TITON 600

COMPRESSOR & PNEUMATICS

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TITON 600
COMPRESSOR & PNEUMATICS

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1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.

COMPONENTS OF PNEUMATIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.1. Description of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2. Locations of pneumatic circuit components . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3. Compressor system specifications (HP). . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.

AIR END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2. Air end main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3. Screw compressor - functional description . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.

OPERATING PRINCIPLE OF COMPRESSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . 29

5.1. Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6.

CONTROL INSTRUMENTS OF THE PNEUMATIC CIRCUIT . . . . . . . . . . . . . . . . . 38

7.

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8.

FLUSHING VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.1. Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

9.

USING IN EXCEPTIONAL OPERATING CONDITIONS . . . . . . . . . . . . . . . . . . . . . 46

9.1. High temperature and humidity (tropical conditions) . . . . . . . . . . . . . . . . . 46
9.2. High altitudes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.3. Cold ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

10. COOLER FAN SPEED TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

11. COMPRESSOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11.1. Compressor drive shaft seal changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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TITON 600
COMPRESSOR & PNEUMATICS

1.

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GENERAL

This document describes the components, operating principle, adjusting and troubleshooting of the TITON 600 compressor system and the circuits of the auxiliary air components.
BPI drill rigs utilize high volumes and high pressure air delivery to the down the hole drill
tools. Please review Driltech Missions extensive line of rock drilling hammers and custom
made drill bits.

2.

SAFETY
Always follow the safety instructions and be careful with your work.
CAUTION

Service and adjustment procedures are only allowed to persons who

have been given specific service training. Read the instructions before
any adjusting or repairing.
CAUTION

Hazardous moving and rotating parts. Do the service and repair work
only when the rig is not running. Make sure that accidental starting or
moving of the rig is prevented during service.
WARNING

High pressure air injection hazard. Can cause severe injury. Relieve
pressure before removing filler plug or fittings.
WARNING

3.

COMPONENTS OF PNEUMATIC CIRCUIT

Pneumatic circiut diagram, see next page.

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TITON 600
COMPRESSOR & PNEUMATICS

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7 (55)

TITON 600
COMPRESSOR & PNEUMATICS
1 Diesel engine
2 Air end
3 Filter
4 Suction throttle valve
5 Receiver
6 Servo cylinder
7 Cooler
8 Oil temperature controller
9 Oil filter
10 Oil stop valve
11 Pressure reduction valve
12 Safety valve
13 Bleed valve
14 Minimum pressure valve
15 Interrupt controller
16 Bleed valve
17 Strainer
18 Non return valve
19 Venting valve
20 Loading solenoid valve
21 Shuttle valve
22 Relief valve (max. pressure)
23 Nozzle
24 Nozzle
25 Selector solenoid valve
26 Temperature switch (LP)

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27 Temperature switch (HP)

28 Oiler OE200
29 Dust collector
30 Proportional controller- HP
31 Proportional controller- LP
32 Solenoid valve (filter cleaning)
33 Solenoid valve (air cylinder)
34 Water separator
35 Pressure reducing valve
36 Solenoid valve (full flushing)
37 Solenoid valve (half flushing)
38 Ball valve
39 Ball valve (compressed air connection)
40 Non return valve
41 Receiver drain valve
42 Pressure gauge
43 Foam injection
44 Non return valve
45 Pressure difference indicator
46 Water separator
47 Thread greasing (optional)
48 Solenoid valve
49 Pressure reducing valve
50 Lubricator
51 Throttle valve
52 Pressure regulator
55 Water separator

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3.2. Description of components

Attention! All position numbers in the text refer to the pneumatic circuit.
1. Engine

See CAT manual for the C-15 engine

2. Air end

See detailed description in chapter 4

3. Air filter
Service indicator

Air filter
The intake air gets into a double stage Donaldson air filter, which consist of a precylone, main
filter element and safety element. The coarsest
impurities are separated in the precyclone and
blown out through the vacuator valve. From
the precleaner the air passes through the filter
element and the safety element, and enters the
airend via the butterfly valve. A filter service
indicator shows the operator a warning light in
the control panel when the filter is clogged.

Vacuator valve

4. Suction throttle valve (inlet control

valve)

Air capacity is controlled steplessly from full

load to zero load according to the air demand
of the consumer (DTH or rotary tooling). The
butterfly valve is actuated by a servo cylinder
and is normally closed at startup and zero air
consumptions.
The valve opens with increasing signal pressure which comes from the proportional controller (30/31) to the servo cylinder. Minimum
flow at closed position is achieved either by
adjustment of the servo cylinder and mainly by
a hole in the valve disk (16mm) D.

