Section 6 - MAINTENANCE, PV351D-RCS4 Instruction Manual Hydraulic System Table 19: Hydraulic Tank Maintenance Service Interval Type of Service Hydraulic Capacity ‘Approximately 360 Gallon (1360.8 liters) Required Lubricant: ISO AW32 Only Frequency to Inspect: | None Required | Operator Display will indicate when hydraulic filters require replacing. 40hours or | Check oil level in hydraulic tank. Add if every day low. Frequency to Sample: | Every 500 ‘Sample hydraulic fluid. Change fluid is operating hours | sample indicates necessary. Frequency to Replace: | 2000 hours Replace hydraulic tank breathers (4), 5000 hours Change hydraulic fluid (ISO AW32 Only) Replace hydraulic filters when Operator Display indicates or at 5000 hours. Check Oil Level add hydraulic oil, Check the hydraulic oil level in hydraulic reservoir every 10 hours or daily. The following procedure is proper for checking the oil level in the reservoir. If the hydraulic oil level is low, 1. The drill must be level. 2. The tower must be horizontal, the power head at the top of the tower, and all leveling jacks fully retracted. 3. Verify uid level is near the maximum level indicated on the sight glass. HIGH MARK HYDRAULIC FLUID LEVEL, SIGHT GLASS HYDRAULIC. RESERVOIR LOW MARK DRILLING SOLUTIONS 6-556-56 PV351D-RCS4 Instruction Manual Section 6- MAINTENANCE Excessive hydraulic oil can rupture hydraulic tank and cause injury or property damage. Do not fill hydraulic tank with cylinders extended. Retract all cylinders and fill tank to indicated level, Liquid explosion can cause severe injury. Disconnect heater before draining or filling system. leiteS Do not use the quick-fill system to drain or remove fluid. Use the fittings at the bottom of the hydraulic tank. Add hydraulic oil through the quick-fill using the following procedure: Add Hydraulic Oil 1. The drill must be level. 2. The tower must be horizontal with the rotary head at the top of the tower, and all leveling jacks must be fully retracted. 3. The engine must not be running. 4. Ensure the breathers on top of the tank are clean and will allow the tank to breathe. 5. Locate the proper fitting in the quick-fill box for hydraulic tank, Remove cap and clean the fitting. HYDRAULIC PORT DRILLING SOLUTIONSSection 6 - MAINTENANCE PV351D-RCS¢4 Instruction Manual 6. Locate the proper quick-fill hose. Clean the hose fitting and connect to quick-fill fitting, 7. Add or refill with new and clean oil 8. Verify the low hydraulic oil level operator alarm tums off when the float reaches the safe level (bottom of the sight glass). 9. Verify hydraulic tank has not been over filled. Fluid should not be above the top of the sight glass. 10. Verify both of the main valves under the tank are fully open, Add hydraulic oil through the manual quick connect port in the return/drain manifold using the following procedure: 1. The drill must be level. 2. The tower must be horizontal with the rotary head at the top of the tower, and all leveling jacks must be fully retracted, The engine must not be running. 4, Make sure the breathers on top of the tank are clean and will allow the tank to breathe 8. Locate the proper fitting in the hydraulic return/drain manifold. Remove cap and clean the fitting MANUAL FILL QUICK CONNECT PORT DRAINRETURN MANIFOLD 6. Locate the proper quick fill hose. Clean hose fitting and connect to quick fill fitting. ‘Add new and clean oil Verify tank has not been over filled Fill the hydraulic tank with proper fluid. Verify the low hydraulic oil level operator alarm turns off when the float reaches the safe level (bottom of the sight glass). 410. Verify both of the main valves under the tank are fully open. DRILLING SOLUTIONS 6-576-58 PV351D-RCS¢4 Instruction Manual Section 6- MAINTENANCE, Grease Drum ‘The operator display will indicate the grease must be replenished if needed prior to the 10 hour or daily check. To add grease, follow these steps: 1, Add new grease through the Quick-Fill Grease Port. COOLANT ENGINE OIL, COMPRESSOR PORT PORT OIL PORT GREASE HYDRAULIC DIESELFUEL ENGINE OIL PUMPORWVE THREAD OIL PORT PORT PORT Ear PORT GREASE 2. An indicator light above the Quick-Fill will glow bright when the grease tank level is near full. STOP ADDING GREASE WHEN LIGHT IS GLOWING BRIGHT. The tank has a visual dial indication of grease level and should be monitored while tank is being filled. VISUAL, INDICATOR GREASE TANK 3. Follow the procedure below to check for leaks @. Look for signs of excessive grease around grease points and on the drill b. Inspect the areas of concern closely to determine if leaks exist or the injector needs to be adjusted. DRILLING SOLUTIONSSection 6 - MAINTENANCE. PV351D-RCS¢4 Instruction Manual ¢. Ifa leak is verified or an adjustment is required, contact maintenance and ake corrective action. 