Table of Contents

Revised 3-05

Table of Contents . . . . . . . . . . . . . . . . . . . . . . i GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
HIGH PRESSURE COMPRESSOR SYSTEM IN- Draining Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
TRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1 Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
AIR RECEIVER RESERVOIR SEPARATOR MAIN-
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 TENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
ENGINE AND COMPRESSOR SPECIFICATIONS
3 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Static Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
AIR RECEIVER RESERVOIRS . . . . . . . . . . . . . . . . . . . . .28
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
HIGH PRESSURE COMPRESSOR COOLING
COMPRESSOR SYSTEMS SPECIFICATIONS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
(HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
HIGH PRESSURE COMPRESSOR POWER GROUP COMPO-
NENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 FAN SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
HIGH PRESSURE COMPRESSOR CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 REGULATION SYSTEM . . . . . . . . . . . . . . . . . 33

ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Air End Clutch Assemblies . . . . . . . . . . . . . . . . . . . . . . . . .10
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
HIGH PRESSURE COMPRESSOR OIL LUBRICA- High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
TION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Calibrating Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
VOLUME CONTROL . . . . . . . . . . . . . . . . . . . . 41
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Air Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Minimum Pressure Valve . . . . . . . . . . . . . . . . . . . . . . . . . .14
Separator Element Filter . . . . . . . . . . . . . . . . . . . . . . . . . . .14 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Scavenge Oil Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Mechanical Adjustment Type Volume Control Mounted On A
Compressor Main Oil Filters . . . . . . . . . . . . . . . . . . . . . . . .15 Butterfly Inlet Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Thermal Manifold With Bypass . . . . . . . . . . . . . . . . . . . . . .16
Oil Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Oil Stop Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
AUXILIARY AIR COMPONENTS . . . . . . . . . . 43
Two Stage Air End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Discharge Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Compressor Safety Relief Valves . . . . . . . . . . . . . . . . . . . .20
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
AIR COMPRESSOR LUBRICANT RECOMMENDATIONS 23 Dust Collection And Dust Suppression . . . . . . . . . . . . . . . .43
Dust Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Automatic Thread Greasing System . . . . . . . . . . . . . . . . . .45
COMPRESSOR OIL CHANGE PROCEDURE 25 Hydraulic Tank Pressurization . . . . . . . . . . . . . . . . . . . . . .46
Bit Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Table of Contents - Book 1 Page i

Automatic Grease System . . . . . . . . . . . . . . . . . . . . . . . . . 48
Chain Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . 49
Air Line Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

TROUBLESHOOTING HIGH PRESSURE COM-

PRESSOR SYSTEMS . . . . . . . . . . . . . . . . . . . 51

SERVICE LITERATURE . . . . . . . . . . . . . . . . . 55

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Page ii
 HIGH PRESSURE HP compressor control regulation system
Volume controls
COMPRESSOR SYSTEM Auxiliary air components
Troubleshooting HP compressor systems
INTRODUCTION Service literature

GENERAL DESCRIPTION

Driltech Blasthole and Waterwell drilling Driltech equipment are crawler and truck mount
machines utilize high volumes and high pres- models. The compressor (air end) is centrally
sure air delivery to the rock drilling tools. located in the front of the machine frame.

This HP compressor system manual is to be Compressor oil and air components are local to
used with machines that use a DTH Down The the compressor.
Hole drill tools. Please review Mission’s exten-
sive line of rock drilling hammers and custom Auxiliary air options for drilling and non-drilling
made drill bits. features are positioned at strategic areas on the
machine deck.
Driltech machines by model are:
• GATOR
D245S
• D25KS
• T25KW
FRONT
• D245S
• T35KS COMPRESSOR
• D40KS
• D40KW
• T40KS machineoverview.tif

• D45KS
• D55SP
• D75KS

This manual is to be used in factory approved

drill clinic training programs and compressor
specialty training programs.

• Book one
HP compressor system introduction
Engine and compressor specification REAR
Compressor spec sheet
Power group components (HP)
Oil lubrication (HP)
Compressor oil change procedure
Seperator maintenence
HP compressor cooling system

High Pressure Compressor System Introduction Page 1

 COMPRESSOR

D25KW TRUCK MODEL WATERWELL

Published by Driltech - USA

All rights reserved. No part of this manual may be repro-

duced in any form without the prior written consent from
Driltech.

Part No. 023501-031

Page 2
ENGINE AND COMPRESSOR Compressor ratings are based on volumes of
air discharged or SCFM standard cubic feet per
SPECIFICATIONS minute. There are many compressors available
for various drilling conditions.

GENERAL Driltech have partnered with Sullair Corporation

to offer a engine mounted two stage high pres-
Driltech has partnered with Caterpillar and sure compressor package for our drilling equip-
Cummins engine manufactures to offer our cus- ment. The main concept is to drill a hole in the
tomers ‘E series’, ‘HEUI’ and ‘QSK Celect earth with a tool(s) known as down the hole
series’ model engines to direct drive compres- hammer (DTH). Consult Driltech Mission for
sors (also referred to as the air end). compressed air volume requirements for a spe-
cific hammer size.

DESCRIPTION Common compressor volumes CFM and maxi-

mum pressure ratings PSI:
Engine horsepower is used to drive the com-
• 750 CFM / 350 PSI (21.2m³ m / 24 bar)
bined volume and pressure from a two stage
high pressure air end. • 900 CFM / 350 PSI (25.5m³ m / 24 bar)

Engine horsepower requirements are greater • 1000 CFM / 350 PSI (28.3m³ m / 24 bar)
when driving a 1350 cfm (38.2m³ m) air com-
pressor verses the 750 cfm (21.2m³ m) air com- • 1150 CFM / 350 PSI (32.8m³ m / 24 bar)
pressor. • 1350 CFM / 350 PSI (38.2m³ m / 24 bar)
Common engine horsepower (HP) at engine Engine and compressor packages are compati-
high idle speeds is based on (RPM). The speed ble for specific drilling applications.
rating given is engine loaded high idle speed.
Climactic conditions and operating conditions
The actual ‘TEL’ Top Engine Limit calibration such as altitude are factors in selecting the
will be slightly higher than 1800 or 2100 rpm. proper power group components to fit the over-
• 450 HP (336kw) 3406E @ 1800 RPM all drilling needs.

• 500 HP (373kw) @ 1800 RPM

• 505 HP (376kw) @ 1800 RPM

• 525 HP (389kw) C15 @ 1800 RPM

• 530 HP (395 kw ) QSX @ 1800 RPM

• 600 HP (447 kw ) C16 @ 1800 RPM

• 600 HP (447 kw ) QSX @ 1800 RPM

• 630 HP (470kw) @ 1800 RPM

• 650 HP (485 kw) @ 1800 RPM

• 760 HP (550kw) 3412E @ 2100 RPM

• 760 HP (550kw) QSK19 @ 2100 RPM

Engine and Compressor Specifications Page 3
When selecting a compressor size and drilling Down the hole drilling tools may need to be pur-
tools (DTH) follow the altitude correction chart chased or modified to compensate for air loss
as shown. due to altitude conditions.

ALTITUDE ALTITUDE CORRECTION

FEET METERS FACTOR
4000 1200 .86

5000 1500 .82

6000 1800 .79

7000 2100 .76

8000 2400 .73

9000 2700 .70

10000 3000 .68

11000 3400 .65

12000 3700 .63

13000 4000 .60

14000 4300 .58

Use the altitude correction table;

Consult your hammer supplier for details
• For drilling applications above 4000 feet regarding valve or choke modifications.
(1200 meters).

• When determining actual compressor output

or standard cubic feet per minute (SCFM).

• In selecting the correct DTH drilling tools.

Example:

900 CFM @ 5000 feet (1500 meters).

compressor output = 900 x.82 = 738 SCFM

1150 CFM @ 11,000 feet (3400 meters).

compressor output = 1150 x.65 = 748 SCFM

Page 4
 COMPRESSOR SYSTEMS SPECIFICATIONS (HP)

GENERAL

High pressure compressor systems specifications are general. The main components listed are
designed purchased parts that are designed to compliment a Driltech blasthole drill machine. The
primary drilling concept is DTH down the hole drill method and the secondary drill concept is rotary
drill methods.

COMPONENT SPECIFICATION

STANDARD COMPRESSOR OIL THERMOSTATS COLD SIDE EXTEND TO CLOSE @ 184° F (84.4° C) *
* ALTERNATE STATS AVAILABLE HOT SIDE EXTEND TO CLOSE @ 175° F (79.4° C) *
900 SERIES THERMOSTATS COLD SIDE EXTEND TO OPEN @ 185° F (84.6° C)

OIL COOLER BYPASS VALVES 1 0R 2 @ 50 PSI (3.5 BAR)

AIR RECIEVER SAFETY RELIEF VALVE 1 @ 375 PSI (26 BAR) OR

FOR HIGH PRESSURE MODELS ONLY 1 @ 400 PSI (27.5 BAR)

COMPRESSOR SAFETY RELIEF VALVES 1 OR 2 @ 140 PSI (9.7 BAR)

MINIMUM PRESSURE VALVE 1 @ 140 PSI (9.7 BAR)

UNLOAD PRESSURE @ LOW PRESSURE 150-160 PSI (10.3-11 BAR)

UNLOAD PRESSURE @ HIGH PRESSURE 350 PSI (24 BAR)

SEPERATOR DIFFERENTIAL INDICATOR (CSP) 1 @ 10 PSI (.70 BAR)

MAIN OIL FILTER BYPASS VALVE (CFP2) 25 PSI (1.7 BAR) SWITCH - 30 PSI BYPASS OR
35 PSI (2.4 BAR) SWITCH - 40 PSI BYPASS

AIR CLEANER FILTER INDICATOR (CFP1) 1 @ 25 INCHES WATER

AIR/OIL TEMPERATURE SWITCH (CAT) 265° F (129° C) COMPRESSOR AIR TEMP

AIR/OIL TEMPERATURE SWITCH (CIT) 250° F (121° C) COMPRESSOR INTERSTAGE TEMP
COMPRESSOR PRESSURE SWITCH (COP) 90 PSI (6.2 BAR) COMPRESSORE OIL PRESSURE

Y2000 FACTORY FILL COMPRESSOR OIL SHELL CORENA AW32 / CORENA POA 32

Specifications listed are consistent on all Driltech high pressure model machines. Minor changes
have taken place for component longevity and to improve operation for the drilling cycle.