5. Air receiver with oil separator

Two stage high pressure compressor utilize oil circulated by pressurezed air through the
whole oil system. There is no oil pump in the system, only air pressure on oil volume in the
receiver creates the flow.
The receiver is calculated, manufactured and tested according to certain national regulations (EU,ASME o.o). Therefore alterations (welding, drilling holes etc.) on the receiver body are strictly forbidden.
CAUTION

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TITON 600
COMPRESSOR & PNEUMATICS

The oil saturated air from the airend enters

the receiver tangentially. Speed of the air
flow decreases, because of that the oil is
separated from the air and it drops to the
lower part of the receiver. (Preseparation).

A
14
12
Separator
element

45

Sight glass
Oil filling
Oil
41
Oil level
indicator
27

Scavenge oil
return

The remaining oil is separated in the separator element and is drawn off from the dry
side through a centrally positioned line running from the base cup of the separator via a
strainer (17) and a check valve (44) back to
the compressor housing. Flow in the scavenge line is normally 0,3 l/min. Air leaving
the receiver has a residual oil content of 1-3
mg/m. The oil separated air leaves the
receiver finally through the minimum pressure valve (14), located on the receiver
cover
A pressure difference indicator (45) measures the pressure difference over the separator element - max. 1 bar. If the indicator
turns red the element must be replaced.The
access cover on top of the rig must be
removed first. After replacing,mount the tank
cover with the torque bolts.
The separator element has a static ground
device (Detail A). This ground device (Ushaped copper strips) is used to eliminate
the static electricity inside the element filter.

45

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Tightening torque
370 Nm (273 lbf.ft)
U-shaped
copper strips

CAUTION

Remember to install the Ushaped copper strips properly

when mounting the oil separator.

The receiver safety relief valve (12) restricts

the maximum pressure to 27 bar. (Testing
and adjusting, see description of component
no. 12).
A sight glass indicates oil level in the
receiver. The oil level should be checked
and possible maintenance started minimum
of 2 minutes after machine shutdown.
Drain valve: On the lowest position a Rlex
valve (41) enables to drain condensate,
which should be done periodically (especially in humid ambient conditions) .

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COMPRESSOR & PNEUMATICS

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Should the sight glass need to be replaced,

use torque of 100 Nm for the holder bolts
(8 pcs).

Replacing oil seperator element

If the pressure difference indicator (1) on
the side of the reciever turns red (check
daily, while engine running) or each 2000
hours, the seperator element must be
replaced.

5
4

WARNING

Wait at least 2 minutes after

engine shutdown, and check
the air pressure gauge in the
cabin to ensure the pressure
is zero

1. Remove the cover on top of the rig,

above the reciever.
2. Open the receiver top cover (2) and
replace the seperator element (3).
3. Refit the grounding copper strips (4) and
the top cover carefully.
4. Tighten the tank cover bolts (5) to 370
Nm (273 lbf. ft.).

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TITON 600
COMPRESSOR & PNEUMATICS
6. Servo Cylinder

3
5
6
14
E

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Function
The cylinder is designed for exact positioning of the butterfly valve proportional to the
servo pressure at inlet E.
The servo pressure acts against the force of
the control spring (5) via the
roller diaphragm (6) and the piston (3) and
opens continuously the inlet control disk.
The high performance rolling diaphragm (6)
is pressure tight and stick-slip free.
Polished surfaces contacts the active surface of the roller diaphragm.
They are protected against incoming dirt by
a filter plug.
If there is an inlet nozzle (14) delivered with
a spare cylinder - remove the insert before
connecting the control line again! (Otherwise valve cant close as fast as possible
during unloading)
Standard cylinder stroke is 40 mm (1,57
inch). Installation with inlet E facing downwards is recommended with humid air for
drain of condensate.
Maintenance
The cylinder is designed for non-lube service.
The roller diaphragm (6) is recommended to
be replaced after 3000 hours.
If other components are damaged, replacement of the whole servo cylinder is recommended.
Never attempt to disassamble a cylinder whilst under
pressure!
WARNING

For disassembling of cylindercover (6) piston rod (3) must be fixed with a steelpin (4) the spring is under preload!

