test manual 2657868267_005.pdf

2657868267-005 DML-E Test Procedure Last Revision 07/05/11 Page 1 of 77

MANUAL SPECIFICATIONS

PART NUMBER: 2657868267 MANUAL DESCRIPTION: DML - ELECTRIC TEST PROCEDURE WARNING Export of this manual to countries Copyright 2011 outside of the U.S. is subject to U.S. Atlas Copco Drilling Solutions Export Administration Regulations. All Rights Reserved Rig model __________________, does it agree with Manual Description indicated above?

_______ If not, see supervisor.

005 13230-001 L.BENDER 07/05/11 004 10765-006 R Harper 12/09/10 003 9655-001 M.Martin 002 8829-055 J Denk 2/11/09

001 7231 -058 Nicole 8/16/07

000 7231-056 Ajay Kumar 2/08/07 Rev. No.

E/C Number Revised By Date Signature Date


DML-E

TEST PROCEDURE

Instructions for this test procedure:

1. This test procedure is a controlled document, do not make copies or remove pages. One copy of the latest revision of this procedure will be distributed by the Production Coordinator for each applicable rig.

2. Quality Control will maintain revisions to this procedure. Changes from the previous version will

be indicated by a vertical bar in the left margin. A log of all revisions will be maintained by Quality Control.

3. Initial each blank as work is performed. If a test does not apply, write "N/A" in the signature

blank.

4. Quality Control may audit this procedure during the functional and final audits. All items are subject to approval.

5. The test procedure should remain with the rig at all times. After completion, forward to the

Quality Coordinator. The Quality Coordinator will log the rig serial number and forward the procedure to Product Support for final storage.

6. If a test or condition is incorrect or fails to reach given values, contact your supervisor or quality

control inspector for proper corrective action.

7. For systems troubleshooting; refer to hydraulic, pneumatic, and electrical schematics in rig bill of material.

8. If nameplates or decals are not available during functional test, refer to part drawing for

operational compliance.


MANDATORY ELECTRICAL STANDARD PRACTICES Review these practices regarding this rig for compliance, initial at the end.

1. Use Teflon tape, pipe sealant or gasket on all connections, whether NPT to NPT or into a box.

2. Always use insulated throat fittings, a bushing or insulated molding to protect wires from chafing or cutting on edges or corners. Make sure no wires rest or are secured to an edge or corner.

3. Except for the inside of an operators cab, all fittings, boxes and connections shall be rated or made to be dust-tight and weather resistant.

4. For AC electric rigs, do not rely on the conduit as a grounding means. Always provide a ground (green) wire to each load and ample ground wire size in each circuit, a grounding (bonding) jumper shall be installed in each box using a solid copper wire or grounding strap. Reference Article 250 in the 1999 National Electric Code (NEC). All shields be connected to ground at one end only (preferably at the indicating instrument end).

5. Whenever possible, route wires without breaks in pull or junction boxes eliminate unnecessary connections to terminal strips and wire nuts.

6. Junction and control box interiors will be free from foreign material. All wiring will be neatly routed (for professional appearance) before the covers are secured for rig shipment.

7. Temperature gauge capillary tubing routing: near the engine, run capillary tubing inside inch Sealtite 2695333217. Route the Sealtite away from high heat sources, i.e., turbo charger and exhaust manifold. After installation, inject silicon compound 2656776792 in the end near the bulb to a depth of 2. Center the tubing inside the Sealtite until the compound sets. The Sealtite that holds the capillary tubing should be secured so the tubing and bulb are not subjected to any pull forces.

8. Prior to a rig being shipped, spray all exposed electrical connections with insulating varnish 2657168916, to protect exposed connections when the machine is washed.

9. Prior to a rig being moved outside, insure that all electric device covers, box covers, conduit and cord grip fittings are properly secured to keep out water.

10. For AC electric rigs, Per 1999 NEC Article 350-18: Flexible metal conduit shall be secured by an approved means at intervals not exceeding 4.5 feet and within 12 inches of every box or fitting, where possible.

11. Insure that all conduit, cord and wires shall not be in contact with corners or knife-edges which can cause cutting or chaffing of the outer protective jacket. Secure away or protect against this type of condition.

12. A label, CPN 2657093080 or standard material, indicating the wire number or option function if a wire number has not been established shall identify all wires. Where practical, use Grafoplast wire marking product. Use 3M material for wire pulls or where Grafoplast is not practical.

13. Use pipe sealant on all screws for screw-cover type boxes (Stonco), unilets (LB, T, etc.), and limit switches, this will protect threads from rusting.

14. For rotation tachometer signal wire in tower, use black high strength cable (2657522021) and a kellem type strain relief at each end; one near the power head and the other near the end of the hose at the hose tray. Make sure that at least 8 of extra cable is in the hose, for hose stretching.

15. The 24 VDC (-) terminal need to be terminated separately on the terminal strips and connected to the Ground (if any) only as indicated in the schematics.

_________________________/_______________________


PRE-START CHECKS

SERIAL NUMBERS

______ /______ 1. Rig model ____________ Serial Number _____________________________________________

______ /______ 2. Airend __________________________________________________________________

if the gearset is changed from original, make sure proper gearset code is stamped in housing.

(One of the digits of the compressor S/N is always "U" typlically the 5th)

______ /______ 3. Rotary head _____________________________________________________________________

______ /______ 4. Rotation motor(s) ________________________________________________________________

______ /______ 5. Jib hoist ________________________________________________________________________

______ /______ 6. Jib hoist motor ____________________________________________________________________

______ /______ 7. Receiver tank National Board number _________________________________________________

______ /______ 8. Main Electric Motor (serial number is all numbers no letters)

*_____________________________________________________________

Manufacturer _____________________________________________________________________

______ /______ 9. Main pumps: CS __________________________________________________________________

______ /______10. Main pumps: DCS__________________________________________________________________

______ /______ 11. Triple pump ______________________________________________________________________

______ /______ 12. Pump gearbox ____________________________________________________________________

______ /______ 13. Cooler S/N _______________________________________________________________________

Cooler Manufacturer _______________________________________________________________

______ /______ 14. Undercarriage CS __________________________________________________________________

Undercarriage DCS_________________________________________________________________

Undercarriage Manufacturer__________________________________________________________

______ /______ 15. Undercarriage motors CS ____________________________________________________________

Undercarriage motors DCS ___________________________________________________________

______ /______ 16. Water injection pump _______________________________________________________________

______ /______ 17. Dust collector ______________________________________________________________________

______ /______ 18. Dust collector motor ________________________________________________________________

______ /______ 19. Jack cylinders: Drill end CS __________________________________________________________

Jack cylinders: Drill end DCS _________________________________________________________

. Jack cylinders: Rear _________________________________________________________________


IF 4 Jack = Rear (2) _________________________________________________________________

______ /______ 20. Feed cylinders CS ___________________________________________________________________

Feed cylinders DCS _________________________________________________________________

______ /______ 21. Tower raising cylinders CS ___________________________________________________________

Tower raising cylinders DCS __________________________________________________________

______ /______ 22. DEI ______________________________________________________________________________

______ /______ 23. Stratalogger box_____________________________________________________________________

______ /______ 24. Aquila display ______________________________________________________________________

______ /______ 25. DM1 box __________________________________________________________________________

______ /______ 26. Operators cab ______________________________________________________________________

______ /______ 27. Main Transformer*___________________________________________________________________

Main Transformer* Mfgr _____________________________________________________________

______ /______ 28. DOL Starter * _____________________________________________________________________

DOL Starter * Mfgr _________________________________________________________________

______ /______ 29. A/C compressor serial number _________________________________________________________

A/C compressor Mfgr ________________________________________________________________

______ /______ 30. Tower S/N_________________________________________________________________________

_____/________ 31. Mainframe S/N______________________________________________________________________

_____/________ 32. Auto Wrench (Mammoth) S/N__________________________________________________________

(items marked by asterik * are for electrical machine only

RIG PRE-START OILS, LUBRICATION AND COOLANT

(See rig bill of material (BOM), or supervisor for proper fluid information) ______ /______ 1. Verify that all tower and main frame lubrication points have been lubed.