When connecting electrical switches into the compressor system refer to the abbreviated descrip-
tions (COP) (CAT) or (CIT) on the machine specific electrical system schematic.

Compressor Sytems Specifications (HP) Page 5

 FEATURES AND CUSTOMER PREFERRED OPTIONS ADDED ON TO THE AIR SYSTEM

FEATURE/OPTION SPECIFICATION

HYDRAULIC TANK PRESSURIZATION 5 PSI (.3 BAR) RELIEF @ 12 PSI (.8 BAR)

DRY DUST COLLECTION AIR REGULATION 50 PSI (3.5 BAR) RELIEF @ 90 PSI (6.2 BAR)

HAMMER LUBRICATOR TANK REGULATION 60 PSI (4 BAR)

AIR BLOWDOWN REGULATION 30 PSI (2 BAR)

AUTOMATIC THREAD LUBE REGULATION 100 PSI (6.8 BAR)

AUTOMATIC GREASE SYSTEM REGULATION 60-100 PSI (4-6.8 BAR)

CHAIN LUBRICATION SYSTEM REGULATION 60 - 80 PSI (4 - 5.5 BAR)

Page 6
 HIGH PRESSURE
COMPRESSOR POWER 1350/350
GROUP COMPONENTS SHOWN

GENERAL

This section will describe the engine, drive cou-

pling and two stage compressor mounting, and
the importance of proper engine speeds.

DESCRIPTION

The engine and compressor driven compo-

nents are purchased parts installed to Driltech
specifications. The compressor shaft and drive coupling
should rotate free after final component installa-
Compressors are direct drive to the customer tion.
selected engine.

! CAUTION
Using a hammer on or apply high forces to
the input shaft when installing the coupling
can damage the bearings.

It is a recommended practice to add 5 gallons

(20 liters) clean compressor oil into the open
compressor inlet prior to starting a new or
BOLT TORQUE remanufactured air end unit.
75 - 85 FT LB
(102 - 115 Nm) The compressor inlet porting will have a intake
LOCTITE 242 manifold, inlet control valve (butterfly plate)
using gaskets as seals between the compo-
nents.

Refer to service material 008674-000 taperlock NOTE!

bushing installation procedure for any new (air Two of the series of bolts mounting the inlet
end) compressor installation. The same proce- manifold are inside the manifold. It is essential
dure shall be used when re-installing the taper- to use loctite 242 during the bolt mounting pro-
lock bushing onto a compressor shaft. cedure. Final intake manifold bolt torque shall
be 280 -310 FT LB (280 - 420 Nm).

Power Group Components Page 7

 3/4 GRADE 8 BOLTS
LOCTITE & TORQUE
280 -310 FT LB
(280 - 420 Nm) COMPRESSOR TO ENGINE INSTALLATION

ENGINE SPEED
When mounting the inlet control valve, align-
ment and free acting butterfly plate movement Maintaining the correct engine high and low idle
are requirements for correct acting air pressure speeds are essential for the compressor, drive
build-up (load and unload modes) of operation. coupling, machine frame cross members and
related equipment longevity.
Maintain all intake pipe and hump hose connec-
tions. Replace worn and weathered rubber A minimum engine low idle speed of 1200
seals as needed. RPM is essential to maintain drive coupling
wear and minimizing machine vibrations.
When removing and installing a compressor
with warranty consideration it is necessary to:
ENGINE SPEED METER (ESM)
• Locate Equipment Serial Numbers

• Maintain Cleanliness During Component

Removal and Return Process

• Follow System Cleaning Procedures

• Replace Worn Components As Needed

• Record Appropriate Documentation For

Return To Vendor, Startup Papers Provided
With Replacement Air End

• Specify Oil Type

• Follow Common Mechanical Procedures

During Compressor Installation, Some Of Engine high idle speed settings will vary from
Which Are Stated Herein machine model. The engine high idle speed is
required in order to deliver the expected com-
pressor air delivery spec (SCFM).
Page 8
 HP COMPRESSOR HOSING CIRCUIT

WORKING AIR PRESSURE

RECEIVER AIR PRESSURE

HYDRAULIC TANK
PRESSURIZATION

021003-002

Gauges on drill operator stations enable visual reference to drilling air temperature and pressure
functions.

Power Group Components Page 9

Air End Clutch Assemblies

INSTALLATION INSTRUCTIONS

Clutch type air compressor input shafts are • Clutch is disengaged when the handle is
extended to allow the addition of a 14 inch towards the compressor
clutch disc package. Engage the clutch when
the engine is in the off mode only. • Lubricate collar with one or two strokes of a
lithium base #2 grease at a interval not to
• Clutch is engaged when the handle is exceed 50 hours. Do not mix greases or
towards the engine over grease the throwout collar

006490-002
THROWOUT COLLAR
TORQUE NUT TO
175 - 200 FT LB
237 - 271 Nm

COMPRESSOR SHAFT

PROPER CLUTCH ADJUSTMENT IS

DETERMINED WITH A TORQUE WRENCH
CONNECTION ON THE SHAFT ASSEMBLY

CORRECT TORQUE FOR SHAFT

ENGAGEMENT IS 150 TO 200 FT LB
203 - 271 Nm
DRIVE RING GEAR

A new clutch generally requires several adjust- operating lever pressure of 150 - 200 ft lb, (203
ments until the friction surfaces are worn in. Do - 271 Nm).
not let a clutch slip as this will glaze the friction
plates and may ruin them. Turn the adjusting
ring clockwise to obtain the recommended
Page 10
 006490-002
COVER PLATE

OPERATING LEVER

LEVER AND LINKAGE SHOULD

BE LUBRICATED WITH ENGINE
OIL AFTER EVERY 500 HOURS
OF OPERATION

When clutch adjustments are required remove • Clock wise adjustments will tension the
the cover plate to access the adjustment ring. operating lever torque
Machine must be in the off mode prior to
attempting clutch adjustments. • Counterclockwise adjustments will lessen
the operating lever torque
• Locate the retaining pin

• Move the retaining pin and hold in place

while turning the adjustment ring
006477-001 CLUTCH TWIN DISC FRICTION
ASSEMBLY PLATES

ADJUSTMENT RING
AND LOCK ASSEMBLY

Clutch applications are limited to truck model

T25KW, T40KW and T40KX machines that
have optional mud pumps installed.

Power Group Components Page 11

Page 12
 HIGH PRESSURE This section will show oil circulation through
these components.
COMPRESSOR OIL
As of January 2000 the factory fill compressor
LUBRICATION oil is synthetic, Shell Corena AW32 series.

Air Receiver Tank

GENERAL
Driltech uses two types of air receiver tanks for
Two stage high pressure application machines high pressure drill applications.
utilize contained air pressure to direct circulat-
ing oil through hoses, valves, oil coolers and The ‘vertical’ mount tank units are used on
the two stage air end. GATOR and D25KW series water well
machines.

DESCRIPTION

Components of the compressed air system are

common throughout the Driltech high pressure
application machines.

• Air receiver tank

• Fluid level sight glasses

• Synthetic compressor fluid

• Safety relief valve verttank.tif

• Minimum pressure valve

• Separator element filter

• Separator differential indicator

• Scavenge oil return system

• Oil temperature thermostats

• Oil cooler bypass valves

• Oil cooler

• Oil stop valve

‘Tee tank’ mount units use a small vertical sec-
• Temperature safety switches tion welded to a larger horizontal section. Appli-
cations are: D25KS, D245S, D40KS, D45KS,
• Pressure safety switch D50KS, D55SP, D60KS, D75KS, D40KW,
TM40KW, and T40KX machines.
• Two stage air end

• Discharge check valve The tee tank is our most commonly used
receiver tank. With either design, fluid levels
• High temperature hoses are to be checked 2 minutes after machine
shutdown or when the fluid is at rest.
Oil Lubrication Page 13
 ! WARNING
The cap is under spring pressure. Use
extreme caution when removing the cap
from the housing.

Minimum pressure valves should be free of

compressor oil. Only dry air should be passing
through this valve.
560art.tif
When testing the minimum pressure

1. Operate the machine at the rated high idle

speed.

2. Turn the working air on and observe the air

receiver pressure gauge on the operator
console. Extra gauge ports are available to
install a test pressure gauge on the tank.