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COMPRESSOR & PNEUMATICS

7. Oil Cooler
The compressor oil cooler is placed horizontally on top of the engine compartment.
The hydraulic oil cooler is located on top of
the compressor oil cooler. Cooler units are
flow controlled with thermostatic valves,
683365 for the hydraulic and (1) 692202 for
the compressor oil cooler.

Air in

2
Air out
2

Cooler

Compressor
oil filter

Compressor

Air receiver

The cooling fan system is designed to pull

air through the heat exchanger. Compressor oil and hydraulic oil are being air cooled
by the speed of the cooling fan, and ambient air temperature.
The fans are driven with two hydraulic gear
motors (2). The alu cooler bodies are
designed to withstand working pressures up
to 24 bar (350 psi). Test pressure is 35 bar,
the max. oil temperature is up to 70C
(158F) over ambient temperature.
The impeller has wing profiled blades, and
this is way the correct direction of rotation
has to be checked. The fan must always
push the air in from the top of the machine.

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TITON 600
COMPRESSOR & PNEUMATICS
8. Oil temperature controller

Thermostat
Air end

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The thermostat directs the oil below 55 C

(131F) directly to the air end. The thermostat starts closing when the oil temperature
rises over 55 +/-4C (131 +/-7 F), allowing
part of oil to flow through the cooler. When
the oil temperature is over 68C (155F) the
thermostat is fully closed, and all the oil circulates through the oil cooler (692202).

Cooler

Housing
Receiver

For high temperature and humidity (tropical

ambient) thermostat must be changed to
692201.
This thermostat directs the oil below 83 C
(182F) past the oil cooler. The thermostat
starts closing when the oil temperature rises
over 83 +/-4C (182+/-7 F ), allowing part
of oil to flow through the cooler. When the
oil temperature is over 95C (203F) the
thermostat is fully closed, and all the oil circulates through the oil cooler.
max. flow : 300 l/min (10,6 cfm)

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COMPRESSOR & PNEUMATICS

9. Oil filter
service indicator

The oil filter is equipped with electrical service indicator. If p rises over 2 bar, the light
for the compressor oil filter is lit and the filter
element must be replaced.
p indication 2bar (29 psi)
p bypass = 3bar (43,5 psi)
max. p on filter element = 25 bar (362 psi)
filter: 20 m (micrometer)

filter element

venting line

Before replacing the filter element wait 2

minutes until the system is completely
vented. Then empty the filter inlet line by
opening the filter venting line drain plug on
the left side of the frame. Make sure you
use an oil drain container with sufficient volume.

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10. Oil stop valve

The connection between the oil separator

and the oil injection nozzles in the airend
has to be cut off during the shut down, to
avoid blowing out oil through the suction
line. During the start up the oil stop valve
should be open as fast as possible to
ensure an accurate lubrication and cooling
of the compressor.

Function
Type OSV-NIH: The valve is controlled by the discharge pressure of the airend. The oil
stop valve opens when the compressor starts operating. It closes at shut down. When the
OSV-NI is closed after shut-down, a small amount of oil can pass from inlet P to outlet A
via the nozzle I in the valve piston. At start-up this small amount of oil is used for lubrication and sealing between rotors and housing of the compressor.
Installation
The oil stop valve is installed in the oil injection line downstream from the oil cooler and the
oilfilter. The signal pressure inlet E is connected directly to a connection in the discharge
duct of the compressor upstream from the non-return valve 18 .
Maintenance
Never attempt to disassemble the valve whilst under pressure. Drain the
oil system before the valve is disconnected.
WARNING

Normally the valve needs no maintenance. However the diaphragm and seal rings have to
be replaced if the valve is dismantled for inspection or cleaning.

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11. Pressure reduction valve

The pressure reduction valve reduces the
oil pressure for the lines which inject oil into
the 1st stage of the compressor.
Adjustment : max. 8bar (116 psi)
Pressure fluid temperature : -30C to 100C
(-22F to 212F)
Flow Q max= 300 l/min (10,6 cfm)
The leak oil line Y must be connected with
the air intake on the airend.

12. Safety valve

The valve restricts the maximum pressure

in the receiver to 27 bar. Valves are delivered with a factory set pressure.
Technical data:

Step 1

Gunmetal tested TV-SV.780. D/G

Permit No. 11 D 92

Lever

ASME-Certificate of Authorization No.

