required. First, measure the gap at the top and bottom of the coupling; then, shim as required to align these faces.
The easiest way to determine the amount of shims required is as follows:
General Maintenance BD120149 Mechanical Systems Manual
The tilt required at the coupling face is the same as the angle of change at the base of the unit. Therefore the shim thickness required is proportional to the misalignment.
As an example, the misalignment at the coupling faces is 0.006" in 5 inches. Therefore, each five inches of base must be tilted 0.006" to correct misalignment. Since the base length is 10 inches, the shim thickness required is twice 0.006" or 0.012".
NOTICE
A rule for shim thickness selection is: Shim thickness is as many times greater than the mis-alignment as the base length is greater than the coupling diameter.
A.5.3.2 Vertical Height Alignment
Measure the height difference from the coupling hub base to the shaft centerline. Then raise the lower unit as required without changing its angular position. This adjustment corrects parallel misalignment in the vertical plane.
A.5.3.3 Horizontal Face and OD Alignment
When the units are properly aligned vertically, shimming is complete. Then move the unit as required to align the coupling hub faces and O.D's at the sides of the coupling.
1. Using feeler gauges, measure the width of the gap at top and bottom between the coupling faces.
2. Assume the gap at the top is 0.160 and at the bottom is 0.152. This equals 0.008" misalignment in 5 inches (the diameter of the coupling). Base length is 12 inches. Therefore, shim thickness required is about 2-112 times 0.008" or about 0.020". A shim placed under the low end of the driver will tilt it into approximate angular alignment with the driven unit.
3. Using a straightedge and feeler gauges, measure the height difference between driver and driven unit height at the OD of Figure A-8. Straight Edge Feeler Gauge Alignment the coupling halves. Then, place shims at all driver support points equal in thickness to the measured height difference.
4. Finally, use a straightedge to check alignment of O.D's at the sides of the coupling. Using a feeler gauge, check the gap between coupling hub faces at the sides of the coupling. Adjust the driver as necessary to align the O.D's and to set the gap equal at the sides.
A.5.5 Coupling Alignment - Dial Indicator Method
A dial indicator can be used in two ways to check coupling alignment. They are:
1. Attached to one shaft or coupling half while contacting the second hub or shaft while both shafts are rotating, or
2. Attached to one shaft or coupling half while contacting the second hub or shaft while one shaft is rotating.
The ideal method is the first, dial indicating while both shafts are rotating. In this method, when the indicator is rotated its tip will proceed in a circle which is concentric with the shaft bearings. The mating unit shaft should also
BD120149 Mechanical Systems Manual General Maintenance
be rotated, since the point contacted by the indicator tip will also describe a true circle. When these two circles coincide (zero runout on the indicator) the shafts will be in alignment in the plane being measured. The reason this method is ideal is that coupling surface runout does not affect the accuracy of shaft alignment. In other words, it is possible by this method to accurately align shafts in spite of coupling surfaces that are not running true to each other. However, in some cases, the above method is not possible. In such cases, it becomes necessary to use the method of attaching the dial indicator to one shaft or coupling half while contacting the second hub or shaft while one shaft is rotating. Refer to Figure A-9 and proceed as follows:
A.5.5.1 Vertical Face Alignment
Attach the indicator to the shaft or coupling half of the driver. Place the indicator tip in contact with the face of the coupling half on the driven unit. Rotate the shafts of both units together and note the total indicator readings (T.I.R.) at top and bottom. T.I.R. is a measure of vertical angular misalignment. Place shims (calculate the amount as pre-viously described) under the driver at the low end to bring it into vertical alignment with the driven unit.
A.5.5.2 Vertical Height Alignment
Place the indicator tip in contact with the outside surface of the driven unit coupling half. Rotate shafts of both units. Note the indicator readings at top and bottom. The height difference between the units is one-half of the T.I.R. Place shims at all driver support points equal to one-half total indicator runout.
A.5.5.3 Horizontal Face Alignment
Place the indicator tip in contact with the face of the driven unit coupling half. Move the driver as necessary to obtain zero reading on the indicator.
A.5.5.4 OD Alignment
Place the indicator in contact with the OD surface of the driven unit coupling half. Move the driver as necessary to obtain zero reading on the indicator. Repeat steps 3 and 4 as necessary to obtain zero readings on both face and OD surfaces at the sides of the coupling. Do not disturb shims during horizontal alignment adjustments.