______ /______ 2. Verify that the Funk gearbox driveshaft has been lubed.

______ /______ 3. Verify that all main frame, tracks, and jack barrel points have been lubed.

______ /______ 4. Lubricate both tower pivot bushings and verify bushing locks are welded in place. Verify grease is getting to the shaft before raising the tower for the first time.


______ /______ 5. Verify the following fluid levels

Receiver tank to middle of sight glass. Jib hoist gear box Carousel gear box Track Final Drive (Cat), SAE 50W Oil. Track Final Drive (AC), 80W90 oil. Bean water injection pump (and oilers if applicable) 30W Nondetergent Oil Hydraulic tank ,ISO 32W or SHC525 (Use oil specified in rig BOM) Rotary head, 80/90W oil or 75/90W synthetic (Use oil specified in rig BOM) Funk gear box oil. Fill and check at side plug or dipstick.

_____ /______ 6. Verify triple pump suction line has fluid by looking into the top of the suction manifold. Add with clean hydraulic oil, if required.

Bushing lock


______ /______ 7. Verify CS and DCS pump cases have fluid, by looking into the H port, and rear Allen plug. Allow air to bleed out of these ports, until oil starts to flow out of ports. Check both main pumps to make sure there is no isolation plug inside the H port. Probe inside the ports with a long, clean Allen wrench or rod. A long rod will reach about 8 inches into the pump if the isolation plugs are not installed. A long rod will stop about half way (4 inches) through the pump if the isolation plug is installed. If an isolation plug is found in either pump, remove and discard it.

H ports

H port

Allen Plug


COMPRESSOR

______ /______ 1. Verify safety valve is stamped for the correct relief.

XL900 150 psi

XL1050 150 psi

XL1200 150 psi

XL1900 150 psi

226mm WW 150 psi

285mm 150 psi

HP900 (HR2) 400 psi

HP1050 (HR2.5) 400 psi

HP1250 (HR2.5) 400 psi

HP1070

HP1450

400 psi

400 psi

_____ /_________ 2. HR2 and HR2.5, Remove the cap from the fitting in the large tube connecting the

pump and filters. Inject 7 gallons of compressor oil into the manifold, this will prime the pump, fill the filters, and get oil into the compressor before starting. Reinstall the cap. Add 1-gallon of compressor oil through butterfly intake valve.

Fill point

Relief pressure


______ /_________ 3. Verify the check valve in the compressor air discharge line is installed properly with the nameplate located at the top, therefore the hinge pivots from the top (free flow into tank).

HR2 and HR2.5 Only (Non EARS)

______ /______ 4. Remove butterfly end of the linkage between the UL88 and the butterfly valve. Insert a 5/8" key between the lever arm and the housing on the UL88. Close the butterfly valve completely and adjust the linkage arm until it pins back together with no force.

______ /_________ 5. With the 5/8" key still in place, adjust the lever arm stop bolt until it touches the arm. Turn the bolt an additional 1/4 turn and tighten the jam nut. Remove 5/8 key.

5/8 Key insertion point

Closed stop bolt


XL Only (Non EARS)

______ /______ 6. With the ON/OFF lever in the OFF position, adjust the linkage stop bolt until it just touches the linkage. Stroke the control cable several times, adjust the linkage stop bolt as needed to prevent the butterfly valve from sticking closed. Add 1 gallon of compressor oil through the butterfly intake valve

______ /______7. Shift the ON/OFF lever to the ON position. Manually extend the air cylinder and verify the control cable does not interfere with the cylinder travel.

XL EARS LP SETUP (OPTION) (Must do general compressor setup section also)

Standard Test Conditions: EAR/EFR system is fully assembled with all connectors, actuators, and

sensors connected and tight. The motor is not running The motor (Key Switch) is ON Receiver tank discharged Compressor on/off switch set to off position Flow or volume knob set to minimum (fully counter clockwise)

IQANRun (2657930976) must be installed on laptop.

______ /______ 1. Verify the correct sensors are installed in compressor and receiver tank by reading the

label on the sensor itself: Vacuum (compressor) sensor rating: ________ (0-1bar) Pressure (receiver tank) sensor rating: ________ (0-50bar) ______ /______ 2. Power MC2 and check to make sure lights flash on the MC2 showing the controller

has power. Using IQAN RUN:

Stop bolt


______/______ 3. Using Adobe Reader open the latest revision of the correct EARS Machine Software

(Look up the drawing for the software called out under the programmed controller) and follow software load instructions.

Record Rev of the EARS software installed: _______

______ /______ 4. Verify that the butterfly valve actuator turns CW (to horizontal position) to close the

butterfly valve and the vent valve actuator turns CCW (to vertical position) to open the vent valve, once the program is uploaded to the controller.

______/______ 5. Check EARS error light for any error codes. Light will flash a number of times, pause

and repeat the error code. (light will come on for 2 sec after the software uploads)

Record error code (0 if no error code) and diagnose using EARS Diagnosis Manuel. Error Code: ______

______/______ 6. Using the Laptop and IQANRun. Go to the online tab.

Open the measure group Check that the following values are within the ranges specified (Group may need to be expanded by clicking the + sign under the measure group. All status boxes should be green. Ignore the system status group.):

Max Pressure should read 115: Max Pressure: ______ psi

(If Max Pressure is incorrect the wrong program has been loaded.) Pressure Sensor should read between +5 psi: (with the compressor not turning) Pressure Sensor: ______ psi

(If pressure is out of range check that pressure sensor (receiver tank) is connected to the right cable and tight. If status box is red check wiring and pressure sensor.)

Flow Sensor should read between range 14 to 14.7 (compressor not turning and an attitude of 0-500ft) Flow Sensor: ______ psi

(If flow is out of range check that flow sensor (compressor inlet) is connected to the right cable and is tight. If status box is red check wiring and sensor.)


_______/______ 7. Verify compressor on/off agrees with compressor on/off switch. Verify Commanded Max Pressure (PSI) reads 30 at min (fully CCW) and 115 at max (fully CW). (Venting pressure is 15psi above commanded pressure) Verify Commanded Flow (PSI) reads 2.5 at min (fully CCW) and 14.7 at max (fully CW)

_______/______ 8. Delete machine software off laptop so that the newest version will be used next time. _______/______ 9. Hook EARS tester (2657817579) inline with the BFV actuator and command CCW

(open) fast. Verify that actuator turns a full 90 degrees in the CCW direction and stops in the vertical (open) position.

_______/______ 10. Remove EARS tester and reconnect BFV actuator and verify that actuator turns a full

90 degrees in the CW (close) direction and stops in the horizontal (closed) position. _______/______ 11. Hook EARS tester (2657817579) inline with the vent actuator and command CW

(close) fast. Verify that actuator turns a full 90 degrees in the CW direction and stops in the horizontal (closed) position.

_______/______ 12. Remove EARS tester and reconnect vent actuator and verify that actuator turns a full

90 degrees in the CCW (open) direction and stops in the vertical (open) position.

HR 2/HR 2.5 EARS HP SETUP (OPTION) (Must do general compressor setup section also) Standard Test Conditions: EAR/EFR system is fully assembled with all connectors, actuators, and

sensors connected and tight. The motor is not running The motor (Key Switch) is ON Receiver tank discharged Compressor on/off switch set to off position Flow or volume knob set to minimum (fully counter clockwise)

IQANRun (2657930976) must be installed on laptop.

______ /______ 1. Verify the correct sensors are installed in compressor and receiver tank by reading the

label on the sensor itself: Vacuum (compressor) sensor rating: ______ (0-1bar) Pressure (receiver tank) sensor rating: ______ (0-50bar) ______ /______ 2. Power MC2 and check to make sure lights flash on the MC2 showing the controller

has power.


Using IQAN RUN:

______/______ 3. Using Adobe Reader open the latest revision of the correct EARS Machine Software (Look up the drawing for the software called out under the programmed controller) and follow software loading instructions.

Record Rev of EARS software installed: _______

______ /______ 4. Verify that the butterfly valve actuator turns CW (to horizontal position) to close the

butterfly valve and the vent valve actuator turns CCW (to vertical position) to open the vent valve, once the program is uploaded to the controller.