31.820

Step 2

Working temperautes: -196C (77K) up to

+185C (458K)
Discharge capacity : 1766 m/h (1040 cfm)
Operating test of the lifting device:
Step 1: Push the lifting lever in direction of
the bonnet until a clear diascharge of the
medium is audible.
Step 2: Let go the lifting lever. Now the
valve is ready for operation.
This maintenance procedure should be
done minimum each month.
A slight leakage can be cured by blowingoff. If this does not stop the leak, the sealing
surfaces are propably damaged. The valve
should be closed by a sudden release of
the lifting lever

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TITON 600
COMPRESSOR & PNEUMATICS
13. Bleed valve (Running blowdown
valve)

10

10

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The bleed valve is a component of the zero

load bypass system, when the compressor
is controlled by an inverse acting proportional controller and the discharge pressure
has to be kept constant.
(inverse = controlled pressure decreases if
the controller inlet pressure increases).
Function
The bleed valve AVP (13) is governed by
the pneumatic signal of the inverse acting
proportional controller when the compressor loading valve (20) is energized. It opens
steplessly and blows off excess air if the
controller signal decreases to zero load
level.
Thus the minimum suction pressure and
the desired pressure ratio for zero load
conditions is maintained accurately. The
good flow characteristic of the AVP ensures
smooth transition from load to zero load
conditions by gradually increasing blow off
air quantity. On the other hand the valve
opens fast if solenoid valve (20) is switched
off and the pilot line is vented.
Installation
The inlet P is connected to the main line
upstream from the minimum pressure valve
(14) . The lateral outlet connection R is
equipped with a suitably sized silencer for
full blow off capacity. The signal pressure
inlet E on top of the bleed valve is connected to the signal pressure line downstream from the proportional controller (30/
31).
Maintenance
The valve normally needs only to be
cleaned in certain intervals.
For this unscrew the whole cylinder unit
and silencer completely out of the housing.
Clean the components with proper solvents
and connect them again. Dont disassemble the conical valve unit .The diaphragm
can be replaced only by removing the bolts
(10) on the cover. Retightening torque is
5Nm.

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14. Minimum pressure valve MPVL65 FH For oil-injected high pressure screw compressor to uphold the minimum oil pressure
required for cooling and lubrication during
start-up, off-load and when user ports are
fully open. The valve is installed in the discharge line after the separator (5).
Operation
Valve opening:
The valve opens when the inlet pressure
exceeds the adjusted opening pressure of
10 bar (145 psi). Both the non-return
(check) valve assembly 4 and the piston
5 are opened by the pressure in the oil/air
separator against the force of the spring 7.

Valve closing
The minimum pressure valve begins to close, when the pressure at either valve inlet or
outlet decreases below the opening pressure plus approx. 0.5 - 1 bar (7,2 - 14 psi).
If compressor is loading, the valve closes as much that the pressure in the oil separator
will be held slightly higher than the opening pressure is set.
If compressor is idling, the oil separator is maintained at appr. the opening pressure.
If compressor is stopped, the non-return valve closes automatically. The non-return
valve closes if there is no air demand or the compressor is stopped. It is shut tight, if the
pressure at the valve inlet is lower than the pressure at the valve outlet by more than
0.5 -1 bar (7 - 14 psi).
Maintenance
The minimum pressure valve is to be serviced at the same interval as the separator element has to be changed, or each 3 years.
Disassembly
Never attempt to disassamble a minimum pressure valve whilst under pressure!
Remove plug (3) out of threaded ring (5) and tighten the spring (9) by means of a
threaded bolt and a nut ( M10) and bolt with a length of 260 mm /10,5 inch) which should
be prepared first. Unscrew the whole insert (10) out of the housing (8). Release spring
carefully by loosening nut (1). Remove the bolt and nut
Inspection
Check non-return insert, piston and spring for wear and replace the parts if necessary.
(Replace all parts after 10000 hours).
Assembly
Lubricate each part with compressor oil or "Autol Top 2000. Insert gasket (O-ring) in the
lower housing groove. Connect piston and spring (9) and tighten the spring again with the
threaded bolt and the M10 nut. Insert nonreturn unit with spring (11) into piston.
Reconnect reassembled upper part (10) with the housing (8). Remove threaded bolt with
nut and reinsert plug (3).