4, To check the grease level, follow the procedure below. a. The drill is equipped with a fluid monitoring system. Under normal conditions the operator display will indicate "Low Tank Level” when required. b, When the main power is “off” or the system is malfunctioning, use the visual gauge on top of the tank, Note: The visual gauge should be compared with the operator display on a daily basis. Pump Drive Gearbox The type of service and the operating conditions will determine the maintenance interval. However, it is recommended that the oil level be checked daily. At the same time, check for oil leaks. Because the lubricant system is the heart of the unit, it is especially important that the oil be kept clean. Table 20: Pump Drive Gearbox Service Interval Type of Service Frequency to Inspect: | 10 hours or | Check gearbox oil level. (Add oil if low). every day ———— —| Check for hydraulic leaks. Frequency to Replace: | 100 hours Change initial gearbox cil 1000 hours Change gearbox oil every 1000 hours. Note: The oil in the pump drive gearbox should be changed whenever the oil shows traces of dirt or the effects of high temperature, evidenced by discoloration or strong ador. Hotoil or components can burn. Avoid contact with hot oil or components. Do not allow used oil to drain into the ground. Dispose the used oil properly. Check Oil Level 1. Move the drill to a level surface 2. Stop engine before checking or adding oil 3. Dipstick - If the gearbox is furnished with a dipstick, clean around the oil level dipstick and the oil fill plug before checking or adding oil DRILLING SOLUTIONS 6.59eco PV351D-RCS4 Instruction Manual Section 6- MAINTENANCE ._ No Dipstick - If the gearbox is not furnished with a dipstick, clean around the 7. Ifnecessary, add SAE 80W90 cil and fill o the correct level. Always use clean DIPSTICK Check the oil level within the gearbox with the dipstick. Remove the dipstick and wipe it clean. Insert and withdraw the dipstick to read the oil level within the gearbox. petcock (Full" level check port) and oil fil plug before checking or adding oil PETCOCK (FULL LEVEL CHECK PORT BREATHER VENT ‘QUICK DRAIN HOSE CONNECTION POINT ‘Slowly open the petcock and verify fluid flows out of the port. oil from clean containers. Do not overfill. This will cause overheating. The required lubricant must meet EP goar lubricant spec MIL-L-2105C or API classification GL-5. Maximum operating oil temperature is 25°F (107°C). SAE 80W90 oil is recommended for use when ambient temperatures are between -10°F (-23.3°C) and 100°F (38°C). Mobil SHC 630 is recommended for use when ambient temperatures are above 100°F (38°C). Check and clean the gearbox breather. DRILLING SOLUTIONS:Section 6 - MAINTENANCE PV351D-RCS64 Instruction Manual Inspect Pump Drive Gearbox Inspect the hydraulic pump drive gearbox for leaks by the following steps. HYDRAULIC PUMP DRIVE. GEARBOX Look for signs of oil on the case and around the bottom of the case. 2. If there are signs of cil leakage, clean the outside of the case and around the bottom. Verify signs of oil are from the case and not another source. 3. Ifa leak is verified, contact maintenance and take corrective action Receiver Tank Table 21: Receiver Tank Maintenance Service Interval Type of Service Receiver Capacity: 60 Gallon (227.1 liter) Required Lubricant: DRILLCare™ LP-150 Frequency to Inspect. | 10 hours or Check oil level in receiver tank. every day Frequency to Change: | 1000 hours Change compressor oil 2500 hours Replace receiver separator element Check Compressor Oil Level Check compressor/receiver oil level at the sight glass on the receiver. The procedure to check fluid level is as follows: DRILLING SOLUTIONS 661PV351D-RCS4 Instruction Manual Section 6- MAINTENANCE MANUAL LOWER SIGHT UPPER SIGHT FILL PORT GLASS GLASS 1. The engine must “off” and not be running, There must be zero pressure in the receiver tank. The fluid level should be between the bottom of the lower sight glass and near the top of the upper sight glass 4, Add fluid if level is low. Required lubricant is DRILLCare™ LP-150. Oil Carry Over Check daily for oil carry over. Oil carry over is simply a condition where the receiver separator ‘element is not completely separating the air and oil in the receiver tank. Oil is getting past the ‘separator element and entering into the drill air going down the drill string. There are two main indicators of oil carry over to watch for. 41. Ifthe cil level keeps dropping while driling, this is a good indicator there is cil carry over and needs to be checked further. 