______/______ 5. Check EARS error light for any error codes. Light will flash a number of times, pause

and repeat error code. (light will come on for 2 sec after the software uploads)

Record error code (0 if no error code) and diagnose using EARS Diagnosis Manuel Error Code: ______

______/______ 6. Using the Laptop and IQANRun, Go to the online tab.

Open the measure group Check that the following values are within the ranges specified (Group may need to be expanded by clicking the + sign under the measure group. All status boxes should be green. Ignore the system status group.): Max Pressure should read 355

Max Pressure: ______ psi

(If Max Working Pressure is incorrect the wrong program has been loaded.)

Pressure Sensor should read between +5 psi (with the compressor not turning)

Pressure Sensor: ______ psi

(If pressure is out of range check that pressure sensor (receiver tank) is connected to the right cable and tight. If status box is red check wiring and pressure sensor.)

Flow Sensor should read between range 14 to 14.7 (compressor not turning and an attitude of 0-500ft) Flow Sensor: ______ psi

(If flow is out of range check that flow sensor (compressor inlet) is connected to the right cable and is tight. If status box is red check wiring and flow sensor.)


_______/______ 7. Verify compressor on/off agrees with compressor on/off switch. Verify Commanded Max Pressure (PSI) reads 90 at min (fully CCW) and 355 at max (fully CW) (Venting pressure is 15psi above commanded pressure) Verify Commanded Flow (PSI) reads 2.5 at min (fully CCW) and 14.7 at max (fully CW)

_______/______ 8. Delete machine software off laptop so that the newest version will be used next time. _______/______ 9. Hook EARS tester (2657817579) inline with the BFV actuator and command CCW

(open) fast. Verify that actuator turns a full 90 degrees in the CCW direction and stops in the vertical (open) position.

_______/______ 10. Remove EARS tester and reconnect BFV actuator and verify that actuator turns a full

90 degrees in the CW (close) direction and stops in the horizontal (closed) position. _______/______ 11. Hook EARS tester (2657817579) inline with the vent actuator and command CW

(close) fast. Verify that actuator turns a full 90 degrees in the CW direction and stops in the horizontal (closed) position.

_______/______ 12. Remove EARS tester and reconnect vent actuator and verify that actuator turns a full

90 degrees in the CCW (open) direction and stops in the vertical (open) position.

MISCELLANEOUS

______ /______ 1. Verify that the hose from the case drain filter to hydraulic tank is connected at the quick disconnect.

______ /______ 2. Verify that all hump hose clamps on the compressor air ducts are constant torque type, are tight, but no bulges or air gaps.

Quick disconnect

Clock no/date


AC Electrical Tests

Insulation tests are done with the machine power off. Remove the main fuses and switch off the circuit breakers before starting these tests.

Initial Tests:

______ /______ 1. The following test is to be performed before the motor is coupled to the gearbox and compressor. The insulated bearing must be on the gearbox side. Megohm Range: remove ground strap and test resistance from insulated post to motor frame.

Gearbox end ______________

______ /______ 2. Disconnect power to machine. Disconnect trail cable to sub station.

______ /______ 3. Starter fuse documentation:

Voltage Current P/N

Main fuses _______ _______ _______

Secondary fuses _______ _______ _______

______ /______ 4. If starter compartment contains additional fuses, identify and record fuse symbol, voltage and current ratings below. All fuses are shown on starter electrical schematics.

Fuse symbol Voltage Current

____________ __________ _______

____________ __________ _______

____________ __________ _______

______ /______ 5. Fuse link documentation for medium voltage cutouts is located in the transformer enclosure. The three MV cutouts wired to the transformer bushings should contain fuse links at the primary. Contact Engineering for appropriate current values and verify that the fuse links in the MV cutouts are correct. Look at spare fuse link bag/box for rating and part number.

Left cutout has fuse link _______

Right cutout has fuse link____ Center cutout has fuselink_______

Clock no/date


Insulation Resistance Test

CAUTION All tests to be conducted by qualified electricians only. Isolate and lockout/tagout all electrical power to the component being tested. After the test is completed ground the test point with a ground wire to provide a discharge path for the absorption

voltage/current. Use the correct Megger voltage range during testing. Incorrect range selection could damage the components

being tested. Use minimum and maximum sensitivity of the meter as values when measurement is at either end of the scale

such as >200 M-ohm or

Clock no/date


Distribution Transformer

______ /______ 1. Transformer Manufacturer________________________________

Serial Number__________

PRI Voltage_______SEC Voltage_________Freq_________

______ /______ 2. First check the resistance between the three high voltage primary terminals. (Check

these values with a standard multimeter.) Open the EU cutouts and measure the resistance between the following points:

Resistance: H1-H2__________ ohms



______ /______ 3 Select an insulation tester voltage range of 5kV and test the insulation resistance of the primary side of the distribution transformer.

Resistance: H1-Frame/Ground__________ Mohms



______ /______ 4. Next, remove the grounding strap from the X0/neutral terminal on the secondary side

of the transformer. Check the resistance between the terminals on the secondary side as below using a standard multimeter.

Resistance X0-X1__________ohms



Resistance X0-T1__________ohms

Replace the grounding strap at X0 and resume testing as below.

Clock no/date


______ /______ 5. Select an insulation tester voltage range of 1kV and test the insulation resistance of the secondary side of the distribution transformer.

Resistance X1-Frame__________ Mohms



Resistance T1-Frame__________ Mohms

______ /______ 6. Jumper X0, X1, X2, X3, and T1 together. Jumper H1, H2, & H3 together. Then test

the insulation resistance as below:

Resistance X0 X1 X2 X3 T1 H1 H2 H3__________M ohms

SHD-GC Trailing Cable Before interconnecting the SHD-GC cable between the motor and starter, starter and distribution transformer,

transformer and disconnect box measure the insulation resistance of EACH interconnecting cable as below.(Keep the tester range at 5kV for this test.)

______ /______ 1. Check interconnecting cable between motor and starter (Keep both ends disconnected

and insulated from the ground before measurement.)

Resistance Red-Ground__________ Mohms

Resistance Black-Ground__________ Mohms

Resistance Blue-Ground__________ Mohms

Resistance Red-Black__________ Mohms

Resistance Black-Blue__________ Mohms

Resistance Blue-Red__________ Mohms

Resistance Pilot-Ground__________ Mohms

Clock no/date


______ /______ 2. Check interconnecting cable between starter and distribution transformer. (Keep both

ends disconnected and insulated from the ground before measurement.)







Resistance Pilot-Ground__________ Mohms

______ /______ 3. Check interconnecting cable between distribution transformer & Cable Coupler/ or disconnect box. (Keep both ends disconnected and insulated from the ground before measurement.)







Resistance Pilot-Ground__________Mohms

______ /______ 4. Check interconnecting cable between input junction box and output junction box of cable reel (optional).






Resistance Blue Red __________ Mohms

Clock no/date


Resistance Pilot-Ground__________Mohms

Cutler -Hammer D.O.L. Starter Test

Starter Serial Number_______________ Reference Drawing: 2657812208 (6 sheets) Reference Documents: 369 Motor Management Relay Instruction Manual (GE Power Management) Medium Voltage Starter Instruction Manual (Cutler-hammer/ Eaton Electrical) THE FOLLOWING TEST IS TO BE PERFORMED WITH THE STARTER DISCONNECTED

FROM MEDIUM VOLTAGE. CONNECT ONLY THE 110V CONTROL SUPPLY. Keep the control supply selector switch inside the starter to the OFF position. Remove the primary fuses PF1s and PF2s, 2 nos. each for safety so that no voltage is fed back to the

primary side of the starter panel. Connect a single-phase, 120V, 50/60 Hz. control supply through the AC1- AC2 or CUST RCPT (Pl.

refer page2/6 of AC Schematics #2657812208) Turn the control supply selector switch inside the starter box to the TEST/or NORMAL position.

Control supply is now available inside the starter panel. ______ /______ 1. Check the voltage level between control terminal block (CTB) numbers 01 and 012.