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15. Pilot valve

The ARC type valve (15) acts as a pilot
valve to activate 2-way fast-venting valve
(16) each time the flushing valve (36) is
shut off.
If the flushing valve is shut off, the discharge pressure in the receiver is suddenly
rising, and the servo cylinder (6) has to be
vented rapidly to close the intake valve (4)
as fast as possible. Otherwise the safety
valve (12) in the receiver has to limit the
max. discharge pressure in the system.

Operation
When the receiver pressure reaches the upper limit (slightly below the adjustment of the
safety valve 12), Inlet E (at bottom of instrument) is connected to Outlet A. The venting
hole R is then closed. If the monitoring pressure reaches the lower limit, outlet A is connected with the venting hole (R). At the same time Inlet E is being closed. Both switching
positions are obtained via a snap action movement of the ball (9).
Adjustment
Before delivery, the pilot valves are adjusted to the cut-out and cut-in pressures.
Cut-out pressure (upper switching point) :
Loose the lock nut and turn the screw clockwise to rise the pressure. The readjustment
range is limited by the execution of the upper part and the spring .
Cut-in pressure (lower switching point):
The differential pressure between upper and lower switchingpoint is increased by removing some of the shims beween upper and lower part of the valve.
The cut-out pressure (upperswitching point) has then to be readjusted. The readjustment
range is limited by the recommended lift of the ball (0.2 to 1 mm).
Readjustment check:
After each readjustment both upper and lower switching points have to be checked. If the
pilot valve shows a shift of the adjusted settings due to strong external vibrations, readjust
it on the running compressor.
Maintenance
Pilot valve normally needs no maintenance. Disassemble the valve occasionally and clean
the parts in solvents. If the seat of the ball is worn remove a shim to compensate the wear.
Never attempt to disassemble pilot valve whilst under pressure.

WARNING

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16. Fastventing valve HEV08EG

This valve is used to vent the signal line

between pressure controller outlet (30 or
31) and the servo cylinder (6). It is controlled by the pilot valve (15) which is connected to port E. Outlet R normally has a
silencer screwed in.
Operation
The venting valve HEV08EG is normally
closed. It opens when pressure is applied
to port E and the signal pressure lasting on
inlet P is released to port R in the ambient.
Thus the servo cylinder is enabled to close
the inlet valve rapidly.
Maintenance
The valve has only to be cleaned occasionally from dirt and oil-residuals.

17. Strainer

Prevents impurities getting into the air end.

18. Discharge Check valve

Function
Discharge check valves prevent a reverse
air/oil flow from the receiver tank back to
the airend after machine shutdown.
Failure of the check valve could allow oil
collection on the air filter element on the
suction side, as well as fluctuating oil level
and reverse run of the airend at shutdown.
Valve design
The valve consists of a housing with valve
seat, a valve disc, a conical spring,a spring
support ring and a retaining ring. The valve
disc is guided by the valve housing. The
valve opens fully at minimum flow, because
the conical spring's force is carefully
matched to the weight of the valve disc.
Installation
At the discharge flange of the second compressor stage, between standard flanges.

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TITON 600
COMPRESSOR & PNEUMATICS
19. Bleedvalve (Final blowdown valve)

2
4

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The VVL10NO bleedvalve is used to vent

the receiver (5) automatically on machine
shut-down. The bleed valve is controlled
by the airends discharge pressure in front
of the check valve (18).
Operation
Venting Valves are normally open two way
valves without return spring. Open or
closed valve position is determined by the
previous valve action. Venting Valve is closing when the compressor starts operating if
a pressure < 0.5 bar/7 psi applied to inlet E
is reached. It opens at compressors shutdown when the airend is vented to suction
side and receiver is still pressurized.

Inlet air throttle

Despite their compact design bleed valves have a considerably low flow resistance.
It is recommended to either reduce or throttle the air line diameter upstream of the valve
inlet P if excess oil foam appears during the venting process. The valve outlet A has normally a silencer screwed in.
Maintenance
Cleaning of the valve: Disassemble screw 2 by turning counterclockwise. Disassemble
piston 4 (with seal ring) by applying compressed air at inlet P. Clean valve with petrol or
cleaning agent. Do not damage sealing surfaces.
Lubricate piston with compressor oil before assembly, and assemble in reversed order.
20. Loading solenoid valve

The selector solenoid valve controls the

pressure line to the servo cylinder.
Valve de-energized - suction throttle valve
(4) is closed and servo cylinder (6) vented.
Valve energized - suction throttle valve (4)
opens.