2. If you notice oil in the drill air string when adding drill rod, this is another indicator of oil carry over. If compressor oil is carried over into the drill string and the cause is the separator ‘element, replace the separator element. Change Separator Element ‘A change of the separator element is required when there is excessive oil carryover with the compressed air. Otherwise, change the separator element at 2500 operating hours. The following maintenance procedure must be followed: 1. Park the drill on a stable, level surface and shut down the engine. Allow time for the compressor cil to cool DRILLING SOLUTIONS.Section 6 - MAINTENANCE. PV351D-RCS¢4 Instruction Manual Do not attempt fo remove any hoses or remove the receiver tank cover while under pressure. the engine must be off and all pressure bled from the tank, ensuring zero pressure on the tank gauge. High pressure can cause severe injury or death. Do not attempt to remove any plugs or open the drain valve before making sure all air pressure has been relieved from the air system. Completely relieve air pressure before opening the drain valve or removing the filler plug, fittings or removing the receiver tank cover. Hot oil or components can burn. Avoid contact with hot oif or components. 2. Engine must net be running and the pressure bled from the tank. The gauge on the tank must read zero psi. 3. Verify no pressure is in system by opening the service air valve and checking the gauge. SERVICE AIR GAUGE SERVICE AR DRILLING SOLUTIONS 6-63PV351D-RCS4 Instruction Manual Section 6- MAINTENANCE 4. Remove the swivel nut and discharge hose from the swivel connector. Empty any fluid in the hose into an approved container. Place a clean rag or towel over tho end of the hose. Carefully and gently lay the hose end on the deck. TANK COVER BOLTS (REF.) SWIVEL CONNECTOR SWIVEL NUT DISCHARGE HOSE 5. Remove the tank cover bolts. Use a pry bar to keep door aligned during removal of the last bolt. 6. Swing tank cover open. Use a pry bar to keep door aligned during removal of the last bolt. The cover is heavy and will drop slightly, so be prepared while opening the cover. RECEIVER TANK DOOR OPEN, EXPOSING ELEMENT EB. CENTERING AND GUIDE \I am BAR TO ALIGN DOOR TO. —<- 7 = HOUSING BOLT HOLES. a acon DRILLING SOLUTIONSSection 6 - MAINTENANCE PV351D-RCS¢4 Instruction Manual 7. Remove the old element by grabbing the filter lange and lift while pulling. Use alifting device. This fiter will be heavy, so two people should be used to keep filer level while removing and replacing. Clean the gasket surface of housing, USE LIFTING DEVICE TO REMOVE. ‘AND INSTALL ELEMENT ‘SEPARATOR ELEMENT #5884241 UFT FLANGE WHILE PULLING 8. Inspect new filter to make sure it has the two scavenge holes, gasket is continuous and not damaged, and there are several grounding staples in the flange. Do not use a filter that is missing scavenger holes or grounding staples. SCAVENGE HOLES AT BOTTOM AND GROUNDING STAPLES DISTRIBUTED AROUND ENTIRE FLANGE 7 9. Use a lifting device and install the new element by raising it horizontal and slide it into housing. The element will have "TOP" stamped on the face. This should be toward the top of the opening as shown. You will feel some resistance when the end makes contact with the end guide. Push filter so flange is flush with housing. Make sure the scavenger holes in the filter are located at the bottom of the housing. Top SCAVENGE HOLES FRONT AND REAR FILTER GUIDES DRILLING SOLUTIONS 6-65PV351D-RCS¢4 Instruction Manual ‘Section 6- MAINTENANCE, Compressor Fire Prevention a. A fiber gasket is installed between the outside cover of the receiver tank and the metal tube holding the separator element in place. This gasket prevents cil from leaking around the metal tube and down the hole. b. When air and oil flow through the filter media, static electric charges are created. If these charges are allowed to build up, a spark similar to a lightning flash will occur. This will set the oil and the media on fire. The fire will burn from the inside of the element through the standpipe hose and will follow the air flow until it burns through the air hose, This is NOT a fire caused by the compressor flashing, c. To prevent this from happening, several metal staples have been installed THROUGH the gasket so each side comes in contact with the metal. This bridge serves to allow the static charge to drain off outside the receiver tank and not cause a static buildup When replacing the separator element, be sure there is at least one staple that shows through on both sides of the gasket and is not covered with glue. oO ouTsi0e coven. OUTSIDE COVER 0,0 99 PP] wa oasner ewe © exe) uncom ~ © OZQ| Osetra AND ALLOWS STATIC CHARGE TO BRAT. ‘OFF OUTSIDE RECENTER TANK. erat coven 10. Close and lift the cover. Use a guide bar to assist in aligning the cover's holes to the housing flange. Make sure the gasket seats properly. Apply “Anti-Seize” lubricant to the bolts and replace them into the cover. Torque these bolts to 250-270 ft. Ibs (339-366 Nm). 