Air pressure inside the air receiver tank should

never drop below the preset spring value of the
Fluid levels are to be checked 2 minutes after
minimum pressure valve.
machine shutdown or when the fluid is at rest.
Drain condensation daily through the bottom Separator Element Filter
mount drain valve.
Inside the vertical section of the air receiver
Minimum Pressure Valve
tank there is one single element filter.
A minimum pressure valve positioned on the
vertical section of each type of air receiver tank
maintains air pressure inside the tank during
the run mode. The minimum air pressure is 140
psi (9.7 bar) which is capable of pushing the oil
through all the lubrication parts.

separator element
minimum pressure
PISTON AND SPRING
DRY AIR IN

CHECK
VALVE

VENT

DRY AIR OUT

MINIMUM PRESSURE VALVE

Page 14
The concept is to slow down the air movement
that contains compressor oil. Oil mist will be
trapped on the inner element filter diffusion cas-
OIL STOP
ing. Air and microscopic oil will pass through VALVE
the paper pleated filter media.

Separator elements in a high pressure applica- FILTER

tion pass air through the element from the inner ASSEMBLY
to outter air flow direction.

The separator element has a static ground

device (spring or staple type). This ground
device is used to eliminate the static electricity
inside the element filter. CFP2

THERMAL
Scavenge Oil Return VALVES

A oil return system referred to as a scavenge BYPASS

SCAVENGE
system enables oil carry over that passes STRAINER VALVES
through the paper pleat separator element to be FILTER
returned to the compressor stator housing or
compressor gear housing. Perform maintenance with the machine in a
shutdown condition.
The scavenge return line will have a strainer
screen filter, sight glass, with a inline orifice that For safety purpose allow a minimum of 2 min-
controls the return oil flow. utes or more after machine shutdown prior to
starting maintenance.
Oil carry over is dependent on receiver tank
pressure. Expect one cup (236 ml) to one quart Compressor Main Oil Filters
(.94 l) during a drilling condition.
A 1/4 inch bleed port positioned on the filter
Compressor component maintenance is cover may be opened prior to filter removal.
required at 250 service hour intervals. This port will vent the filter canister of any resid-
ual pressure trapped inside the filter assembly
after machine shutdown.
SCAVENGE LINE
TO COMPRESSOR
GEAR HOUSING The original filter micron rating is identified on
the filter container cover. There are two permis-
sible filters that may be installed in the
Schroeder filter canister.

• KS15 applicable 1992 thru 2002

• KZ25 current filter application

Use OEM replacement filters. Failure to utilize

Schroeder OEM type filters will affect compres-
sor warranty.

Oil Lubrication Page 15

Replace the plastic connector as needed when Thermal valves require one seal ring upon
it appears to be worn or damaged. Failure to installation into the thermal housing port. Do not
maintain the plastic connector can allow poor use more than one seal ring per thermostat
filter sealing areas enabling contamination into upon installation.
the compressor oil lubrication system.
OIL COOLING MANIFOLD
COMPRESSOR BLEED PORT TWO THERMAL VALVES
FIL
OIL FILTERS TWO BYPASS VALVES
184°F 184°F

FC
RETAIN FILTER X
SEALS, 2 PER FILTER 50

X
ART
PLASTIC FILTER BYPASS TC
CONNECTOR VALVE

Oil cooling is dependant on the position of the

thermal valve position.

• ART air receiver tank

• TC to oil cooler

• FC from oil cooler

When performing routine maintenance observe • FIL filters (KS15 or KZ25)

filter condition. Be sure to retain all seals on
• X test ports
both filter elements.
The thermal valves extend approximately 5/8
Use caution when installing new compressor oil
inch (15 mm) to seat into the manifold bore. As
filters into the housing not to unseat the filter
the valves extend they restrict free flowing oil,
seal and push the seal into the filter
and force compressor oil into the oil cooler.
Loose or missing seals should be located prior
For cold ambient conditions when cold oil or
to reinstating the machine into service.
fluid viscosity is high during the cold start cycle,
Thermal Manifold With Bypass two 50 psi (3.5 bar) valves can open that allows
free flow cold oil 4 flow paths to the filter assem-
Two thermal valves direct compressor oil to the bly and two stage compressor.
compressor through filter assembly and com-
pressor oil cooler depending on fluid tempera- 900/350 Thermal Valve Upgrade
tures. There are seven applicable thermal
valves suitable for use according to ambient A new temperature control is added to 900/350
operating conditions. high pressure air compressors. The upgrade
became effective in 9/03.
The thermal valves and cooler bypass valves
are threaded into a manifold. Test ports are This thermal valve is a single 185° F thermostat
available on the manifold to test oil pressure and a 50 psi bypass relief valve.
drops through the cooler.
Page 16
The 027842-055 cooling manifold kit is adapt-
able for field installation.

TEST PORT

FROM
COOLER
TO
FILTER

oilcooler.tif

TO
COOLER COMPRESSOR
FROM SECTION (AKG)
RECEIVER
TANK

027842-055 COOLING MANIFOLD KIT

Oil Coolers It may become necessary during cold ambient

operating conditions to cover the entire cooler
High ambient oil coolers are high quality alumi- cores with a curtain.
num header and terbulator tube design. Low
ambient oil coolers are high quality steel with re A cooler curtain restricts external ambient air-
placable turbulator tubes sealed at the top and flow through the oil cooling fins. The restricted
bottom headers. air can aid oil flow through the internal turbula-
tor tubes of the oil cooler therefore decreasing
Pressure in the oil cooler is dependant on regu- oil cooler pressure and temperature drops.
lated system pressure. When testing oil cooler
pressures the gauge readings will be >140 psi Expected oil cooler pressure drop, measured
up to 375 psi (9.7 to 25.8 bar) as differential pressure drop through the oil
cooler.
Flow through the oil cooler is dependant on
thermal valve position, oil temperature, oil vis- • less than 5 to 15 psi (.3 to 1 bar)
cosity and bypass valve position. • less than 15 to 35 psi (1 to 2.4 bar)

• above 35 to 50 (2.4 to 3.4 bar)

Expected oil temperature drop, measured as

differential temperature drop through the oil
cooler.

• 20° to 40° F (+ 4.4° to - 6° C)

Oil Lubrication Page 17

Oil Stop Valve The second stage has one male and one
female rotor supported in the stator housing by
Oil stop valves are mounted after the filter radial and thrust bearings.
assembly mounted on the compressor bearing
distribution block. The oil stop valve receives a Each unit is dependant on the gear ratio, a
pilot pressure signal equal to the discharge driven speed and designed oil lubrication.
pressure from the air end.

IN DISCHARGE INTAKE
CAT SWITCH

2ND STAGE
1ST STAGE
OUT
OIL STOP VALVE

The primary function of the oil stop valve is to U-TUBE

maintain compressor oil in the hoses and X CIT SWITCH
X
related components after machine shutdown. 02/99 SULLAIR

The oil stop valve is direct mounted to a oil

manifold that in design delivers compressor oil New and remanufactured air end units are
to required lubrication points of the air end. available from Driltech Mission spare parts
dept. Verify machine model and serial number
This bearing distribution manifold is last point for compressor specification.
oil injection. A compressor oil pressure switch
COP is rated to open with pressures below 90 During the machine run mode the compressor
psi (6.2 bar). This safety switch will shut the oil temperatures should be maintained at a min-
machine down. imum of 100° F (37.7° C) above the ambient
condition.
The manifold hoses are sized for flow require-
ments to the desired points of oil injection. Operators should be aware of compressor
operating temperatures. A sensor on the com-
Two Stage Air End pressor discharge elbow and a gauge on the
operators panel allows visual reference to air/oil
High pressure compressed air is made avail- temperatures.
able from two sets of rotating rotor assemblies.
It is common to see compressor temperatures
The first stage has one male and one female operating between 195 and 210° up to 230° F
rotor supported in a stator housing by radial and (90.5 - 98.8° up to 110° C) during the loaded
thrust bearings. drilling cycle. Compressor operating tempera-
tures 220 to 240° F (104 t0 115° C) are com-
mon in extreme environments.

Page 18
Operating the machine in extreme ambient con- hot oil returning to the air receiver tank under
ditions may require special operating compo- high pressure. Air pressure may be as high as
nents. It may be necessary to: 375 psi (25.8 bar) with oil temperatures capable
of 240° F (115° C).
• Upgrade The Fluid Viscosity Using Either
Iso 32 Or Iso 46 Grades. Compressors are a major investment. It is rec-
• Change Thermal Valve Temperature Values. ommended to protect the investment with pres-
sure and temperature safety switches.
• Modify The Cooling Fan System By Slowing
Or Increasing The Fan Rpm To Spec. Electrical switches and a shutdown relay are in
a series without monitor systems or parallel cir-
• Restrict Air Flow Over The Oil Coolers With cuits when the drill monitor system is supplied.
A Cooler Curtain. With either application Driltech products will
have compressor protection.
Discharge Check Valve
90 PSI
One discharge check valve is mounted on the COMPRESSOR SAFETY
outlet flange discharge elbow from the second RELIEF VALVES
stage stator housing.

Discharge check valves stop oil from the

receiver tank from draining into the compressor
250R
after machine shutdown.

Without a discharge check valve air pressure

inside the air receiver tank could run the com-
pressor reverse at shutdown. 265R
SAFETY SWITCHES
Failure of a discharge check valve could allow
oil collection on the air cleaner elements, as
well as fluctuating oil level and a reverse run Driltech options allow the compressor systems
condition at shutdown. to be monitored with one common circuit panel,
cabin mounted on the operator station.
DISCHARGE
GASKET CHECK VALVE The option is a drill monitor system (DMS).