It should be 120 VAC.

______ /______ 2. Check that the Multilin 369 relay gets its control supply and its display is illuminated.

If the Aux 2 (machine remote emergency interlocks) DC control wiring is not connected, then to bypass it jumper the control terminal block (CTB) numbers 06 and 07 (Pl refer Schematic 2657812208 sheet 2 of 6/ grid 6B. This is done to bypass the remote e-stop interlocks for the Starter test.

______ /______ 3. Depress the START green pushbutton on the outside door of the starter panel. The

control relay (MX) should energize immediately. After this the Vacuum Contactor (M) should energize.

______ /______ 4. Depress the STOP red pushbutton on the outside door of the starter panel. The control relay (MX) should de-energize which in turn will de-energize the vacuum contactor.

______ /______ 5. Repeat the above test with the tripping of the Multilin 369 relay. This should de-energize the vacuum contactor.

______ /______ 6. Check whether the motor space heater relay (HR) energizes/de-energizes when the vacuum contactor is de-energized/energized.

Clock no/date


______ /______ 7. Check whether single-phase, 110V, 50Hz. control supply appears at the control terminal block (CTB) numbers 016 and 12 when the vacuum contactor is de-energized.

______ /______ 8. Check for no control voltage at these terminals when the vacuum contactor is energized.

______ /______ 9. Check the energization of the starter panel space heater when the control supply is ON and Vacuum contactor is OFF.

CENTRALIZED LUBRICATION SYSTEM

______ /______ 1. If manual system, purge air from all grease lines. Grease each lube point at the central lubrication manifold. Verify grease is supplied to each bearing point.

Main frame lube:

a) All points at Jacks b) Two points at Tower Raising Cylinders c) Two points at Main Shaft d) Two points at Oscillation Yoke Ends e) Two points at Oscillation Yoke Pivot f) Two points at Tower Support Tower Lube Points:

a) Upper feed sprockets b) Lower feed sheaves c) Center and lower support for rod changer d) Jib hoist e) Jib hoist sheave f) Upper and lower carousel pivot blocks. g) Carousel swing cylinders h) Tower raising cylinder pins i) Index pivot bushing on upper carousel arm j) Carousel lower arm

Clock no/date


START-UP

______ /______ 1. Record supercharge gauge pressure, no compressor load at maximum motor speed. ____________ (Must be 65 min. to 110 max. psi.)

Record motor speed at time of pressure reading ____________

______ /______ 2. Verify fan turns clockwise when referenced from standing on the fan side of the cooler.

______ /______ 3. Verify all the gauges on the console panel in cab are functioning.

Average Line Voltage Discharge Temperature AV Phase Current Insulation Resistance 6KV Motor Load Insulation Resistance 6KV Hottest Stator RTD Insulation Resistance 380V

______ /______ 4. Verify Actual Values on 369 display in the starter panel.

- Motor Status (A1) Motor Thermal Capacity Used (A1)

- Voltage metering (A2) current metering(A2) Power Metering(A2)

- Motor Running Hours(A4)

Clock no/date


______ /______ 5. With the rig running, disconnect the terminal with at the compressor discharge sensor. Verify rig shuts down.

AC ELECTRICAL SYSTEM FUNCTION (HEATERS) Note: Refer to AC electrical system schematic # 2657812208 sheet 1 of 6. 380V,3PH Power is provided through ACCB Box (via Distribution Transformer).

WARNING: TO PREVENT FIRE OR EXPLOSION: TURN OFF ELECTRIC HEATERS IN HYDRAULIC RESERVOIR AND RECEIVER TANK BEFORE ADDING OIL.

Procedure: Verify that each heater is correct per B.O.M. and is wired to produce correct heat (power), based on schematic or heater nameplate. Should measured current readings not match expected results, ensure heater is wired correctly according to schematic then adjust heater settings to obtain expected heat (power) output. Calculation: Based on voltage input, calculate the expected current and verify that the expected current and measured current are equal. For single phase heaters: Current (amps) = Power (watts) / 3 V x Powerfactor (0.88) * Heater Power value should be taken from heater nameplate or electrical schematic.

Temperature sensor

Clock no/date


______ /______ 1. Open 15Amp Low Hydraulic Oil Contactor Circuit Breaker. The Contactor should de-energized. Reset the Circuit Breaker, the Contactor should energized.

______ /______ 2. Hydraulic Tank Heater. Use an ammeter/ clamp on meter to measure the current. It may be necessary to increase the thermostat temperature setting. Repeat this process for the each Oil Reservoir Heater. Note: Insure that oil covers heaters to prevent damage when running test.

*Heater Power _______________ watts Input Voltage ________________ volts Calculated current _______________ amps Measured current ________________ amps

______ /______ 3. Water Tank 1&2 Heaters. Use an ammeter to measure the current. It may be necessary to increase the thermostat temperature setting. Repeat this process for the each Water Injection Tank Heater. Note: Insure that water covers heaters to prevent damage when running test.

HTR1 HTR2

*Heater Power _______________ watts ______________ watts Input Voltage ________________ volts ________________ volts Calculated current _______________ amps _______________ amps Measured current _______________ amps _______________ amps

_____ /______ 4. Receiver Tank Heater (Optional). Use an ammeter/Clamp on meter to measure the current.

*Heater Power _______________ watts Input Voltage ________________ volts Calculated current _______________ amps Measured current _______________ amps

______ /______ 5. DHD Tank Heater(Optional). Use an ammeter/ clamp on meter to measure the current.


______ /______ 6. Auxiliary Cab Heater(Optional). Use an ammeter/ clamp on meter to measure the current.


Clock no/date


______ /______ 7. Cab Convenience Receptacles (optional). Measure voltage with V.O.M. Check ground fault circuit breaker for proper operation.

Record voltage ______________________ volts

______ /______ 8. Air Conditioning Compressor motor. Measure the current using Ammeter.

______________________ Amps

JACKS (Rig must be in drill mode for the jack tests.)

______ /______ 1. Verify jack lever direction and jack direction matches nameplate.

______ /______ 2. Fully stroke all jack cylinders twice to purge air. Check for leaks, correct as required.

PRE-TEST CONTROLLER SETTINGS

Measured Current tolerance is plus 5 mA, minus 0 mA. Small LED indicators are illuminated when output is on and varies in intensity as output changes.

Main Pump Controller Settings - Propel Controls (If rig includes jack-up and/or propel interlock, make sure interlocks are in their propel position or are by-passed for the following test.) Note: Make sure the key is in ON position, but the main motor is NOT running. Put the rig in propel mode. Remove the B wire from CS (right track) propel controller and connect an ammeter, 1 amp or less scale, between the controller B terminal and the open B wire (red lead to B and black lead to the open wire). If no current is measured, verify optional interlocks are operational. ______ /______ 1. Pull the CS controller handle slightly on stroke (till the micro switches just click).

Adjust the threshold pot until the ammeter reads 150 milliamp (mA). If you do not get a current reading, check the wiring.

______ /______ 2. Pull the CS controller handle fully on stroke and set the max-out pot to 350mA. Return handle to center, check current reading in opposite direction, return handle to center. Then reconnect the wire to the B terminal. It should be 198mA at full stroke on reduced speed (knob pressed)

______ /______ 3. Repeat steps 1 and 2 for the DCS (left track) propel controller.

Output adjustments Output

adjustment

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Main Pump Controller Settings - Feed and Rotation (Drill) Controls Note: Put the rig in the drill mode, engine off, key-switch on. If the machine is a HP machine turn the holdback controller knob to the half way position. The rotary head should be at the bottom in the tower. ______ /______ 1. Make sure the handle is in the center, off, position. Remove the B wire from the Feed

controller and measure the resistance between the open B wire and the controller A terminal. Resistance should be 82 ohms, indicating that the controller is attached to the pump electric stroker coil. If not, check the wiring.

______ /______ 2. Connect an ammeter between the controller B terminal and the open B wire (red lead to B and black lead to the open wire).

______ /______ 3. Pull the Feed controller handle slightly on stroke (till the micro switches just click). Adjust the threshold pot until the ammeter reads 150 milliamp (mA).