21. Maximum pressure selector valve

Application
Maximum pressure selection for the
airends control system .
Function
PMAX transfers the higher of both pressures at the inlets E1 and E2 to the outlet
A, which is connected to the servo cylinder
(6). E1 and E2 are connected with the outlets of the proportional controllers (30,31).
Maintenance
Only occasionally to be cleaned .

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22. Pilot pressure relief valve

A proportional controller P3P3E is here

used as a pressure relief valve for the signal pressure between the proportional controller outlet (30/31) and the servo cylinder
(6).
If the inlet pressure exceeds the preset
value of 6 bar (87 psi) the diaphragm is
lifted and the excess signal air is blown off
via port A.
Function
Type P3P3E give a rising control signal at
A on increasing pressure at E (positive acting or direct acting - see graph).
The controller nozzle opens steplessly, if
the pressure at inlet E exceeds the set
point. The amount of air vented via the outlet A is proportional to the increasing pressure at inlet E.

Maintenance
Proportional controllers normally need no maintenance. They are protected from contamination by means of an filter / water-separator in the supply line from the receiver. Contaminated controllers should be cleaned with petrol or other liquid solvents after the
diaphragm has been dismantled. Do not scratch sealing surfaces. Replace diaphragm
during each service.
Check pressure adjustment after a short operation periode when the controller is
recomissioned
25. Selector solenoid valve

The selector solenoid valve connects the

servo cylinder (6) for the suction throttle
valve (4) to high or low pressure controller.
valve de-energized - low pressure
valve energized - high pressure

28. Lubricator OE370_600

See oiler instruction

29. Dust collector

See dust collector instruction

23 (55)

TITON 600
COMPRESSOR & PNEUMATICS
30/31. Proportional controller
10

tm 600 07 0-1 en 0107

The P3PN controllers (30) for the higher

pressure and (31) for the lower pressure
are designed to govern the actuator (servo
cylinder (6) of the compressor intake valve
(4) steplessly (infinitely variable).
Installation
Inlet E is connected to the air receiver via a
signal pressure line. Outlet A is connected
to the signal pressure line for the servo cylinder (6),
Outlet nozzles: Air consumed by control
devices are vented via the outlet nozzles
(23 and 24). The nozzles are mounted in
the housing of the controllers (not shown).

Operation
The pressure at inlet E is transformed directly to an analogue pneumatic signal at outlet
A. Within the control band of the controller this signal is proportional to an increasing or
decreasing pressure at inlet E. Type P3PN gives a rising control signal at A on decreasing pressure at E.
Adjustment
Set point: The set point, i. e. the desired pressure at which the controlsystem starts acting, is adjusted by turning the screw (10). The controller is adjusted during the commissioning period of the compressor:
The set point is increased to a higher pressure, when the screw (10) is turned to the
right (clock-wise).
The set point is decreased to a lower pressure, when the screw (10) is turned to the left
(counter-clockwise).
The direction of turning the screw (10) should be maintained when the set point is
adjusted.
The set point is to be readjusted when one outlet nozzle has been exchanged.
Maintenance
Proportional controllers normally need no maintenance. They are protected from contamination by means of an filter / water-separator in the supply line from the receiver.
Contaminated controllers should be cleaned after the diaphragm has been dismantled
with petrol or other liquid solvents. Do not scratch sealing surfaces. Replace diaphragm
during each service.
Check pressure adjustment after a short operation period when controller is recomissioned.

24 (55)

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COMPRESSOR & PNEUMATICS

32-34. Dust collector components

See dust collector instruction

35. Pressure reducing valve

Adjustment: 7 bar (116 psi)

41. Roelex oil drain plug R1

Consists of drain valve, connecting piece

and a hose

45. Pressure difference indicator

Measures pressure difference over the oil

separator, max. 1 bar (14,5 psi).
If the pressure difference is over 1 bar (14,5
psi) the indicator switches from green to
red. Replace the oil separator and reset the
pressure difference indicator from red to
green.