HOUSING Compressor related monitoring using pre set

switches includes:
STOP PLATE
• CFP compressor air filter restriction indica-
tor @ 25 in vacuum (manual and electric)
SPRING
• CSP compressor separator pressure @ 10
RETAINER RING
psi (.68 BAR)

• CIT compressor interstage temperature @

GASKET
250°F (121° C) tagged as 250R

• CAT compressor air temperature @ 265°F

Discharge check valves are a one way check (129° C) tagged as 265R
valve. Free flow oil out the discharge hose with

Oil Lubrication Page 19

• COP compressor oil pressure @ 90 psi Interstage pressure above 80 psi means com-
(6.2 bar) tagged as 90F pressor repair and or replacement is required.

Compressor Safety Relief Valves

All two stage high pressure application com-

pressors used on Driltech equipment require 1
or 2 each 140 psi (9.7 bar) valve(s) mounted on
the compressor gearbox.

Safety relief valve(s) are an integral part of a

new or replacement compressor, air end unit.

These valves are designed to vent the com-

pressor gearbox in the event of compressor
wear and or failure. These valves should not
vent air under normal operating conditions.

Air pressure will vent to atmosphere from these

safety relief valves and is an indication that
bearing or housing wear or failure has
occurred.

Do not continue to operate the machine with

air venting from the compressor safety relief
valve(s).

Compressor Test Pressures

Normal gearbox pressure will range from 35 to

65 psi (2.4 to 4.5 bar). Pressure may be taken
from a test port on the compressor gearbox.

Air venting through the safety relief valve gen-

erally means compressor repair and or replace-
ment is required.

Follow compressor system cleaning procedures

as needed during compressor system overhaul.

Normal interstage pressure will range from 45

to 55 psi (3.1 to 3.8 bar) during high pressure
mode in a drilling condition. Pressure shall be
taken from the interstage U - tube adapter.

Interstage pressure creates working loads on

the engine. Excess pressure will pull the engine
idle speed down during a drilling condition.

Page 20
HIGH PRESSURE COMPRESSOR SYSTEM FLOW CHART
(COOL OIL)

Oil Lubrication Page 21

 HIGH PRESSURE COMPRESSOR SYSTEM FLOW CHART
(WARM OIL)

Page 22
 AIR COMPRESSOR LUBRICANT RECOM- NOTE!
MENDATIONS Mixing synthetic oils with an ATF may lead to
operational problems, foaming, or plugging of
Driltech encourages the user to participate in an orifices. Do not mix different types of fluids.
oil analysis program with the oil supplier. This
could result in an oil change interval differing
from what is stated in these tables.

AMBIENT CHANGE LUBRICANT

ISO
TEMPERATURE INTERVAL DESCRIPTION

-40°F to +95°F (-40°C to +35°C) 1000 Hours 32 Mobil SHC-624, 924 & 1024

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Chevron HiPerSYN

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Chevron Tegra Synthetic

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Shell Corena PAO

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Royco 432

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Conoco Syncon R&O

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Texaco Cetus PAO

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Valvoline Syn Guard CP

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Petro-Canada Super SCF32

+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Chevron HiPerSYN

+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Citgo CompressorGuard

+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Conoco Syncon R&O

+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Petro-Canada Super SCF46

+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Royco 446

+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Texaco Cetus PAO

+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Valvoline Syn Guard CP

+80°F to +120°F (+27°C to +49°C) 1000 Hours 68 Conoco Syncon R&O

+80°F to +120°F (+27°C to +49°C) 1000 Hours 68 Mobil SHC-626, 926 & 1026

High Pressure Compressors

When operating between +80 and 100°F (+27

and 38°C) with a relative humidity above 80%,
synthetic hydrocarbon type fluid Mobil SHC or
equivalent as recommended above should be
used.

All lubricant recommendations are based on

1200 rpm maximum WARM-UP speed.

Oil Lubrication Page 23

Page 24
COMPRESSOR OIL CHANGE Draining Oil

PROCEDURE Depending on the ambient temperature, it may

be necessary to start the machine and warm the
compressor prior to changing fluid.

GENERAL 1. Once compressor oil is warm, shut off the

machine and remove the key from key
This procedure is to be used: switch.

• When a total system cleaning is necessary. 2. Locate 1 or 2 containers of 50 gal (190 liters)
capacity for each.
• Severe duty applications.
3. Connect a hose to the drain valve located on
• Changing brand name, type or viscosity of the bottom of the receiver tank.
compressor fluids.
4. Open the ball valve to drain compressor oil
Starting January 2000 Driltech drilling machines into the containers. Follow applicable laws
are shipped from the factory with Shell Corena prescribed for waste oil recovery.
AW32 or Corena POA 32 in the compressor
system.

In certain areas of the world, this oil may not be

! CAUTION
available. If this is the case it will be necessary
to change to the local available oil. When this Starting the engine when the compressor oil
occurs it is mandatory to clean the system of the has been drained will damage the compres-
original oil. sor. Do not allow the engine to start!

Mixing of two different oils can cause the follow- 5. Insert the key into the key switch, hold the
ing problems: engine stop button and roll the engine and
compressor over two (2) or three (3) times.
• Oil Foaming, big air bubbles can cause cav- This will push out any residual oil that was
itation on components and make air pockets left in compressor into receiver tank.
in the oil cooler restricting oil flow
6. Remove top and bottom hose from com-
• Overheating, compressor fluids not flowing pressor oil cooler. This enables oil to drain
through the oil cooler will not dissipate heat out of cooler.

• Excessive Oil Carry Over through the sep- 7. Remove separator filter. Replacing the sepa-
arator element wasting the oil down the drill rator element is dependent on service hour
pipe. interval. When in doubt or service hours are
unknown, replace the separator element.
When the following procedure is followed, these
problems can be reduced or be non existent. 8. Remove scavenge return line and allow to
drain, remove and clean strainer screen,
replace screen and tighten.
DESCRIPTION
9. Remove the main compressor filters. The fil-
Before changing brand name oil, contact the ter canister may be unthreaded from the
Driltech service department with the specs of housing in order to drain oil from filter canis-
the oil to be used. This step is in order to deter- ter.
mine if the oil spec is correct for the compres-
sor.
Compressor Oil Change Procedure Page 25
10. Remove and drain the pilot hose at the oil 9. Install compressor filters making sure the
stop valve. plastic connection piece is installed between
the two KS15 or KZ25 series filters.
11. Remove all oil cooler and tank lines from
compressor to drain any oil that may have 10. Connect pilot hose to the oil stop valve.
been left in system.
11. Fill air receiver tank with new clean oil to the
12. HIGH PRESSURE APPLICATIONS ONLY required level sight glass port, install the fill
Remove discharge check valve from the dis- plug and tighten.
charge port of the compressor, (location is
12. Holding engine stop button, roll over com-
underneath compressor) to drain any oil that
pressor and check for any leaks. If evident,
may be left in that area.
repair prior to running the machine.
13. Remove intake piping at compressor inlet.
13. Start engine and run at low idle and check
for any leaks. If evident, repair.
New flange O-rings will be needed for connect- 14. Permit compressor to run until compressor
ing hose ends that have been removed for this temperature comes to operating tempera-
procedure. ture. (Approximately 160° to 200°F).
Adding Oil 15. Shut machine down and let set for 15-20
minutes and recheck compressor oil level.
1. Pour some new clean compressor oil into
the top of the oil cooler permitting it to push 16. Add oil as needed to the proper fluid level
any of the existing oil from cooler. Once new sight glass.
oil is coming through oil cooler, attach the
top cooler hose. 17. After several hours of operation and if a
foaming problem exists, you may need to
2. Pour some new clean compressor oil into drain the oil from the separator tank and
the intake of the compressor to flush out any refill.
original oil. Once this is done, install the dis-
charge check valve high pressure applica- Oil may be transferred from air receiver tank to
tions and all other hoses that were clean drums using a portable filtration cart as
removed. shown.
3. Pour some oil into the receiver tank to push
PORTABLE FILTRATION CART
out any existing oil. P/N 023912-001
4. Close the drain valve.
5. Install separator filter, with a new gasket, do
not remove the static staple that is clipped in
the separator gasket. No additional sealants
are necessary.
6. Mount the receiver tank cover, torque bolts
to spec.
7. For low pressure applications install the
scavenge return tube and tighten adapters.
8. Connect scavenge return hose to appropri-
ate ports.

Page 26
AIR RECEIVER RESERVOIR It may be a written law that pressure vessels
require recertification. This recertification may
SEPARATOR MAINTENANCE only be performed with a qualified test proce-
dure and a qualified engineering firm.
GENERAL
Due to the complexity of such laws worldwide
Routine maintenance on air receiver reservoirs Driltech ask that the customer bare this respon-
require a skilled maintenance person using safe sibility as a company standard operating proce-
operating principals and clean working habits. dure.