______ /______ 4. Pull the Feed controller handle fully on stroke and set the HiRange pot to 350 mA.

______ /______ 5. Leave the controller handle fully stroked and hold down the button on top on the controller. Set the LoRange pot to 198 mA at full stroke. Return handle to center. Check current reading in the opposite direction, return handle to center when finished. Reconnect the wire to the B terminal.

______ /________ 6. Repeat steps 1 through 5 for the Rotation controller.

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UNDERCARRIAGE

Drill/Propel valve pressure Settings

Inlet Pressure Setting

______ /______ 1. Connect a 600 psi gauge to the TST3 port on the Drill/Propel Control Valve to verify inlet pressure setting, put rig in propel mode, adjust to 500 psi, if required.

Record inlet pressure _______________

Device Type Device ID # Calibration Due Date

Measurement or Test Device Information 0-600 Pressure gage

Adjustment

Test port

BR port

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______ /______ 1. With rig on level ground, fill the final drive with oil to the top of the lower plug.

______ /______ 2. By-pass jack-up interlock, if required. Raise the rig on the jacks and rotate the tracks 4 or 5 revolutions to distribute the final drive oil.Repeat for reverse direction. Return controls to center off position, verify the tracks stop and do not creep. Return the tracks to level ground, recheck the final drive oil level, and re-fill as required.

______ /______ 3. Verify the main pump lever coincides with track movement and nameplate.

______ /______ 4. Tram the rig in the direction of the idler to release tension on the idler end of the undercarriage. Lay a straight edge on top of the grousers, long enough to reach between the first carrier roller and the idler. Measure and record the sag halfway between the carrier roller and idler. Adjust idler tension for sag of 1 to 1.5 inches on CAT tracks. Adjust idler tension for sag of 7/8 to 1.125 inches on AC tracks.

Record initial sag: DCS ______________ CS ______________

Record final sag: DCS ______________ CS ______________

______ /______ 5. Enable the jack-up interlock, if required. While in drill mode, raise the rig to get the tracks off the ground. Stroke both main pumps to maximum and verify that the tracks do not move, return controls to center off position.

______ /______ 6. With the tracks still off the ground, to test the jack-up interlock. Shift the drill/propel selector to PROPEL. Stroke both propel controllers to forward, reverse, then return, and verify that both tracks do not move or creep.

Check oil here and add, if needed.

One plug at 3 Oclock position.

Do not forget to replace plugs!

Make sure final drive is orientated as indicated in photo. Typical all undercarriages.

Final Drive oils: CAT SAE 50W AC 80W90 Gear oil

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TOWER CHECKS (Make sure pivot points are lubricated, upper and lower points of tower raising cylinders.)

_____ /______ 1. With the rig leveled on the jacks and the power head at the top of the tower, raise the tower about 15 degrees and back to rest. Repeat for 30, 60 and 90 degrees. Verify lever and tower direction coincides with nameplate.

______ /______ 2. With the tower vertical, verify the Rotary head slides along the tower front chords smoothly. Verify that the main air hose does not bind. Adjust if required.

______ /______ 3. With all cylinders retracted, re-check the hydraulic oil tank and refill if needed.

______ /______ 4. Verify tower raising control by raising tower to 45-degree position and move control lever to neutral. Tower must not drift.

_____ /________5. With the tower vertical and the head at the bottom, check the rotary head oil level. Fill to center of the sight gage if needed.

______ /______ 6. Verify that all rod cups rotate freely. ______ /______ 7. Verify that carousel rotates freely.

______ /______ 8. Verify that all-remaining tower controls on the console function in the proper direction as indicated on the nameplates.

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TOWER PINNING ______/______ 1. Verify the tower-locking pin slides

into the clevis holes in the frame smoothly. The console indicator light should turn off when the pin is fully extended (engaged). Check pin engagement with tower.

______ /______ 2. Angle drill rigs only. Stamp the rig serial number on the angle pinning banana bar.

STROBE LIGHT FUNCTION

______ /______ 1. Tower strobe light is flashing at all times when ignition is on.

______ /______ 2. Cab strobe light is flashing any time rig is in propel mode with ignition on.

NIGHT LIGHTS

______ /______ 1. Verify all external lights are wired and functional with nameplates.

______ /______ 2. Verify cab light is wired and functional.

Instructions for the use of Heat Developer on the DML-electrical machine: The following sequence need to be followed: 1)With power off (380VAC Heater, from the ACCB box circuit breaker and the 24VDC control circuit, from the heat Developer ON/OFF switch), fill the water tank of the Heat Developer with antifreeze up to the top (approximately gallon). 2) Open the water valve and Switch the pump on (Heat Developer ON/OFF SW to ON position). With the pump running, continue to fill the tank to within the 1.00 inch from the top of the cap. Let the pump run for 15 minutes. During this time cut the pump ON and OFF (through the above ON/OFF switch) some 4 times. This will allow air to be purged out of the system. 3) Switch ON the 380VAC circuit breaker in the ACCB box. Check for the heater (3-phase, 6KW) going through the OFF - ON cycle by the Temperature Switch (CLICK sound) to maintain the water temp to 185F +/- 10%. The temperature switch is mounted at the discharge end of the heater. The operation of the temperature switch is essential for the safety of the heater and sub- systems to prevent from attaining the over temperature, which can cause the damage. Example: With Water valve open, the Heater is ON at 173F. Heater is OFF at 185F (all the temp are taken at the heater body).

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AIR CONDITIONER - By a qualified person, charge the A/C before the QC functional audit

Evacuating System Procedure

______ /______ 1. With machine engine off, connect gauges to A/C system. ______ /______ 2. Install center hose from gauge manifold to vacuum pump. ______ /______ 3. Turn the vacuum pump on. ______ /______ 4. Open the high and low side gauge manifold valves and the pump exhaust valves.

System will reach 28-29.5 inches Hg. in not over 5 minutes. If system does not pump down, check connections and return to leak testing procedures if necessary.

______ /_________ 5. Operate vacuum pump for a minimum of 1 hour for air and moisture removal.

______ /______ 6. Close all valves.

______ /______ 7. Shut off vacuum pump.

______ /______ 8. If pressures rise in 5 minutes, check connections and return to leak testing procedures if

necessary.

______ /______ 9. If pressures hold level in a vacuum for 15 minutes proceed to charging procedures.

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Charging Procedure

______ /______1. Check oil present in the compressor. ______ /______ 2. If required, add to the compressor 8-10 ounces of refrigerant oil (2657737934). Record volume ______________ for HG1000 compressor. Record volume ______________ for Sanden compressor. _____ /______ 3.Gauges and A/C system must still be in a vacuum from the evacuating system

procedure _____ /______ 4. Purge air from charging hose. _____ /______ 5. Open shut-off valve at refrigerant bottle.

_____ /______ 6. With machine off, open high side manifold valve. _____ /______ 7. After gauge pressures become slow to increase, close high side manifold valve. _____ /______ 8. Start engine and throttle to working rpm. _____ /______ 9. Adjust A/C controls for maximum cooling and engage compressor clutch. _____ /______ 10. Open low side manifold valve. _____ /______ 11. Charge to weight recommended by manufacturer. _____ /______ 12. Check system for cooling.

_ Measurement or Test Device Information Rig Serial No. A/C Model Compressor S/N. Refrigerant Type R134A Refrigerant Charge Electric Motor S/N

Clock no/date


Determine Refrigerant Weight Procedure

_____ /______1. Record outside ambient temperature ___________ F degrees. _____ /______ 2. Watch sight glass on drier. If bubbles clear on sight glass, system is full. However, some

systems are full and still have bubbles in sight glass. Do not try to clear all bubbles if high side pressure is too high.

_____ /______ 3. Try to keep low side pressure between 5-35 psi and the high side pressure 295 psi or lower. Keep in mind that pressure readings are greatly affected by ambient temperatures. For example, a high side reading of 295 psi on a 75 degree day would not be good while a high side reading of 295 psi on a 115 degree day would be acceptable, assuming the A/C system was cooling good.