46. Water separator

filter: 40 m (micrometer)

50. Lubricator

See 9.3 Cold ambient temperature

25 (55)

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COMPRESSOR & PNEUMATICS

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3.3. Locations of pneumatic circuit components

3
35,36,37
38,39,46
5,12,14,18
41,44,45

47,48,49
4,6
27

21 26 42
10,11
28,34,52
1,2
7,40

31

25
8,9

13

30
43,52

22

29,32
33,34
20

19

16

15

46

*Pneumatic control assembly

50

26 (55)

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COMPRESSOR & PNEUMATICS

3.4. Compressor system specifications (HP)

Components

Specification

Compressor oil thermostat (8)

extend to close at 115C (239F)

(tropical ambiente at 130C (266F))

Air receiver safety relief valve (12)

27 bar (392 psi)

1. stage pressure switch (2B4)

10 bar (145 psi)

Minimum pressure valve (14)

10 bar (145 psi)

Unload pressure / low pressure (31)

15 bar (218 psi)

Unload pressure / high pressure (30)

24 bar (348 psi)

Receiver separator pressure difference indicator (45)

1 bar (29 psi)

Main oil filter bypass valve (9)

2 bar (29 psi)

Air cleaner filter indicator (3)

50 mbar (0,725 psi)

Air/oil temperature switch LP (26)

115 C (239F)

Air/oil temperature switch HP (27)

115C (239F)

Oil injection pressure reducing valve (42)

8 bar (116 psi)

Signal line pressure relief valve (22)

8 bar (116 psi)

Pilot valve for fast venting valve (15)

26 bar (377 psi)

Thermostatic switch for cooler fan (26)

70C (158F)

Features and customer preferred options added on the air end system
Feature/Option

Specification

Dry dust collector air regulator (35)

7 bar (101 psi)

OE 370_600 oil air regulator (51)

6 bar (87 psi)

Water injection air regulator (52)

5,3 bar (77 psi)

Thread greasing system air regulator nozzle (49)

6 bar (87 psi)

Thread greasing system air regulator pump (49)

5 bar (73 psi)

27 (55)

TITON 600
COMPRESSOR & PNEUMATICS
4.

tm 600 07 0-1 en 0107

AIR END

4.1. Technical data

Type
Max. ambient temperature
Outlet-air thermal switch

CF 1000 H two stage compressor

50 C
115 C (max 130C)

Max. output

28 m3 / min
24 bar rated
645 kg
2,825
70 - 75 C above ambient temperature
80 litres
120 litres

Max. output pressure

Weight
Gear ratio
Output air temperature
Filling capacity of oil receiver
Filling capacity of the whole system

4.2. Air end main components

Air intake

3
2

Air output
1) First stage rotors

2) Second stage rotors

The arrows show air circulation inside the air end.

3) Gearbox

28 (55)

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COMPRESSOR & PNEUMATICS

4.3. Screw compressor - functional description

The screw compressor is a two-shaft rotary piston compressor that works following the positive displacement principle. Both rotors,male rotor (1) and female rotor (2), feature screwshaped teeth running with very small play to each other and to the casing (3) that encloses
the rotors.
The asymmetric profile shapes of the five teeth of the male rotor (1) and of the six teeth of
the female rotor (2) match best the pressure conditions of the oil-injected air compressors.
Intake and outlet of the air take place through particularly shaped apertures in the casing (3)
of the compressor block.
When the rotors turn, a V-shaped working space that continuously enlarges forms next to
the intake aperture of the casing between two teeth of the male and female rotors. As the
space filled with intake air reaches its maximum, the teeth profiles close the intake aperture
(III).
The air is conveyed to the still closed outlet and compressed by permanently reducing the
working space. As the rotors continue turning, the working space finally opens by means of
the control edges of the discharge-sided outlet (IV). The position of these control edges
determines the size of the inner compression. When discharging the compressed air, the
working space is decreased against zero, thus providing a compression process with least
lost space.
The previously described processes: suction, compression and discharge are repeated five
times during one male rotor revolution and thus practically ensure a continuous low-pulsation conveyance, in contrast to a reciprocating piston compressor. During operation,oil is
injected into the compression space of the CF compressors. This process allows for high
overpressures (up to 15 bar) in single-stage operation. The oil takes up the greater part of
the generated compression heat and carries it off together with the air. Besides, it is used to
seal the gap between the individual different pressure level tooth spaces and the casing,
and to minimize by lubrication the mechanical friction losses and wear during the torque
transmission from rotor to rotor.

29 (55)

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The oil carried off with the air flow must be separated from the air in a succeeding separator
and be fed back into the oil reservoir that is under discharge pressure.
The screw compresor features no pulsating parts like pistons,bars or valves. This allows for
a largely vibrationless operation and a dynamically low load onto bearings and couplings.
The relatively low number of mechanical parts, in particular of wear parts, means low maintenance cost. The revision intervals depend mainly on the service life of the rolling bearings
and of the shaft seal.