DESCRIPTION Static Discharge

Driltech drilling equipment use compressed air
All models of Driltech drill machines will use a
during the drilling cycle. Air pressure will be
static discharge spring or staple. This device
contained in the air receiver tank during the
makes a secure electrical ground for the sepa-
machine run mode.
rator filter element.
When performing routing maintenance it is
• High pressure applications require a spring
essential that the machine be turned off for a
installed on the bottom end filter holddown
minimum of 2 minutes prior to starting compres-
bolt.
sor system maintenance. Longer periods may
be beneficial to allow oil temperatures to drop.
• Low pressure applications require a static
staple installed on the sealing gasket for the
It is recommended to use the appropriate
top cover.
Driltech machine maintenance manual when
performing the 250, 500, 1000 and 2000 hour
Do not operate the machine with the static
maintenance programs.
spring or gasket staple removed.
The details given in this section are relating to
Compressor oil under heat from compression,
air receiver reservoir air/oil separator element
and velocity may develop static electricity inside
service specs.
the air receiver tank during operating condi-
tions.
The figures given will be noted for machine(s)
specific data.
The contained static electricity may have the
capacity to ignite the oil and cause the com-
pressor to flash. A machine fire will occur.
MACHINE MODELS APPLICATION

T25KW, GATOR HIGH PRESSURE

D25KS, D25KX, D245S HIGH PRESSURE

T35KS, TM40KW, T40KX HIGH PRESSURE

T40KS, D40KS, D45KS HIGH PRESSURE

D55SP, D75KS HIGH PRESSURE

There are different reservoirs for high pressure

versus low pressure applications. Therefore the
maximum pressure ratings and operating tem-
perature specs differ.

Separator Maintenance (HP) Page 27

AIR RECEIVER RESERVOIRS

D25KS, D25KX, D245S

T35KS, TM40KW, D40KX
D25KW, GATOR T40KS, D40KS, D45KS
HIGH PRESSURE APPLICATION HIGH PRESSURE APPLICATION
COVER TORQUE COVER TORQUE
3/4 10 UNC GRADE 8 270 - 292 FT LB (364 - 394 Nm) 3/4 10 UNC GRADE 5 190 - 210 FT LB (256 - 283 Nm)
FILTER HOLDDOWN COVER TORQUE FILTER HOLDDOWN COVER TORQUE
3/4 10 UNC 50 FT LB (67.5 Nm) 3/4 10 UNC 50 FT LB (67.5 Nm)

Page 28
 D55SP, D75KS
HIGH PRESSURE APPLICATIONS

COVER TORQUE
3/4 10 UNC GRADE 5 190 - 210 FT LB (256 - 283 Nm)
FILTER HOLDDOWN COVER TORQUE
3/4 10 UNC 50 FT LB (67.5 Nm)

Separator Maintenance (HP) Page 29

Page 30
 HIGH PRESSURE Cooling fan systems are designed to draw air
through heat exchangers. Engine coolant, turbo
COMPRESSOR COOLING air, compressor oil, hydraulic oil and diesel fuel
are being air cooled by the speed of the cooling
SYSTEM fan and ambient air temperature.

GENERAL

High pressure application drilling will generate

higher than normal operating temperatures.

The two stage compressor is under maximum

load during the drilling mode and receiver air oilcoolers.tiff
pressure is 345 to 350 psi (24 bar).

The engine is under 60 to 80 percent load,

depending on available receiver air pressure.

During the drilling cycle the hydraulic system

will be working hard also.

• Rotation pump delivery for drill pipe rotation

• Feed pump delivery for advancing drill pipe

into and out of the blasthole When cooling problems occur, question which
systems are overheating.
• Cooling fan pump delivery to turn a deter-
mined fan dimension. If there is a true cooling fan speed issue, all the
fluids and the air will be influenced by the
As noted in troubleshooting procedures it may higher than normal operating condition.
become necessary to check the machine
parameters that may allow high operating tem- Experience on the machine will enable visual
peratures during the drilling modes. identification when a cooling fan is not turning
the correct speed.

DESCRIPTION When cooling fans are spinning the correct

speed and direction (CCW), the ambient air is
The current cooling fan systems are described sucking through the cooler assembly.
in detail in the Hydraulic Systems Training Mod-
ule Book 5, Start Up And Setting Procedures.
! DANGER
Determine the cooling system concept as
Fan blades can cause serious injury or
described.
death. Always use caution when testing
cooling fan speed.
• Closed Loop System
When testing the fan speed hot air will rush
• Open Loop System
past the motor. Depending on fan speed the air
will be forceful enough to blow personnel cloth-
• Locate The Components
ing and personnel protective equipment.
Compressor Cooling Systems Page 31
Cooling fan motor and assemblies are mounted • It may be necessary to prepare the fan hub
on support beams. with non reflective paint.

Open loop systems have a fixed angle fan that • Use a photo cell or a hand held photo
is direct driven by a vane type hydraulic motor. tachometer

High idle engine idle speeds should be verified.

FAN SPEEDS
PLACE TAPE
ON FAN HUB
The following performance chart will detail cool-
vfanmtr.tif ing fan speeds for current model machines
available for high pressure applications.

Cooling fan speeds are checked with the

engine at high idle speed.

OPEN LOOP FAN SYSTEM

MODEL DIAMETER STEEL
Closed loop systems have a fixed angle fan GATOR 48” 700 -1200
mounted to the shaft of a over hung adapter.
The piston type motor is mounted to the female D25KS 48” 1150 -1200

end of the over hang adapter. D25KW 48” 1150 -1200

D245S 48” 1150 -1200

PLACE TAPE T35KS 48” 1150 -1200

ON FAN HUB
D40KS 48” 700 -1200
pfanmtr.tif
T40KS 48” 1150 -1200

D45KS 48” 700 -1200

D55SP 48” 700 -1200

D75KS 48” 700 -1200

Fan speeds vary due to fan system concepts.

The 700 to 1200 fan speed are the closed loop

CLOSED LOOP FAN SYSTEM application cooling system available on select
models from 1995 and up.
To determine fan speed it will be necessary to
place a piece of reflective tape on the fan hub. • 700 rpm is low fan speed, cool engine

• Perform this task with the machine shut- • 1200 rpm is fast fan speed, hot engine
down and the fan at rest.
When fan speeds are not sufficient additional
• Clean the surface prior to placing the reflec- hydraulic system troubleshooting may be
tive tape. required. Refer to Hydraulic System Training
Module Book 5 for cooling fan system specs.

Page 32
 HIGH PRESSURE mately 40 to 60 seconds to build low regulator
unload pressure.
COMPRESSOR CONTROL
Control air from the air receiver tank is directed
REGULATION SYSTEM to the (NO) low pressure regulator ‘PR’ and ‘IN’
ports.

GENERAL LP REGULATOR
100 TO 250 PSI
This section describes the Driltech compressor CLO
regulation system. ICC AIR IN
RBV

reg2.tif
DESCRIPTION

Driltech high pressure drill application machines 4 EA

have two regulation systems. VENT
SHIMS

The primary system is high pressure air regu-

lated up to 350 psi (24 bar). DTH down the hole ADJUSTMENT
hammer tooling is required to enable 350 psi SCREW
(24 bar).
Regulators adjustment procedures are on page
The secondary system is low pressure air regu-
34 and 35 of this manual.
lation up to 160 psi (11 bar). Rotary drill tools
are used for this mode of compressor pressure. Air passing through the LP regulator and it’s
energized low pressure solenoid (CLO) is
Driltech high pressure machines are equipped
directed to the inlet control cylinder ‘attached to
with two air pressure regulators that maintain
the butterfly inlet valve’, and to the pilot port of
receiver air pressure at designated system
the (NO) running blowdown valve.
pressure.
Pilot air pressure from the regulator closes the
Machines should be in low pressure mode for
(NO) running blowdown valve.
start up and shutdown purpose.

Low Pressure REG ICC

PILOT AIR

On start up, a slow rise in air pressure will be

noticed on the receiver air pressure gauge
located on the operator station.
runningbd.tif

Filtered air directed through the inlet control

valve (butterfly plate) into the compressor for
the compression cycle. Compressed air and oil AIR OUT AIR IN
is discharged into the air/oil receiver tank.

Discharged compressor oil pilots the shutdown

RUNNING BLOWDOWN VALVE
blowdown valve to close the receiver air vent to
atmosphere. At this point, air will start to build in
the air receiver tank. It should take approxi- At approximately 90 psi the inlet control cylinder
will extend to open the butterfly inlet valve.
Compressor Control Regulation System Page 33
When the receiver air pressure reaches the low The drilling application requires the drill opera-
pressure regulator setting of 150-160 psi (10.3 - tor to open the service valve for flushing air. The
11 bar) the LP regulator will pilot closed at the service valve consists of one ball valve
pr port closing the inlet to outlet supply air. threaded to air pipes, it is cylinder actuated by
lever and linkage connections. Locate these
parts on the mast pedestal frame.

AIR RECEIVER AIR PIPING GROUP

TANK PRESSURE 007892-006

reg1.tif AIR HOSE

RESTRAINTS

CONTROLLED AIR
INLET CONTROL airpiping.tif
CYLINDER AND
RUNNING BLOW- AIR RECEIVER PILOT
AIR PRESSURE (PR) SERVICE MAST
DOWN VALVE
VALVE PEDESTAL

The air signal trapped in the control hose is vac-

uumed out through a 3/32” (.94) orifice inside
the intake manifold directly below the butterfly CHECK
inlet valve. VALVE AUXILIARY
AIR MANIFOLD

When the drilling cycle is started the receiver air

pressures drop below regulator valve setting at
the pr and in ports. When air is passing through
airinletparts.tif the regulator(s) the inlet control cylinder
extends, and the running blowdown valve pilots
to close receiver tank pressure from atmo-
sphere;
ORIFICE

• Air should not vent to atmosphere during

the drilling cycle.