A.5.6 Sheaves
1. Inspect sheaves to see that belts or wire rope have not worn grooves into the sheaves. Replace sheaves when wear grooves appear since grooves will cause rapid and dangerous belt or rope damage.
2. Make sure the belt or wire rope is correctly sized for the sheave on which it is being used. If there is any doubt, check your operating and/or maintenance manual to determine the proper size for the application.
A.5.7 Gears
Some of the basic terms associated with gears are defined under the topic “Terminology”. Some of the defects for which gears should be inspected are defined under “Inspection”.
TERMINOLOGY.
ADDENDUM. The addendum is the distance a gear tooth extends above the pitch circle (or circular pitch).
BACKLASH. Backlash is the difference between the thickness of a tooth and the width of the gap between the two gear teeth on it's mating gear. Backlash is necessary to compensate for variations in spacing and form of the gear
General Maintenance BD120149 Mechanical Systems Manual
teeth, to provide space for lubricant, and to allow expansion of the teeth when their temperature increases during operation.
BOTTOM LAND. The bottom land is the surface at the bottom between adjacent gear teeth.
CIRCULAR PITCH. Circular pitch is the distance along the pitch circle or pitch line between the corresponding pro-files of adjacent teeth.
CIRCULAR THICKNESS OF TOOTH. The circular thickness of a tooth is the length of the arc between the two sides of a gear tooth as measured along the pitch circle unless otherwise specified.
CLEARANCE. Clearance is the radial distance between the working depth circle and the root circle.
DEDENDUM. The dedendum is the depth of the tooth space below the pitch circle or pitch line; the radial distance between the pitch circle and the root circle.
FACE WIDTH. The face width is the length of a gear tooth in the plane parallel to the shaft centerline (the axial plane).
FILLET CURVE. The fillet curve is the concave portion of the tooth profile where it joins the bottom land.
PITCH CIRCLE. Pitch circle is the curve of intersection of a pitch surface of revolution and a plane of rotation. It is the imaginary circle that rolls without slipping with a pitch circle of a mating gear.
ROOT CIRCLE. The root circle is tangent to the bottom of the tooth space when viewed in a cross section.
TOOTH PROFILE. Tooth profile is one side of a gear tooth in a cross section between the outside circle and the root circle.
WORKING DEPTH. The working depth is the depth of engagement of two gears; the sum of the operating adden-dum.
TOP LAND. The top land is the surface of the top of the gear tooth.
WHOLE DEPTH. The whole depth is the distance from the top land to the bottom land.
A.6 Gear Tooth Wear
A.6.1 Inspection
All gearing should be inspected for signs of wear or damage. If any of the problems illustrated and discussed below are found, the problem should be corrected and, if necessary, the gear or gear set should be replaced as soon as possible.
A.6.2 Gear Wear
Gear wear is usually caused by abrasion, corrosion or lubrication failure. Each is discussed below:
BD120149 Mechanical Systems Manual General Maintenance
NOTICE
If a damaged or worn pinion or gear must be replaced always replace the mating gear or pinion.Do not run a new pinion or gear with a worn mating part as rapid failure of the parts will result.
1. Abrasion. Abrasive wear is typified by a lapped appearance, radial scratch markings or grooving of the tooth contact surfaces and is generally caused by foreign material in the lubricating oil.
2. Corrosion. Corrosive wear is a deterioration of the tooth surface caused by chemical action. It often results from active ingredients in the lubricating oil such as acid, moisture or extreme pressure additives. Lubricants can also be contaminated by atmospheric chemicals, or chemicals or other materials (such as salt water) which somehow leak into the lubricant supply.
3. Lubricant Failure. Lubricant failure results in allowing metal-to-metal contact of gear teeth. This causes over-heating, which produces alternate welding and tearing of the metal, thus removing metal from the tooth sur-faces. This is called “scoring”. The most common cause of this problem is localized overheating of the teeth at the point at which they mesh, causing breakdown of the lubricant film. Another similar condition called “frost-ing” is a form of scoring typified by micropitting under thin lubricant film conditions.
A.6.3 Surface Fatigue
Surface fatigue of gear teeth is divided into three primary categories. They are:
1. Pitting. Pitting occurs when the endurance limit of the tooth material is exceeded. The usual causes are over-loading or excessive shock.
2. Spalling. Spalling is similar to pitting except that the pits are usually larger, very irregular in shape and quite shallow. Spalling is usually caused by high contact stress levels. The edges of the initial spalled areas break away rapidly and larger irregular voids are formed. These voids often join together and form still larger voids.