11, Remove the rag or towel from the end of the discharge hose and reattach to the swivel connector. 6-66 DRILLING SOLUTIONSSection 6 - MAINTENANCE PV351D-RCS¢4 Instruction Manual Change Compressor Oil Under normal operating conditions, the compressor oil must be changed every 1000 hours as Part of a routine maintenance program. Also, change the compressor oil filters whenever the compressor oil is changed ews High pressure can cause severe injury or death. Do not attempt to remove any hoses or the receiver tank cover while under pressure. The engine must be off and all pressure bled from tank, ensuring zero psi on tank gauge. Oil must be at normal temperature when draining. Hot oil or components can burn. Avoid contact with hot oil or components. Care must be taken to ensure fluids are contained during any inspection or work that is performed on this component. Handle and dispose of fluids according to local regulations and mandates. 1. Park the drill on stable, level surface and shut down engine. Allow time for the drill to cool. 2. The best time to drain the compressor oil in the receiver tank is when the oil is. warm. At that time sediment in receiver separator is in suspension and will drain with old oll. Temperature should not exceed 140°F (60°C) before draining oil Place a container with capacity of at least 60 gallon (227 liter) under drain point. Again, the engine must not be running and all pressure relieved from the receiver tank. The gauge on the tank must read zero psi. Verify no pressure is in the system by opening the service air valve and checking the gauge. SERVICE AIR ‘GAUGE SERVICE AIR DRILLING SOLUTIONS 6-676-68 PV351D-RCS4 Instruction Manual Section 6- MAINTENANCE Do not attempt to remove any plugs or open the drain valve before making sure all air pressure has been relieved from the system. 5. Make sure the blowdown valve muffler is clean and free of obstruction to allow air in and out. 6. Locate the proper fitting in quick-fill box for receiver lubricant (compressor oil). Remove the cap and clean the fitting. 7. Locate the proper quick-drain hose and quick-fill hose to attach to the quick-fill box. Clean the fittings on both hoses. Attach the quick-drain hose to the receiver fitting in the box. 8. Evacuate the receiver tank and allow the compressor oil to drain into a container. Dispose of the used oil in accordance with local guidelines. 9. Remove the quick-drain hose and clean the fittings. 10. Attach quick-fill hose. Fill receiver tank with DRILLCare™ LP.150 (required compressor oil) 11. Verify the receiver tank has not been over or under filled (correct as needed). DRILLING SOLUTIONSSection 6 - MAINTENANCE, PV351D-RCS¢4 Instruction Manual Rotary Head Table 22: Rotary Head Maintenance Service Interval Type of Service | Capacity: '55 Gallon (208.2 liter) Required Gear Oil: SAE 90W Required Grease: 5 Exxon Mobil Ronex Extra Heavy Duty Moly 2 (#57818221) Grease Frequency to Inspect. | 10 hours or | Check Rotary Head oil level. Frequency to Grease: | °VO'Y 49 Grease Upper Rotary Head Bearing Frequency to Replace: | 1000 hours Change Rotary Head Oil Rotary Head Oil Check the gear cil level in the rotary head every 10 hours or daily. The following procedure is proper for checking the oil level in the rotary head. If the gear oil level is low, add gear oil. Riding the rotary head can cause severe injury or death. Do not ride rotary head. Glimbing raised tower can cause severe injury or death. Do not climb raised derrick. A falling tower can cause severe injury or death. Ensure all locking pins are in locked position. Rotating shafts or drill string can cause severe injury or death. Do not service the rotary head with drill string in motion. 1. Level the drill. 2. With the tower vertical, bring the rotary head to bottom of the tower. 3. Inspect the case for leaks. DRILLING SOLUTIONS 6-69PV351D-RCS4 Instruction Manual Section 6- MAINTENANCE 4. Inspect fluid level sight glass for damage. 5. Fluid level should be visible near the center of the sight glass. FLUID LEVEL SIGHT GLASS If the fluid level is low, \dd fluid using the following procedure: 1. Level the drill, 2. With the tower vertical, bring the rotary head to bottom of the tower. 3. Clean area around fill plug. 670 DRILLING SOLUTIONSSection 6 - MAINTENANCE PV351D-RCS4 Instruction Manual 4, Remove the fill plug, 5. Add fluid until level is in the center of the fluid level sight glass. 