• Air will vent to atmosphere when the

Air for the running blowdown valve pilot piston machine is at idle, in low or high pressure
will be vacuumed through the 3/32 (.94) orifice. mode(s), not drilling.

The inlet control cylinder spring will close the When the operator shuts off the machine the
butterfly plate, restricting incoming air. compressor stops turning.

With the ‘inlet valve closed’ the (NO) running Compressor oil stops circulating in the system.
blowdown valve will open air above the mini-
mum pressure spring setting < 140 psi to vent to The (NO) shutdown blowdown valve will loose
atmosphere. This operating condition is com- it’s pilot signal of oil. The valve spring will lift the
pressor unload. piston off the seat permitting all air pressure

Page 34
from the receiver tank to exhaust to atmo- NOTE!
sphere. Problems can arise if the machine is shut down
with compressor at the high pressure regulator
setting of 350 psi (24 bar).

Air regulation components are manifold

PILOT OIL
mounted and protected under a cover. To
access the valves for setting remove the cover.

shutdownvalve.tif

verttank.tif

SHUTDOWN BLOWDOWN VALVE

REMOVE
COVER
At low pressure regulated air and a proper
machine shut down it is expected that all air
pressure inside the air receiver tank will vent to
atmosphere through the shut down blowdown
valve within 2.5 minutes. Compressor components have repair kits and
may be rebuilt with minimal tools. Recom-
High Pressure mended service intervals vary due to operating
conditions, expect between 2000 to 4000
When high pressure air is needed for the DTH machine hours.
drilling tools, the operator will switch the com-
pressor toggle switch from the low setting to the Remove the cover to expose the regulating
high setting. valves, air control manifold, solenoid valves and
connecting hoses.
The low pressure solenoid (CLO) will de-ener-
gize and the high pressure solenoid (CHI) will
ICC
energize. CLO and CHI solenoid valves are nor- MPV PILOT OIL
mal closed, toggle switch controlled by the oper- SBD
ator to energize with 24 volts to open.
AIR IN

The air control process will repeat itself except,

RBD
the high pressure regulator set at 350 psi (24
bar) will send the air signal to the control cylin-
der at the butterfly inlet valve. CLO

LP REG
It is recommended that the operator move the
high/low compressor switch to the low setting HP REG

between drilling cycles and at desired shutdown CHI

ATM
times. HIGH PRESSURE AIR REGULATION

Compressor Control Regulation System Page 35

Nomenclature for the air system: Calibrating Regulators

• ATM atmosphere vent muffler Perform air pressure regulator calibration with
the machine shut down and receiver air pres-
• AIR IN air from receiver tank
sure is zero.
• CLO compressor low pressure solenoid
Pressure regulators may be calibrated in place
• CHI compressor high pressure solenoid on the machine with standard hand tools. It is
advisable to install a 500 psi (35 bar) pressure
• HI REG high pressure regulator guage and hose to the test port provided at the
• ICC inlet control cylinder @ butterfly plate air/oil seperator indicator.

• LO REG low pressure regulator 1. Start the machine.

• MPV minimum pressure valve 2. Operate the machine at low engine idle
speed to warm fluids and air. Warm com-
• RBD running blow down valve
pressor oil and air temperature is recom-
• SBD shutdown blow down valve mended prior to regulator calibration.

System schematics labeled HP1 a,b,c detail air 3. Compressor selector switch shall be in the
direction for drill run modes. low air mode.

NOTE! 4. Operate machine to specific rated high

High pressure regulation is used with DTH engine idle speed.
down the hole drilling tools and carbide button
type drill bits 5. Check air pressure guage for actual air
Low pressure regulation is used for rotary type receiver tank air pressure.
drill tools. Rotary drill bits come in many forms
such as roller, claw, drag or blade types. 6. Adjust low pressure regulator adjustment
screw in to increase air pressure to acheive
Regulators (HP and LP) 150 - 160 psi (10.3 - 11 bar) unload air pres-
sure.

Note:
CHI If air pressure over runs the value reduce the
ICC AIR IN regulator setting and slowly adjust the regulator
RBV to the rated pressure value.

7. Actuate the compressor switch to high mode

reg2.tif
8. Check air pressure guage for actual air
VENT 4 EA receiver tank air pressure.
SHIMS

9. Adjust high pressure regulator adjustment

screw in to increase air pressure to acheive
ADJUSTMENT 350 psi (24 bar) unload air pressure.
HP REGULATOR SCREW
200 TO 400 PSI 10. Actuate the compressor switch to low mode,
the receiver air pressure will vent through

Page 36
 the running blowdown valve to atmosphere
to the low pressure regulator calibration.

11. Lower engine idle speed allow adequate

engine cool down period prior to stopping
machine.

12. Stop the machine per standard operating

principals.

13. Allow approximately two to three minutes

for the air pressure in the receiver tank to
empty to atmosphere. Air will blow to atmo-
sphere through a frame mounted vent muf-
fler.

14. Check receiver air pressure on test gauge

for a zero indication prior to service. Air pressures shown are low pressure mode
blowing air through the bit. This would be the
15. Remove test pressure gauge from air/oil start of drilling and/or blowing the hole clean.
separator indicator location and cap test port
adapter. Air pressure will increase with bit contact to the
ground. Air pressure will increase according to
hammer size, machine operating altitude and
Do not operate the machine at either idle speed the condition of the hammer.
and high air pressure mode without performing
the actual drilling application. Air pressures may increase as high as 350 psi
(24 bar) during high pressure mode drilling with
Operating the machine at high receiver air pres- a good hammer.
sure and not drilling:
Air pressure equals production during DTH drill-
• robs engine horsepower and diesel fuel ing. Higher air pressures enable the hammer to
• generates additional heat in the compressor function with greater forces to break rock.
system components
Final note:
• leads to separator filter failures and exces-
sive oil carry over The compressor lubrication system is depen-
dant on operating air pressures. Compressor
Machine options may enable a normal open air system air and oil components are subject to
pressure switch to be added in the working air system air pressures.
pressure piping.
When testing oil coolers, test pressures are rel-
This option will require the working air pressure ative to air regulated pressures. With the excep-
be blowing to the drill bit before receiver air tion of lubrication component pressure drops
pressure can be switched to the high pressure test pressures will be greater than the low pres-
mode. sure regulator and less than the high pressure
regulator values.
This option is intended to save engine fuel and
horsepower due to compressor loads when air
pressure is at the 350 psi (24 bar) value.
Compressor Control Regulation System Page 37
Page 38
Compressor Control Regulation System Page 39
Page 40
 VOLUME CONTROL Inlet vacuum shall be as low as zero during high
idle loaded blowing air to atmosphere condition.
The inlet control cylinder is at full stroke and the
GENERAL butterfly pate is full open.
Air inlet variable volume limiting options may be
Inlet vacuum may be restricted by the load stop
fitted to most compressor intake mechanisms.
screw of the 010368-001 slide bar.
This option may be factory mounted or added
after-market as a field installation package. Mechanical Adjustment Type Volume Con-
trol Mounted On A Butterfly Inlet Valve.
ADJUSTMENTS

The volume control is a simple limit screw

VACUUM
adjustable type bar. This section will detail the TEST
specific components. GAUGE

• Butterfly inlet valve mechanical adjustment

volume control

A butterfly inlet valve will be limited on its open-

ing value with a mechanical stop. Adjustments
are necessary when installing this application. LOAD STOP ADJUSTABLE
SCREW MOUNTING SCREWS
Test equipment required:

• Vacuum Gauge

• Adapter, Connection Hose

• 9/16 (15mm) Wrench UNLOAD STOP

SCREW
• Ambient Temperature Gauge 010368-001

Vacuum shall be monitored upon startup and The 010368-001 tool limits the compressor inlet
during rated high idle engine operation. thus limiting the compressor output. The effect
is approximate 0 to 30% drop in compressor
The engine must be at high idle speed to enable efficiency.
full inlet air for the compressor vacuum test.
Volume controls are used when the compressor
It is recommended to remove the inlet control capacity is too much for the selected DTH drill
cylinder linkage from the inlet control cylinder tool.
prior to testing vacuum. Manual control allows
tuning the inlet butterfly plate to the correct inlet Example:
vacuum. A Mission 55 DTH hammer requires 790 cfm
• Inlet vacuum shall be 26” to 28” hg. (22.37 m3 /min) to maintain 350 psi (24 bar) air
pressure.
Replace the inlet control cylinder linkage prior to
setting the volume control. If the machine is equipped with 1000 cfm
(28.31 m3 /min) the hammer can’t use all the
The compressor must be in a loaded condition available air and the compressor system cycles.
for calibrating the volume control bar.

Volume controls Page 41

Page 42
 AUXILIARY AIR There are many sizes and styles used in the
industry. The concept is common throughout.
COMPONENTS
Dust collection systems have to be tuned for
the ground conditions and material being
GENERAL drilled. Certain applications require special
attention to customize the dust collecting com-
Driltech earth drilling machines are specified to ponents. One size dust collector will not fit all
meet our customer’s needs. applications.

The following optional equipment is made avail- Dust Collection And Dust Suppression
able to assist the drilling or maintenance func-
tions of most of the drill product line:

• Dry Dust Collecting Systems

dustoptions.tif
• Automatic Thread Greasing System

• Hydraulic Tank Pressurization

• Automatic Lubrication Systems

• Blow Down Cleaning Attachments

• Bit Lubrication System

The typical dust collector on Driltech machines
• Chain Lubrication System** is the Drilplex model with 4, 5, 6 or 8 elements.