3. Case Crushing. Case crushing is a subsurface fatigue failure which occurs when the endurance level of the tooth material is dramatically exceeded. Severe shock loading is the most likely cause of case crushing.
A.6.3.1 Plastic Flow
Plastic flow consists of deformation of tooth surfaces caused by high contact stresses as the gear teeth mesh. There are two basic types of plastic flow. They are:
1. Cold Flow. Cold flow is the cold-working deformation of tooth surfaces caused by high contact stresses and the rolling and sliding action of the meshing teeth. The dents and battered appearance of the surfaces are a result of dynamic loading due to operation while the tooth profiles are being damaged by a combination of cold-work-ing and wear.
2. Rippling. Rippling is generally caused by high contact stresses under cyclical operation. This has a tendency to roll and knead the contact surfaces, resulting in the rippling of the immediate surface.
A.6.3.2 Gear Backlash
Gear backlash is the play between teeth which prevents the gears from binding while in motion. It is built into the gearset during manufacture. In terms of tooth dimensions, it is the amount by which the width of the tooth spaces exceeds the thickness of the mating gear teeth. Backlash can also be described as the distance, measured along the pitch line, that a gear will move when engaged with another gear that remains motionless.
General Maintenance BD120149 Mechanical Systems Manual
Normally, there must be some backlash present in gear drives to provide running clearance and room for lubricant. Without backlash, gear binding will result in heat generation, noise, abnormal wear, and possible failure of the gearset.
Backlash is built into standard gears by cutting the gear teeth thinner by 50% of the backlash desired in the set. When two gears made in this manner are mated, at proper center-to-center distance, their two 50% allowances combine to give 100% of the backlash desired by the designer.
On non-reversing drives, or where load is applied in only one direction, the increase in backlash that results from tooth wear does not adversely affect operation. However, on reversing drives and drives where timing is critical, excessive backlash cannot be tolerated.
The following illustration and chart can be used as a rule of thumb to obtain the approximate backlash for a pair of gears operating at standard center distance. See Figure A-12. This chart should only be used when the manufac-turer's recommendations can not be obtained. If any discrepancy between the chart and manufacturer's recom-mendations exists, the manufacturer's instructions take precedence.
In general, check backlash as follows:
1. Hold one gear motionless.
2. Turn the mating gear until it contacts the motionless gear.
3. Install a dial indicator touching the gear which can be moved on the side toward which it can be moved and turn the gear as far as it will go.
4. Read the total backlash on the dial indicator. Note that feeler gauges can often be used in place of a dial indi-cator. The space which constitutes backlash is illustrated in Figure A-12. Backlash must be held within the lim-its specified by the manufacturer or rapid gear wear will result.
A.6.4 Shafts
All shafts should be inspected for nicks, burrs, and wear ridges prior to reinstallation. Smooth defective areas using crocus cloth, India Stone or a very fine file. It is particularly important that shaft seal surfaces (surfaces on which seal lips fit) be smooth to prevent seal lip wear, which will cause lubricant leaks. Keyways must be free of nicks and burrs.
BD120149 Mechanical Systems Manual General Hydraulic System Maintenance
Appendix B
General HydraulicSystem Maintenance
B.1 General
Maintenance of individual hydraulic system components such as motors, pumps or valves is included in the system of which the component is a part. For example, maintenance and repair of the propel motor is covered under Pro-pel System. The purpose of this section is to discuss maintenance of hydraulic systems in general.
This section includes general procedures to be followed in the event of hydraulic component failure, preventive maintenance, bleeding procedures, flushing procedures, and recognition of trouble symptoms.
B.2 General Maintenance Rules
The following points should be kept in mind when working on the hydraulic system or any components of the sys-tem:
CAUTION!
Pressurized fluid escaping from a hydraulic system can penetrate the skin causing seri-ous injury. Always relieve pressure by connecting a microbore hose from the appropri-ate test port to the tank test port before disconnecting hydraulic lines. Tighten allconnections before reapplying pressure. Keep hands and body away from pinholes andnozzles which eject fluid under high pressure. Use a piece of paper to search for leaks.Do not use your hands. If any fluid is injected into the skin, it must be surgically removedwithin a few hours by a medical doctor or gangrene can result.
1. All systems are designed to operate within minimum and maximum pressure limits. A pressure relief (unload-ing) valve is included in nearly all systems to limit maximum pressures to levels for which the system is designed.
WARNING!