_____ /______ 4. Monitor vent temperature with doors closed to cab. If adding refrigerant lowers vent

temperature, keep adding refrigerant as long as high side pressure is acceptable. When vent temperature levels out or starts rising, stop adding refrigerant. A 20-degree difference between the vent temperature and the air intake temperature (Cab temperature at operators chest level) is acceptable.

Record Cab temperature _____________F degrees.

______ /______ 5. Temperature at vent must be 25 to 30o F or less below air intake temperature.

Record vent temperature _____________ F degrees.

______ /______ 6. Verify that the blower works at all speeds.

_____ /_______ 7. Return line at compressor should be cool and possibly sweating.

_____ /_______ 8. Cab temperature should be comfortable.

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FUNCTIONAL AUDIT FOR TOWER AND DRILL ROD

______ /______ 1. Tower IS to be removed; Quality must perform a functional audit before tower is

removed.

______ /______ 2. Tower IS NOT to be removed for shipment.

______ /______ 3. Record the following data:

Test Rod Part NumberTest Rod Length (Feet)Test Rod Size (Diameter of Rod - inches) Test Rod End Size and Type (Example - 4" - Beco)Test Rod QA stamp - number stamped on flat

NOTE: IF THE TEST ROD DOES NOT HAVE A QA STAMP, THEN DO NOT USE THE DRILL ROD, AND CONTACT QUALITY.

Clock no/date


TEST For all tests; when an instrument other than the panel gage is used, the following block must be filled out. Device Type Device ID # Calibration Due Date

Measurement or Test Device Information

Device Type Engineering or quality should enter a brief description of the type of gage required for the inspection or test. This should be part of the test book text prior to release.

Device ID # - The employee is to enter either the unique identification # put on the gage by Atlas Copco or the Serial # of the gage where no Atlas Copco identification # was issued. Any device, which has neither such identifier, should be considered suspect and a Quality department representative should be notified prior to using the gage for inspection or testing.

Calibration Due Date The employee is to enter the Calibration Due Date indicated on the sticker or tag attached to the device. Any device without a due date identifier should be considered suspect and a Quality department representative should be notified prior to using the gage for inspection or testing.

NOTE: If test values are not obtainable or instructions unclear contact your Supervisor or Engineering.

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COOLER RPM

______ /______ 1. Run rig to get hydraulic oil temperature to 110o F, minimum, see tank gauge. Then, set the cooler fan RPM as specified below. Tolerance on fan speeds is 50 RPM.

Compressor Cooler Fan Speed (RPM)

XL 750 Side- By- Side Cooler 750






HP 900 Side- By- Side Cooler 1000




Record Fan Speed (rpm)

Device TypeDevice ID #Calibration Due Date

Measurement or Test Device Information Photo Tach

Adjustment, screw-in (CW) to raise fan speed, out to lower, then lock jam-nut.

Clock no/date


2-SPEED FAN CONTROL (OPTION), see BOM for location drawing.

______ /______ 1. Shift mechanical toggle valve, located at cooler, to low fan speed up position to activate low speed mode. Adjust relief, at this valve, to 300 RPM less than what is indicated in the Cooler RPM chart on previous page.

Record Low Fan Speed (rpm)


Measurement or Test Device Information Photo tach

COOLER RPM-VARIABLE SPEED FAN

______ /______ 1. Block off drain port on fema valve for variable speed fan located toward end of cooler.

______ /______ 2. Run rig to get hydraulic oil temperatures to 110 F minimum, see tank gauge. Set maximum RPM according to chart by adjusting fan relief located on side of cooler. Tolerance on fan speed is 50 RPM.

______ /______ 3. With rig off, reconnect fema drain port.

Drain port

Toggle valve

Relief

Clock no/date


______ /______ 4. With rig running at maximum RPM, turn controller knob slightly clockwise until light at bottom of controller illuminates.

______ /______ 5. Set the threshold setting by turning adjustment screw in until 300 RPM is obtained at cooler fan.

______ /______ 6. Turn variable speed controller fully clockwise to maximum. Adjust controller maximum setting by turning adjustment screw in until maximum fan speed is obtained.

Maximum

Threshold

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JACK TEST

______ /______ 1. Raise the rig off the ground and record the distance between bottom of crosshead and bottom of slide:

CS______________ DCS ______________ Rear ______________

______ /______ 2. After 2 hours, re-check jack measurement and record distances. If more than 1/8 per hour drift is detected, replace fix the problem and retest.

CS ______________ DCS ______________ Rear ______________

______ /______ 3. Level the tower from side to side and front to rear using a long carpenters level. Adjust the bubble level on the console to center the bubble.

HR2/ HR2.5 COMPRESSOR (Non EARS)

______ /______ 1. Close manual blowdown valve and throttle valve in the service air line. Turn the compressor ON/OFF valve, on the console, to OFF. These settings should remain the same for steps 2, 3, and 4.

______ /______ 2. Start rig and increase RPM to maximum. The UL88 valve should close the butterfly valve when the separator tank reaches minimum pressure. If the pressure is not within this range, stop rig, allow tank to blow down, and then remove the relief valve in the regulation line from the separator tank. Reject the valve or use pressure gauge and 1/4" (allen) hex wrench to re-set relief valve to 100 psi (+10, -0). Then, lock adjustment in place by peening the threads with a center punch to keep the jam-nut from moving. Replace the valve and reconnect the hose.

Clock no/date


______ /______ 3. With the UL88 arm fully extended, verify that the butterfly valve is near horizontal. A line is stamped on the end of the butterfly valve shaft indicates the position of the butterfly, verify that the line is near horizontal.

______ /______ 4. Start the rig and increase speed to maximum. The butterfly valve should close when the receiver pressure reaches 150 - 175psi.

Record receiver pressure at point when butterfly closes _______________

______ /______ 5. Shut down the rig and watch the butterfly valve, it must open completely. If the butterfly sticks closed, tighten the lever arm stop bolt on the UL88. Re-check to verify butterfly opens without sticking.

______ /______ 6. Start rig and increase RPM to maximum. Wait for separator tank to build to minimum pressure (120-140 psi-HR2, 150-175 psi- HR2.5) and the butterfly valve to close. Check separator tank gauge for 5 minutes, the compressor must not continue to build air.

Record separator tank pressure after 5 minutes _______________

Note: If steps 5 and 6 cannot be reached simultaneously, verify the 3/32" orifice is drilled in the 50 psi relief mounted to the UL88. If orifice is in place, check butterfly for damage and replace if needed.

______ /______ 7. Verify that all compressor gauges are operating: Bit air pressure, interstage pressure, discharge temperature, and receiver pressure.

______ /______ 8. Remove discharge hose from REC/SEP tank and replace it with the test pad in-ground muffler hose. The airflow can now be blocked, verify that the receiver pressure will build to 345-355 psig (read pressure gauge on the console). Do not allow the pressure to exceed 360 psig. Adjust the spring tension on the UL88 if pressure is low.

______ /______ 9. Set the service air regulator on the receiver tank to 90 psi. Read pressure from the gage on the regulator.

______ /______ 10. Open the throttle valve and switch the compressor to OFF. Shut down the rig and verify the automatic blowdown vents the receiver immediately.

Operating note: Do not shut down the rig with receiver pressure higher than minimum pressure valve setting. This can cause saturation of air cleaners.

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XL COMPRESSOR with a 226-mm airend. (Non EARS)

______ /______ 1. Make sure there is an air pressure gauge at the head of the receiver tank. Close the ball valve to the dust collector filter regulator.

______ /______ 2. Remove the plug on the inlet of the air end just below the butterfly valve and install a mercury manometer or vacuum gauge.

______ /______ 3. Stroke the compressor control cable several times. Verify that the butterfly shaft linkage is contacting the stop bolt when the lever is in the off position.

______ /______ 4. To set the adjustable vacuum switch on the compressor air inlet located just below the butterfly valve. Screw the adjustment knob all the way in (clockwise) and then back out 4 to 5 complete turns. This will cause the solenoid valve to open at approximately 15" Hg vacuum under the butterfly valve and allow air into the compressor.