6. Required lubricant is SAE 90W Gear Oil Rotary Head Upper Bearing There are three grease points on the top of the rotary head. Grease should be added to these points daily. Make sure the grease at the relief is free to move and the port is not plugged. Remove the relief fitting to perform this task. Then, add grease slowly until it is coming out the open port Make sure the relief fiting is operational. Replace the relief fiting and continue to add grease Until the relief indicator pops out. In a short period of time, if the relief has not popped out, stop and determine where the grease is going DRILLING SOLUTIONS ert6-72 PV351D-RCS4 Instruction Manual Section 6- MAINTENANCE Tracks and Final Drive Table 23: Track and Final Drive Maintenance Service Interval Type of Service Final Drive Capacity: 15 gallon (S6.8Ilitet) per track Required Lubricant: 180 VG220; Sow Frequency to Inspect: | 10 hoursidaily | Check for oll leaks and unusual noises 50 hours Check oil level in Final Drives 100 hours Check track adjustment 260 hours Inspect Final Drive mounting bolts Frequency to Replace: | 250 hours Initial oil change for Final Drive 2000 hours Change Final Drive oil. Inspect Track and Final Drive Note: Care must be taken to ensure fluids are contained during any inspection or work performed on this component. Handle and dispose of fluids according to local regulations and mandates. Information below is common to both undercarriages. NON CAB SIDE TRACK SHOWN FINAL DRIVE Under normal operating conditions, inspect the track final drives and hydraulic motors every 10 hours or daily for leaks. Also check for unusual noises. Look for signs of oil on the final drive gearbox case and around the bottom of the case. If there are signs of oil leakage, clean the outside of the gearbox case and around the bottom of the gearbox case. Verify that the signs of oil are from the gearbox case and not another source. If a leak is verified, contact maintenance and take corrective action. DRILLING SOLUTIONSSection 6 - MAINTENANCE PV351D-RCS4 Instruction Manual 6-6 MAINTENANCE (50 Hours or Weekly) General Information Improper maintenance can cause severe injury or death. Read and understand “Safety Precautions and Guidelines” in Section 2 of this manual before performing any type of maintenance, service or repair on this drill. Do not attempt to perform maintenance or operate the drill if you are not experienced with the RCS Drill Operating System, operating instruments and controls, Refer to Section 4 “Controls”. Unexpected drill motion or moving parts can cut or crush. Shut down the engine before performing any maintenance or repairs on the drill. Safety should be the main concer for anyone working on or around the dril. Do not perform any function that could put someone in danger. APPROVED safety equipment (safety shoes or protective footwear, safety glasses, hearing protection, hard hat, gloves, respirator, et.) when operating or maintaining the machine. WEAR PROTECTIVE CLOTHING Anyone working around the drill must wear b> ‘Saety Gees, Operating equipment requires the full attention of the operator. Do not wear radio or music headphones while operating the machine, ‘Wear close fitting clothing and confine long hair. uy ettenly Inet caver Respirator Electrically Insulate Boots The following operational hints should be observed: 1. Donot speed engine when it is cold. Always chock the tracks if there is a possibility of uncontrolled movement. Do not lubricate the drill while the engine is running Always perform safety checks prior to starting and servicing the dri 2RONn Always sound the hom before moving the drill in either direction to alert personnel and allow sufficient time before putting the drill in motion. DRILLING SOLUTIONS: o-73ore PV351D-RCS¢4 Instruction Manual ‘Section 6- MAINTENANCE Compressor Air Hose and Clamps The air hose clamps used on all PV351 Pit Viper drills are Campbell 360° U-Bolt Interlocking Clamps. It is a good practice to check the bolt torques on the Campbell clamps every 50 ‘operating hours or weekly. Air Hose & Clamps 1. Periodic clamping bolts re-tightening is necessary in all rubber hoses. Tighten to recommended torque value of 100 Ibs/ft (135.5 Nm). 2. Examine and change out worn hoses and weakened clamps. If hoses are to be changed out, change the clamps also. Campbell clamps (including nuts and bolts) are for single use only. Do not reuse. Once removed, discard Refer to the “Campbell 360 U-Bolt Interlocking Clamp’ instructions shown in Section 7 “Systems & Troubleshooting’ for the proper way to install Campbell Clamps. DRILLING SOLUTIONS