The setting of a pressure relief or unloading valve must never be increased in an attemptto “get more out of the system”. This could cause the system to operate at a pressurelevel for which it was not designed and equipment damage and/or personnel injury ordeath could result.
2. Because internal leaks waste the power of the system, working parts are designed for extremely close fits. Because of the necessary close fits, even very small amounts of dirt or foreign material can cause wear or damage to components, which will, in turn, cause faulty operation of the system. Every precaution must be
General Hydraulic System Maintenance BD120149 Mechanical Systems Manual
taken to assure absolute cleanliness of hydraulic oil. This includes dirt, chips from failed parts of the system, as well as contaminants such as water or other fluids which are incompatible with the fluid in the system.
3. To ensure cleanliness of the system oil, samples should be drawn from the reservoir every 6 month (more often, if problems are experienced). Each sample should be taken by an approved sampling procedure (e.g. IS0 Standard 4021) and analyzed by a qualified lubrication specialist to determine whether it is suitable for fur-ther use. The interval between normal hydraulic fluid replacements depends on operating conditions and on successfully keeping contaminants out of the system.
4. Whenever there is a hydraulic system component failure that gives reason to believe that there are metal parti-cles or other foreign materials in the system, drain and flush the entire system, clean strainer baskets and replace filter cartridges. A complete change of hydraulic oil must be made under these circumstances.
NOTICE
Flushing the hydraulic system is time consuming and expensive. Therefore, it should be doneonly when necessary. However, avoiding a flush when there is clear evidence of a contami-nated system will prove to be a false economy in the long run.
5. Whenever the hydraulic system is drained, check the magnetic drain plugs for metal particles. If metal particles are present, flush the system and add a new charge of oil.
6. Never change the type of oil used in the system without first checking that the replacement oil is acceptable for use in the system.
7. All containers and funnels used in handling hydraulic oil must be very clean. Use a funnel with a 200 mesh screen for filling the hydraulic oil reservoir and fill the reservoir only through the filler opening. The use of cloth to strain the oil is not acceptable because this will allow lint to enter the system.
8. When removing any hydraulic component, be sure to cap and tag all hydraulic lines involved. Always plug the ports of the removed components.
9. All hydraulic components must be disassembled and assembled in spotlessly clean surroundings. During dis-assembly, pay particular attention to the identification of parts to ensure correct reassembly. Clean all metal parts in a clean mineral oil solvent. Be sure to clean all internal passages. After the parts have dried, lay them on a clean lint-free surface for inspection.
10. Replacement of all O-rings, back-up rings and seals is recommended when overhauling any component. Lubri-cate all parts with hydraulic oil before reassembly. Use small amounts of petroleum jelly to hold O-rings in place during reassembly.
11. Replace all lost hydraulic oil after completing installation of repaired components. Always maintain a sufficient quantity of clean hydraulic fluid of the proper type and viscosity in the reservoir.
12. Bleed air from the system after components have been removed from the system or when it is suspected that air has entered the system.
13. Keep all hydraulic connections tight. A loose connection in a hydraulic line will permit the oil to leak out or air to be drawn into the system. Air in the system can cause damage to components as well as noisy or erratic sys-tem operation.
14. Change filter elements and clean strainers when necessary.
BD120149 Mechanical Systems Manual General Hydraulic System Maintenance
B.2.1 Correct Tightening of Hydraulic Connections
The following procedures are recommended to ensure that system hydraulic connections are correctly made and to minimize the probability of system leaks.
General Hydraulic System Maintenance BD120149 Mechanical Systems Manual
B.2.2 Pipe Thread ConnectionsPipe thread connections tend to leak more at high pressure than any other style of connection. National pipe threads (NPT) leak much more than do the dry seal thread (NPTF) types. However, either will leak if under-tightened or over-tightened. Use a good pipe thread sealant on NPT threads of the male connection, but do not use sealant on the first two threads. This will pre-vent the sealant from entering the system. Always apply sealant on male threads - never apply sealant to female threads. The most probable causes and remedies for pipe thread leaks are listed in Table B-1.
B.2.3 SAE Flare ConnectionsMost leaks from this type of connection are due to lack of tightening and human error. It is impossible to tell if the nut has been tightened by simply looking at the connection. Figure B-1 shows one method of tightening this type of connection. If the joint still leaks after it has been correctly tightened, refer to Table B-2 for possible remedies.