DESCRIPTION

Suppressing drilling dust is a mandatory part of

equipment operator safety. The two available
means for suppressing drill dust are:

• DRY DUST COLLECTING systems by way

of seals, curtains, suction fan, filter media,
collection box with a manual drop vent

• WATER INJECTION systems with seals,

curtains, various water tank sizes and a
water pump with relief valve.

Daily and when required maintenance for either

system is the responsibility of the end user. Dust filters must have a good seal to the hous-
ing. Each filter must be hand tightened with a
Dry dust collection systems are one means of sealed wing nut.
suppressing fine drill dust particles omitted dur-
ing the drilling cycle. A loose filter, bad filter seal or damaged filter
element will emit dust out the fan housing. Dust

Auxiliary Air Components Page 43

blow by will damage dust collector fan and fan Regulated air is directed to flushing valves and
housings. electric solenoids inside the dust collector.

Maintain good door seals. Tighten each door to

maintain adequate vacuum inside the dust col-
lector.

The filters are purged with regulated air from

the machines air system. Dust collector regula-
tion is adjustable set to 50 psi (3.5 bar).
RELIEF SOLENOID
FLUSHING
NOTE! VALVE VALVES
VALVES
The dust collector air regulator may be backed
out to zero air pressure for transportation pur-
pose. Adjust the regulator prior to drilling and
dust collecting.
Maintain good door seals. Tighten each door to
LP APPLICATION maintain adequate vacuum inside the dust col-
REGULATOR lector.

Flushing valve repair kits are available. Electric

power to the solenoids is a timed system by
means of a circuit board.

HP APPLICATION
REGULATOR

x
DCT

50 A This sealed dust collector timer junction box

PSI houses the circuit board. The timer distributes a
F
off time and on time sequence to one filter at a
A time.
90 • Adjust on time to enable a quick burst of air
PSI F to the dust filter. The on time shall be 300
A ms.

F • Adjust the off time according to material col-

lected. Typical setting is 6 seconds off time.
)(
DUST CONTROL SYSTEM

Page 44
The circuit board powers one solenoid and LED
per flushing valve. The LED illuminates to indi-
cate when it receives a on cycle.

Maintain good door seals. Tighten door to mini-

mize dust and water entry.

A hydraulic motor and fan enable vacuum

inside the dust collector housing. The motor
speed is partially responsible for dust control.

Operators use a cab mounted control lever or

electric switch to turn the dust collector or water
injection systems on. Additional controls allow
dust hood and dust hood door options.

Fan speed shall not exceed 3000 rpm. Faster

fan speeds may over load the filters and not let
the filters clean adequately.

Adjust the speed according to ground material.

Turn the dust collector fan off between rod

changes. Better filter cleaning occurs when the
fan is not turning.

Dust Hood The drill dust collecting system with fan motor
speed, air pressurization, and electrical timed
Cylinder actuated dust hoods and dust hood pulse settings are detailed in service literature
doors allow adequate seals for dust suppres- 007702-000.
sion under most drilling conditions.
Automatic Thread Greasing System
Depending on application, dust skirts may need
to be modified. The old method of operators applying thread
grease to the drill pipe with a brush still exists.
It may be necessary to use two dust skirts and
overlap them at the corners to enable a relief New concepts allow the operator to remain in
for drill cutting accumulation. the operator cab and still apply thread grease
the drill pipe.

Auxiliary Air Components Page 45

Special drill pipe thread grease can be pumped Adjustable flow control valves at this pump to
by air actuation through hose and adapters meter regulated air pressure to the grease
onto the drill pipe thread box or pin ends. pump and to the injector nozzle located near
the table bushing.
Brand name thread grease:
Lock flow control valve position.
• Texaco Threadtex
Regulated air pressure for this pump is
• Kopper Koat by Jet lube
between 80 up to 100 psi (5.5 - 6.9 bar)
• J89 by Jet lube
THREAD GREASE SYSTEM
• Driltech Copper 024178-003
x
Metered air directs thread grease to drill pipe
threads near the table bushing.

100
PSI
POSITION GREASE NOZZLE
TO DRILL PIPE THREAD

)(
)(

)(
ADJUSTFLOW
CONTROL VALVES
FOR AIR AND GREASE
DELIVERY

Daily and when required maintenance for the

Add thread grease to the container, position the thread grease system is the responsibility of the
follower plate and pump into the grease and end user.
secure the container cover.
Hydraulic Tank Pressurization

All Driltech Mission products have air regulation

components on the top cover of the hydraulic
reservoir.

ckthrgrsr.tif Hydraulic tank pressurization serves two main

features.
• Maintain a Positive Pressure Into The Pump
Inlet
• Assist In Contamination Control

Page 46
 Bit Lubrication System

Low pressure application machines may be fit-

ted with 2 sizes of reservoirs holding 10 gallon
(38 liter) or 30 gallon (114 liter) of special lubri-
REGULATOR
cant oil referred to as rock drill oil.
RELIEF VALVE
When selecting an oil to lubricate bit bearings it
is recommended to consider the following;
• Ambient Condition
• Operating Temperature

HYDRAULIC TANK The lubrication cycle may be adjusted for oil

PRESSURIZATION
quantity or flow and a timed cycle to inject. Oil is
injected into the air system after the service
Machines operating in altitudes above 4000 valve.
feet (1200 meters) will need to alter the stan-
dard air pressure spec of 5 psi (.3 bar). TIMER
(LTR)
Service literature 004756-000 details the
adjustment setting procedure for hydraulic tank RDOregulation.tif
FILTER AND
air regulation parts. SOLENOID

x REGULATOR

RAP

10u PUMP

40u
x
HYDRAULIC TANK 5u
5-7 12
AIR REGULATION
PSI PSI
Service literature 011362-000 details the
adjustments available to operator and mechani-
Daily, when required and 500 hour mainte- cal personnel. Tune the oil injection rate to pro-
nance for hydraulic reservoir pressurization vide a fine mist or a slight visual film of oil inside
system is the responsibility of the end user. the drill pipe or drill bit rollers.

When servicing the hydraulic reservoir with new With the machine running the lubricator air reg-
oil open the ball valve to vent residual air pres- ulation system should be stable at 60 psi (4 bar)
sure. This is recommended practice to prevent
gasket or seal damage to the cover and inlet Driltech Mission factory setting on the flow con-
supply connections. trol valve is 10 turns out or 1/2 piston volume.

Auxiliary Air Components Page 47

Lubricator timers have adjustable on and off To fast cycle times will over load the piston
time cycles. Timer relays are located in the springs. Spring breakage may occur which will
lubricator junction box or cab junction box. lead to loss of oil flow to the drill bit.

• ON cycle is the duration of time regulated air During normal operating rock drill oil will be
pressure is directed to the lube pump and visual inside the drill pipe connections. It is nor-
should be set for 2 second intervals mal to use 1 quarts (.95 liters) per hour of oil
during the drilling cycle.
• OFF cycle is the time between oil injecting
and should be set for 6 to 10 second inter- Automatic Grease System
vals
All point lubrication grease systems are avail-
able to lubricate cylinder pins, bushings, and
rotating bearings for sprockets.
x
Points that are not lubricated by the automatic
system and require manual lubrication are:

• Rotating Drive Shaft Yoke and U-joint

60
PSI Assemblies

• Feed System Traveling Carrier Sprockets

5u LTR
• Air Swivel Joint On Rotary Head Air Piping
LS
This system may be manual, electric or progra-
mable.

DTH LUBRICATOR SYSTEM

Daily maintenance is required. Use sealed and autogreaseparts.tif

approved clean containers for transporting rock
drill oils.

Contaminants inside the lubricator tank may

block oil flow to the pump supply port.

Lubricator pump service literature 011353-000

details the pump service procedures.

Notes:
Allow adequate pump chamber fill time for the
viscosity of rock drill oil being used.
To fast pump cycle times will not allow some Depending on compressor application the items
grades of rock drill oil (due to viscosity and tem- shown here may be configured slightly different.
perature) to completely fill the pump chamber.
The grease pump requires air line lubricant and
reduced air pressure. A solenoid will open air to

Page 48
the grease pump from either the electric timer The chain lubricant can be petroleum based,
or the program module. engine, machine or chain oil proper for the
ambient operating condition may be used. Syn-
Electrical power is 24 VDC and may be cali- thetic oil may be utilized in sever operating con-
brated to inject grease on a preset timed inter- ditions.
val.
In normal conditions a SAE 20 to SAE 40
Service literature 006113-000 details grease weight lubricant is sufficient.
system components.
Daily inspection of oil capacity is a must to
assure lube pump does not draw air and loose
prime. Fill the reservoir as needed based on oil
consumption.
x
(HP)
(LP)
PUMP
60 -80
PSI
REGULATED AIR
SUPPLY

SOLENOIDS

)( LT

LS

AUTOMATIC IMMERSION
GREASE SYSTEM HEATER

Daily and when required maintenance is the 023192 RESERVOIR ASSEMBLY

responsibility of the end user.
Chain lubrication systems are air activated with
Open the water separator drain tap daily to
reduced air pressure from the reservoir.
empty collected condensation.
Expected air pressure shall be 60 to 80 psi to
operate the pump.
It is recommended to fill the lubricator bowl
daily with a quality air line lubricant, SAE 10w or
Four nozzles positioned in the mast are pointed
an equivalent air line lubrication oil.
toward pull-down and hoist chains to spray
lubricant according to operator control.
Chain Lubrication System
Operators control the chain lube cycles by a
Chain manufacturers prefer to lubricate moving
cab mounted double throw toggle switch.
chain sections with a low volume of chain lubri-
cant.
Auxiliary Air Components Page 49
 Coalescing filter spare part number 022462-
001 may be connected in line for any of the
mentioned air regulated components.