______ /______ 5. Start the rig and set to maximum RPM. With the butterfly valve closed (lever off), check the vacuum under the butterfly valve, it must be less than 25" of mercury. If it is greater, adjust the stop bolt 1/2 turn to prevent the butterfly valve from closing all the way. Repeat as needed to obtain less than 25" of mercury.

Record vacuum reading __________

______ /______ 6. With the compressor control lever off, verify that a small amount of air is exhausting through the vent located under the receiver tank.

Vac. switch

Air gauge

Dust collector ball valve

Test pad in ground muffler hose

Manual blowdown

Clock no/date


______ /______ 7. Remove discharge hose from REC/SEP tank and replace it with the test pad in-ground muffler hose. The airflow can now be turned off with the ball valve connected to the in-ground muffler. Move the compressor control lever to the on position and allow pressure to build to 105-115 psig (read pressure gauge on the console). If the pressure does not build to this range, adjust the relief valve (cigar valve) in the air cylinder regulation line (do not allow the pressure to exceed 120 psi and blow the safety valve). Allow the air to blow out the hose for one minute

Record maximum pressure _______________

______ /______ 8. Allow the compressor to run for 5 minutes with the airflow blocked. Verify that the receiver pressure does not build above 115 psi.

Record maximum pressure after 5 minutes _______________

______ /______ 9. Unblock the airflow, with the compressor on, and allow the full flow of air to pass through the hose. Verify that no air is exhausting through the vent under the receiver tank.

______ /______ 10. Allow the air to blow out into the muffler for one minute. Verify that no oil is present in the airflow, by shutting down rig, allow to blow down, remove test hose and inspect for oil.

XL COMPRESSOR with a 285-mm air end. (XL 1200, 1600, 1900). (Non EARS)

______ /______ 1. Make sure there is an air pressure gauge at the head of the receiver tank. Close the ball valve to the dust collector filter regulator. Close the manual blowdown valve.

______ /______ 2. Stroke the compressor control cable several times. Verify that the butterfly shaft linkage is contacting the stop bolt when the lever is in the off position.

_____ /_______ 3. To set the adjustable vacuum switch on the compressor air inlet located just below the butterfly valve. Screw the adjustment knob all the way in (clockwise) and then back out 4 to 5 complete turns. This will cause the solenoid valve to open at approximately 15" Hg vacuum under the butterfly valve and allow air into the compressor.

Vac. switch

Clock no/date


______ /______ 4. Start the rig and set to maximum RPM. With the butterfly valve closed (lever off), check the vacuum under the butterfly valve, it must be less than 27" of mercury. If it is greater, adjust the stop bolt 1/2 turn to prevent the butterfly valve from closing all the way. Repeat as needed to obtain less than 27" of mercury.

Record vacuum reading __________

______ /______ 5. Remove discharge hose from REC/SEP tank and replace it with the test pad in-ground muffler hose. Start the engine and increase speed to maximum. Shift the compressor ON/OFF lever to ON. Allow the air to blow out the hose for one minute.

______ /______ 6. With air blowing out the hose, verify that the anti-rumble valve is shut and no air is passing out of the vent.

______ /______ 7. Restrict airflow and allow the pressure to build. The butterfly valve should close at 105-115 psi receiver pressure. If it is not in this range, check the reducing check valve set-point, then adjust or reject to get 100 psi (+10, -0). Repeat until the correct unloading pressure is reached.

Record maximum pressure _______________

______ /______ 8. With the airflow blocked, the compressor ON, and the receiver pressure at maximum (butterfly closed by regulation system) record the vacuum reading at the vacuum gage in the anti-rumble circuit.

Record vacuum reading _______________

______ /______ 9. Shift the compressor control to the off position. Verify that the anti-rumble valve opens and a small amount of air is exhausting through the vent. Record receiver pressure and vacuum reading in this condition. After test, reconnect rig discharge hose and verify that there is no oil in the air flow, by inspecting test hose for oil.

Receiver pressure _______________ Vacuum reading _______________

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HR 2/ HR 2.5 COMPRESSOR TEST HP EARS (OPTION)

______ /______ 1. With the compressor off and engine set at maximum RPM. Verify that the receiver/separator tank pressure gauge builds to 105 10 psi, holds and does not blow out test pad muffler.

Record pressure _______________ psi

______ /______ 2. Allow the machine to run for 10 minutes with the compressor off. Verify that the receiver/separator tank pressure gauge maintains 105 10 psi.

______ /______ 3. Shut down the engine and verify that the receiver/separator tank vents. (There will be a delay before the vent valves start opening)

______ /______ 4. Start engine. At full RPMs allow min air to stabilize, turn pressure and flow pots on full. Turn on compressor allow max air to build. Verify Amot valve is working and check that compressor oil level in receiver sight glass is to full.

______ /______ 5. Block the airflow through test pad muffler by closing ball valve, at full pressure and flow and verify that safety valves do not pop. Pressure should be 370 + 10 psi.

Record max receiver/separator tank pressure gauge: _______________ psi

______ /______ 6. With the test pad muffler blocked, run the compressor for 10 minutes and verify that maximum pressure is maintained at 370 10 psi.

______ /______ 7. With the test pad muffler blocked and the pressure holding at 370 + 10 psi, check for leaks at the following areas:

___ Air piping from receiver/separator to rotary head ___ Rotary head swivel ___ Air/oil leaks in compressor to receiver/separator piping.

Clock no/date


______ /______ 8. Open test pad muffler ball valve. Allow air to blow unrestricted at full pressure and

flow. Verify that the receiver/separator pressure gauge does not fall below 100 psi.

Record minimum pressure _______________ psi

______ /______ 9. Turn off compressor. Verify receiver/separator pressure gauge returns to 105 5psi and holds and no air vents through test pad muffler.

XL COMPRESSOR TEST LP EARS (OPTION) ______ /______ 1. With the compressor off and engine set at maximum RPM. Verify that the

receiver/separator tank pressure gauge builds to 45 10 psi, holds and does not blow out test pad muffler.

Record pressure _______________ psi

______ /______ 2. Allow the machine to run for 10 minutes with the compressor off. Verify that the receiver/separator tank pressure gauge maintains 45 10 psi.

______ /______ 3. Shut down the engine and verify that the receiver/separator tank vents. (There will be a delay before the vent valves start opening)

______ /______ 4. Start engine. At full RPMs allow min air to stabilize, turn pressure and flow pots on full. Turn on compressor allow max air to build. Verify Amot valve is working and check that compressor oil level in receiver sight glass is to full.

______ /______ 5. Block the airflow through test pad muffler by closing ball valve, at full pressure and flow and verify that safety valves do not pop. Pressure should be 130 + 10 psi.

Record max receiver/separator tank pressure gauge: _______________ psi

______ /______ 6. With the test pad muffler blocked, run the compressor for 10 minutes and verify that maximum pressure is maintained at 130 10 psi.

______ /______ 7. With the test pad muffler blocked and the pressure holding at 130 + 10 psi, check for leaks at the following areas:

___ Air piping from receiver/separator to rotary head ___ Rotary head swivel ___ Air/oil leaks in compressor to receiver/separator piping.

______ /______ 8. Open test pad muffler ball valve. Allow the air to blow unrestricted at full pressure and flow. Verify that the receiver/separator pressure gauge does not fall below 40 psi.

Record minimum pressure _______________ psi

______ /______ 9. Turn off compressor. Verify receiver/separator pressure gauge returns to 45 10 psi and holds and no air vents through test pad muffler.

Clock no/date


HYDRAULIC PRESSURE SETTINGS AND TEST

Note: Make all adjustments in this section with motor at full speed and with the hydraulic oil temp at 120o F minimum. Tolerance on pressure settings is 50 psi.

6 Spool Pressure Settings_

______ /______ 1. To set the 6 spool main unloader at 3000 psi, stall any jack in the up direction by stroking the valve spool manually using a 1/2 inch wrench and adjust unloader.

Record unloader pressure _____________________


Measurement or Test Device Information0-5000 Pressure gage

_____ /______ 2. To set the tower raise relief, cap off the C2 (raise) port of the tower raise section, spool #2, stroke the valve spool manually (1/2 inch wrench), and adjust relief to 3000 psi.