This type of connection leaks most often because the jam nut and washer are not properly installed before assem-bly of the fitting. As a result, there is not enough room for the O-ring to seat when it is squeezed and the washer cannot seat properly on the face of the O-ring boss (View A, Figure B-2). The compressed rubber between the washer and the boss face will cold flow out of compression and the fitting will loosen and leak. Leakage from straight thread connectors may be indicated by any of the following:
General Hydraulic System Maintenance BD120149 Mechanical Systems Manual
E. Tighten the jam nut to achieve the O-ring seal as illustrated in View B, Figure B-33.
B.2.5 Split Flange Connections
Table B-3 lists probable causes and remedies for split-flange connection leaks. To install a split flange connection, refer to Figure B-4 and proceed as follows:
1. Thoroughly clean the sealing surfaces and the flanges.
2. Lubricate and install the proper O-ring in the fitting groove.
3. Align the fitting with the port and assemble the flanges over the fitting.
BD120149 Mechanical Systems Manual General Hydraulic System Maintenance
4. Snug the bolts in the sequence shown in Figure B-4 to 113 of the torque value obtained from Table B-4. Be sure the flanges remain square with the fitting and bolt surface.
5. Torque the bolts diagonally to 213 of the final torque value from Table B-4.
6. Torque the bolts diagonally to the final torque value in Table B-4.
General Hydraulic System Maintenance BD120149 Mechanical Systems Manual
B.2.6 Flat Face O-ring Seal Connections
Flat face O-ring seal connections allow installation or replacement of connecting parts without mating piping. O-ring failure is the primary cause of leaks in this type of fitting. Contamination, improper fluid, or improper installation of the O-ring or fitting may cause premature failure of the O-ring. To install a flat face O-ring seal fitting, proceed as follows:
1. Be sure the fitting sealing surfaces are clean and free of defects. See Figure B-5.
BD120149 Mechanical Systems Manual General Hydraulic System Maintenance
2. Inspect the O-ring. It must be free of defects.
3. Lubricate the O-ring and install it in the groove. Use petroleum jelly to hold the O-ring in place.
4. Assemble the fitting and hand tighten while pressing the joint together. This will ensure that the O-ring remains in proper position.
5. Tighten the connection to the torque value specified in Table B-5.
B.2.7 Troubleshooting Hydraulic Systems
Probably the greatest aid to troubleshooting is knowledge of the system. Every component has a purpose in the system. The construction and operating characteristics of each component should be understood.
General Hydraulic System Maintenance BD120149 Mechanical Systems Manual
B.2.8 Developing Systematic Procedures
To troubleshoot a system effectively, develop a logical sequence of looking for the cause of the problem, using some or all of the following techniques:
1. Ask the operator how the machine performed when it started to fail or if there was anything unusual happening prior to the machine failure.
2. If the machine is operative, check to see what gauge or other indications are normal and which are out of nor-mal limits.
3. Visually inspect the machine for oil leaks and loose connections.
4. Examine filters and all lines, checking for heat, loose connections and collapsed hoses.
B.2.9 Recognizing Trouble Symptoms
The following symptoms are signs of trouble:
B.2.9.1 Excessive Heat
A misaligned pump places an excessive load on bearings and can be readily identified by the heat generated. A warmer than normal return line may indicate that the system is operating at the unloading valve setting. Low vis-cosity hydraulic oil will increase the internal leakage of components, resulting in a heat rise. Cavitation and slip-page in a pump will also generate excessive heat.
B.2.9.2 Excessive Noise
Wear, misalignment, cavitation or air in the oil will cause noise. Contaminated oil can cause an unloading valve to stick or chatter. Excessive noise may be the result of dirty filters or fluid, high fluid viscosity, excessive drive speed, low reservoir level or loose intake lines, which would allow air to enter the system.
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BD120149 Mechanical Systems Manual
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To assist us in providing you with the most useful publications, we ask that you use this form to express your views concerning this publication, its organization or subject matter, with the understanding that P&H Mining Equipment may use or distribute whatever information you supply in any way it believes appropriate without any obligation to you. All comments and suggestions are both welcome and appreciated.
To report machine problems or to request additional publications, do not use this form; rather, contact the nearest P&H MinePro Services office. They will forward your information or requests to the appropriate division at P&H Mining Equipment.
Please use the space below to identify errors, suggest changes, or to provide additional comments. Includedrawings, photographs, or other graphics as appropriate. For comments regarding the manual, please refer to page numbers and/or paragraph numbers. If necessary, use additional sheets and mail in an envelope.