023182 CHAIN LUBE GROUP

The feed system must be free to travel full

travel up and down the mast to perform proper
chain maintenance.

Control the toggle switch to air mode while

operating feed full travel. This cycle pre-cleans
the chains with compressed air.

Control the toggle switch to oil mode while

operating feed full travel. This cycle lubricates
the chains with oil.

Operate the toggle switch to air mode while

operating feed full travel. This cycle purges oil
from the mast hoses.

Air Line Filtration

Arctic and cold ambient conditions may require

air line filtration to separate condensation mois-
ture in the dry air supply lines.

Page 50
 TROUBLESHOOTING HIGH PRESSURE COMPRESSOR
SYSTEMS

SYMPTOM PROBABLE CAUSE ACTION

Machine shuts down with air demand Air end low oil pressure and/or high air/ Check air/oil discharge temperature
present oil temperature switch may be defective switches.

Check low oil pressure shut down switch

on lube manifold

Airflow through cooler insufficient Check fan RPM, system pressure and
flow

Low oil level in receiver tank Check center sight gauge on receiver
tank and see if oil is in center

Dirty oil and filters and clogged filters Change oil and filters

Incorrect oil for ambient condition

Faulty thermostats Remove thermostats and check

Faulty safety shut down circuit Check shut down switches

Pressure by-pass valves open Remove and check by-pass valves

Machine will not build up full discharge Check service lines for external leaks,
pressure open valves and/or bad hoses in control
circuit

Dirty air filter Check air intake filters, change if needed

Pressure regulator(s) Check pressure regulator diaphragm(s)

low or high pressure for damage, repair and adjust if needed

Hose size changes may affect full dis- Maintain original hose size for air regula-
charge air pressure tion and discharge applications

Machine will not build up full discharge Defective pressure regulator Repair or replace regulator
pressure (cont)
Faulty minimum pressure valve Remove and inspect minimum pressure
valve for movement, check seal and
repair as needed

Running blow down valve Remove, inspect and repair as needed

Shutdown blow down valve Remove, inspect and repair as needed

Air demand greater then supply Compressor not sized correctly for drill
application

Stuck inlet valve Check free movement, stroke adjust-

ment and settings of inlet valve

Check inlet vacuum with machine run-

ning at rated high idle speed

Check orifice in bleed muffler on control

cylinder

Troubleshooting High Pressure Compressor Systems Page 51

 Improper unloading with excess pres- Pressure regulator(s) Check pressure regulator(s) setting.
sure buildup causing tank safety relief Repair or adjust as needed
valve to open
Air inlet Check adjustment and settings of inlet
valve

Jammed control linkage

Control cylinder sticking or loose

Adapter plate Plugged 3/32” orifice in adapter plate

Unload stop screw Unloaded stop screw adjusted too far

“in” allowing intake valve to be open too
much

Vent muffler restriction Clean or replace vent muffler do not use

solvents to clean vent muffler

Insufficient air delivery Intake filter Check filter and change as needed

Separator filter Plugged air/oil separator, change as

needed

Pressure regulator Check, adjust or replace as needed

Engine Check rated high idle speed (TEL)

Inlet valve Check inlet adjustment. Inlet valve may

be stuck closed

Check inlet linkage/shaft

Running blowdown valve Air vents to atmosphere during the drill-

ing cycle. Check, clean, rebuild as
needed

Shutdown valve Check, clean, rebuild as needed

Control line Check for plugged, loose or leaking con-

trol line(s)

Excess oil consumption Separator element Plugged scavenge line strainer or fixed
orifice

Damaged separator element

Damaged O-ring(s) on separator ele-

ment

Hold down nut on element not at 50 FT

LB (37 Nm) torque

Oil Incorrect oil

Foaming of oil

Oil level too high

Contaminated oil, drain, flush and refill

complete system per procedure

Page 52
Compressor overheating Oil cooler External surface dirty

Plugged or partially plugged with dirt

build-up

Weather Oil jelling in cooler due to cold weather

conditions.
Cooler may need covered or a oil viscos-
ity correction for the ambient conditions

Thermostats Broken or incorrect temperature rating

for ambient condition

Single seal ring for each thermostat, do

not use two seals rings

Worn out, replace as needed

Oil Low sump oil level

Incorrect oil for ambient condition

Oil contaminated with water or other

matter

Mixing of two different oils

Filter Filter seal stuck inside filter or filter hous-

ing

Incorrect filter capacity in beta ratio or

micron rating

Cooling fan Low fan speed, check RPM

Low fan system pressure

Fan pump oil flow to fan motor low

Bad fan motor

Worn out fan blades

Engine RPM low

Fan direction is CCW acting as a

“sucker”

Fan shrouding on cooler letting air

around fan blade slip

Faulty hydraulic hoses from fan pump to

fan motor

Faulty oil stop valve

Compressor Plugged bearing injection lines

Collasped hose or restriction in oil cool-

ing hosing

Troubleshooting High Pressure Compressor Systems Page 53

 Compressor system will not shift to dif- Control circuit Defective solenoid valves or dirt in
ferent pressure settings Electric solenoid control valves (CLO - CHI)

Environmental conditions Air line restriction by condensation add

022462-001 coalescing filter

Frozen condensation

Operator controls Defective “high/low” toggle switch

Defective wiring from switch to sole-

noid’s

Defective air pressure switch

Pressure regulator adjustments

Inlet control cylinder, linkage or mounting

hardware

Compressor oil dumps out air filter dur- Improper shutdown procedure Machine shut down with compressor at
ing shutdown “HIGH” pressure setting. Must be set in
“LOW” position and engine at low idle for
Machines that share compressor and proper shutdown
engine air filters require both primary
and secondary filter replacement and Machine shutting down at high idle RPM
intake pipe cleaning prior to starting the during drilling at high pressure
engine
Run engine out of fuel

Compressor components Faulty oil stop valve

Faulty discharge check valve

Excessive foaming oil

Oil level in sump over full

Engine high idle speed drops Poor fuel Replace fuel filters as needed

Turbo boost Inspect turbo and air to air cooling sys-

tem components, replace silicon hose as
needed

Air venting through the safety relief valve Normal gearbox pressure will range from
generally means compressor repair and 35 to 65 psi (2.4 to 4.5 bar). Pressure
or replacement is required may be taken from a test port on the
compressor gearbox

Interstage pressure creates working Normal interstage pressure will range

loads on the engine. Excess pressure from 45 to 55 psi (3.1 to 3.8 bar) during
will pull the engine idle speed down dur- high pressure mode in a drilling condi-
ing a drilling condition, pressure above tion. Pressure shall be taken from the
80 psi means compressor repair and or interstage U - tube adapter
replacement is required.

Driltech
13500 NW County Road 235
Alachua Florida 32615
386-462-4100

Page 54
 SERVICE LITERATURE 006477-000 Compressor Clutch Assembly

007702-000 Dust Collector Service (Driltech)

GENERAL 008674-000 Taperlock Bushing Installation
This section will give reference material specifi-
010119-000 Air Inlet Valve Adjustment
cation numbers for high pressure and low pres-
sure air systems that are available in Driltech
010756-101 Dust Collector Service (Tipton)
service procedures.
011060-000 Centralized Lubrication
DESCRIPTION
011353-000 DTH Lube Oil Pump Instructions
When componets adjustments or repairs are
needed it is advisable to use the service proce- 011362-000 Lube Oil Injection Instructions
dures.
012457-000 Lp Air End Shaft Seal Instructions
This section may be updated as new proce-
dures are written. 015702-000 Dms Instructions/troubleshooting

001036-000 Air Cleaner 016708-000 Air Cleaner Engine/compressor

001044-173 Lp Air End Shaft Seal Instructions 017144-000 Connector Expansion Instructions

001111-000 Swivel Seal Housing Packing 017239-000 Air End Shaft Seal Instruction

001217-000 Air Piping Swivel (Chiksan) 018190-000 Air Cleaner Engine/compressor

001217-001 Air Piping Swivel (Dover) 0019602-052 Turn Valve Assembly 90 Series

001658-000 Hydraulic Tank Pressurization 020247-000 Dust Collector Service (Qmp)

001670-002 Pressure Relief Vent 020845-001 Dual Poppet Inlet Valves 90 Series

001958-121 Hp Air End Shaft Seal Instructions 020965-000 Drill Monitor System Dms

002428-000 Air Filter/regulator Instructions 021237-000 Air Cleaner Engine/compressor

003751-000 Side Mount Swivel (CRS) Instruc- 021531-001 Dms DIP Switch Chart
tions
021740-000 Cooler Assembly
004320-000 Air Inlet Valve Adjustment
023260-01A Variable Speed Control
004756-000 Hydraulic Tank Pressurization

006113-000 Centralized Lube Systems

006113-010 Centralized Lube Systems

006307-000 Air Cleaner Engine/compressor

Appendix 1 - Air Systems Service Literature - Page 55