Record tower raise relief pressure ______________



Main unloader

Clock no/date


______ /______ 3. To set the tower retract relief, cap off the C1 (retract) port of the tower retract section, spool #2, stroke the valve spool manually (1/2 inch wrench), and adjust relief to 3000 psi.

Record tower retract relief pressure ______________



______ /______ 4. To set the water injection relief setting, cap off the C2 (water injection) port of spool #6, stroke the valve spool manually, and adjust relief to 1000 psi.

Record relief pressure _______________



_____ /______ 5. To set the dust collector relief setting, cap off the C1 (dust collector) port of spool #6, stroke the valve spool manually, and adjust relief to 2750 psi.




______ /______ 6. To set the Winch relief setting, disconnect the hoses and cap off the ports of spool #1, stroke the valve spool manually, and adjust relief to 2000 psi. Set both extend and retract reliefs.




Clock no/date


9 Spool Pressure Settings

______ /______7. Extend the tower pinning cylinder and set the tower pinning work port relief, spool #4 in the 9-spool valve, at 1200 psi.




Feed relief valve setting

______ /______ 8. Remove the cap for the relief located in the drill-propel valve. Stall the feed on the bottom stops and adjust the feed relief valve, if required, as listed below. Lock adjustment.

Record feed relief valve pressure



Note: This valve is pre-set at 3500 psi. For rigs with 35 foot towers check and verify this pressure setting. For rigs with 25/30 foot towers set the feed relief valve at 4000 - 4500 psi .

#4

Cap for relief adjustment

Drill-propel valve with internal feed relief setting

Clock no/date


Main Pump Pressure Settings

______ /______ 9. To set both main pump compensators at 4500 psi, install a 5000 psi gauge at the test fitting in the forward propel side of the pump. Stall forward propel, by removing the brake release hose and install plug at the BR port on the drill/propel selector valve. Make sure tracks are off the ground, rig is in propel mode. Move propel controller to full stroke, then read pressure and adjust as needed.

Record DCS main pump compensator pressure ____________ Record CS main pump compensator pressure ________________

Device TypeDevice ID #Calibration Due Date


ROTARY HEAD MOTOR SETTINGS

______ /______ 10. Loosen all the swivel cap bolts on the rotary head ( 4 or 5 full turns ) to prevent burning the packing. Also, loosen the wash pipe clamp and pull the swivel cap away from the swivel housing to remove any squeeze from the packing. Do not tighten until the drilling simulation test is complete.

Single Variable motor (7.25 Cu. In.) rotary Head

______ /______ 11. To set the pressure-reducing valve on the rotary head motor, install a 1000 psi gauge in the mini check fitting in the motor servo port. Stall the rotary head by engaging the breakout wrench, and adjust the pressure to 500 psi.

Record actual pressure _______________



Test fitting

Adjustment

Clock no/date


_____ /______ 12. Back out the upper volume stop on the variable motor. Screw in the lower volume stop to reach a spindle speed of 200 RPM 10. Screw in the upper volume stop until it stops and lock into place.

Record actual spindle RPM obtained _______________



______ /______ 13. Back out the lower volume stop to reach a spindle speed of 140 RPM 10 and lock into place.




Dual Fixed Motor ( 2 x 4F Cu. In. ) Rotary Head

______ /______14. Record actual rotary head spindle speed with the engine at 2100 RPM and the main pump fully stroked.

Record actual spindle RPM obtained _______________ ( 115 125 RPM )



Dual Variable/Fixed Motor ( 6V x 4F Cu. In. ) Rotary Head

______ /______ 15. To set the pressure-reducing valve on the rotary head motor, install a 1000 psi gauge in the mini check fitting in the motor servo port. Stall the rotary head by engaging the breakout wrench, and adjust the pressure to 500 psi.

Record actual pressure _______________



Clock no/date


______ /______ 16. Back out the upper volume stop on the variable motor. Screw in the lower volume stop to reach a spindle speed of 160 RPM 10. Screw in the upper volume stop until it stops and lock into place.




______ /______ 17. Back out the lower volume stop to reach a spindle speed of 130 RPM 10 and lock into place.




DML-E

SPINDLE SUB INSTALLATION ______ /______ 1. Remove any grease from spindle threads.

______ /______ 2. Evenly apply joint compound lubrication on threads of spindle sub. ______ /______ 3. Thread the spindle sub into powerhead spindle. ______ /______ 4. Make up a tight joint using the sliding fork wrench located at the tower bottom.

Impact using half swing twice followed by full swing twice against stop block at maximum rotation and engine speed.

______ /______ 5. Check joint using feeler gauge to ensure that no gap exists between shoulders of spindle and spindle sub.

______ /______ 6. Protect rotary spindle seals and shock sub rubber elements from direct heat with insulating blanket or similar. Direct flame away from powerhead oil seal and shock sub rubber elements (if applicable) to prevent damage.

______ /______ 7. Use temp stick, then thermocouple or infrared heat gun to monitor per-heat temperatures.

______ /______ 8. No tack weld prior to preheat. ______ /______ 9. Pre-heat tabs and shaft with torch heating bud at weld area only to 300F. ______ /______ 10. Using E11018 SMAW welding rod, immediately weld heated area and then remove

slag. ______ /______ 11. Verify and maintain pre-heat temperature between weld passes. Continue welding

until complete. Do not stop and allow material to cool. ______ /______ 12. Post-heat weld area after welding to 300F. Wrap with insulating blanket and let cool

to ambient temperature (approximately 2-3 hours). ______ /______ 13. Weld stamp.

Clock no/date


FEED SYSTEM CONTROL VALVE

Low Pressure Machines:

______ /______ 18. Install a test gauge in the cylinder feed pressure test port. With the rotary head moving slowly down the tower (2 to 10 feet/min), adjust the sequence valve until the test gauge reads 700 psi. Lock the adjustment in place.

High Pressure Machines:

______ /______ 19. Adjustment should not normally be required. Screw in as required on the sequence valve adjustment (1 turn at a time) only if the rotary head has a tendency to drift with the feed control lever in neutral.

Clock no/date


ELECTRICAL CONTROLLER SETTINGS (Perform test with motor running at full speed)

Drill Feed Force Controller - (adjust with the head against lower stops) ______ /______1. To set the controller threshold, pull the feed direction controller down to maximum.

Turn the feed force controller knob slightly away from off (till the micro switches just click) and adjust the threshold pot until the pulldown pressure is 200 - 400 psi.

Record minimum pulldown pressure _______________



______ /______ 2. To adjust the controller maxout, turn the controller knob fully clockwise, then adjust the maxout pot until the pulldown pressure is obtained as stated below.

3500 psi max for rigs with 35-ft towers. 4000 to 4500 psi for rigs with 25/30-ft towers.

Record max pulldown pressure _______________ Device Type Device ID # Calibration Due Date


Holdback Controller High Pressure option - (adjust with the head feeding down, pulldown controller fully clockwise)

______ /______3. To set the holdback controller threshold, turn the controller knob slightly away from off (until the micro switches just click) and adjust the threshold pot until the holdback pressure is 200 - 400 psi.

Record minimum holdback pressure _______________



______ /______ 4. To adjust the holdback controller maxout, turn the controller knob fully clockwise, and then adjust the maxout pot until the holdback pressure is 3500 to 4000 psi.

Record max holdback pressure _______________ Device Type Device ID # Calibration Due Date


Clock no/date


Torque Limit Controller - Torque Limit Option - (adjust with the rotary head spindle stalled in the breakout fork)

______ /______5. To set the torque limit controller threshold, turn the controller knob slightly away from off (till the micro switches just click) and adjust the threshold pot until the torque limit pressure is 200 - 400 psi.

Record minimum torque limit pressure _______________



______ /______ 6. To adjust the controller maxout, turn the controller knob fully clockwise, then adjust the maxout pot till the torque limit pressure is obtained as stated below.

Reco

test manual 2657868267_005.pdf

Documents

functional test

quality coordinator

quality control inspector

applicable rig

rig serial number

manual description

rig bill of material

manual specifications