5.

OPERATING PRINCIPLE OF COMPRESSOR CIRCUIT

23

36

30

37

20
19

21

22

24

46

50

31

38

14

15

3
25

4
2
I=2,825

CF1000H

16

51

8
CAT C-15

13

26
40

45

44

17

12
27

10
9

18

11
42
41

Air line
Oil containing air

Oil line
Control line

The compressor is a screw-type compressor designed for an operating pressure up to 24

bar (to be switched to 15 bar). In each compressor element are mounted 2 screw rotaries.
The air is compressed in the interstice built by the rotaries. The oil injected in the compressor stage is mixed there with the air and lubricating the 2 rotaries - avoides metal contact,

30 (55)

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COMPRESSOR & PNEUMATICS

stopping up of chinks the interstice between rotary and housing and absorbs part of the
compressor heat.
Air is forced into the screw compressor via the air filter (3) and compressed to approx. 24
bar in the compressor stage. Oil is also injected for cooling and stopping up chinks. The oilair mixture is forced into the separator.
In the oil separator the air-oil mixture rebounds against the bottom of the separator element,
as a result of which most of the oil is separated off. Air is then introduced through the separator element, which causes the oil mist in the air to be filtered. The oil remaining in the separator element is sucked off via the strainer (17) and check valve (44). The air flows to
suppliers via the minimum pressure valve (14) and flushing valves (36, 37).
The separated oil is collected in the lower part of the oil receiver (5) and then flows to the oil
cooler (7). An oil temperature controller (8) makes sure that the oil does not fall below 71 C
in low outdoor temperatures. The oil is then injected into the both compressor stages via
the oil filter (9) and the oil stop valve (10). For the first stage airend, the pressure is reduced
to 6-8 bar by means of a pressure reducing valve (11). To prevent overpressure, a pressure
switch (2B1) is integrated and set to 8 bar.
The receiver pressure is connected to the pressure controllers via a water separator (46).
Depending on the input pressure, the pressure controllers (30,31) transmits a signal of
varying sizes to the servo cylinder (6) on the suction control valve (4) as follows:
CONSUMER

REQUIRED
AIR

PRESSURE in
receiver

Control pressure

Butterfly valve

ON

increases

decreases

increases

opens

OFF

decreases

increases

decreases

closes

(DTH or rotary
tooling)

If the pressure in the consumer falls excessively during operation, the minimum pressure
return valve (14) will close until the pressure of 10 bar remains in the separator. This pressure is necessary for the oil to circulate properly. Temperature switches (26 and 27) make
sure that the compressor is switched off in case of overtemperature (set to 115 -130C
(239-266 F) depending on ambiente conditions).
The receiver is protected from excessive pressure (malfunction in controls, blocked sep.
cartridge etc.) by means of a safety valve (12). Additionally a difference pressure indicator
shows a clogged separator (45).

31 (55)

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5.1. Function
1. STARTING - unloaded (solenoid valve 25 not energized):
Servo cylinder (6) vented via loading solenoid valve (20) (not energized) - butterfly valve is
closed by spring.Airend starts rotating and creates suction. A small amount of air enters the
unit via throttle (16) in the butterfly valve. Oil stop valve (10) opens and the venting valve
(19) closes.Then airend sucks oil from the receiver (5) and pilot pressure is build on pressure controller (31). Residual air is blown through control nozzle (24) and bleed valve (13).

23

36

30

37

20
19

21

22

24

46

50

31

38

14

15

3
25

4
2
I=2,825

CF1000H

16

51

8
CAT C-15

13

26
40

45

44

17

12
27

18
10

11
42
41

Air line
Oil containing air

Oil line
Control line

Engine starting

32 (55)

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2. OPERATING - loading (solenoid valve 20 opens):

Receiver pressure closes bleed valve (13) butterfly valve (4) opens receiver pressure
increases at once (flushing valves (36,37) closed: output = ZERO) P-controller ND (31)
closes pressure decreases on controller output and butterfly valve (4) closes (compressor is idling) residual air streams via controller nozzle (24) and pressure relief valve for
signal pressure (22) final pressure is controlled via bleed valve (13)

23

36

30

37

20
19

21

22

24

46

50

31

38

14

15

3
25

4
2
I=2,825

CF1000H

16

51

8
CAT C-15

13

26
40

45

44

17

12
27

18
10

11
42
41

Air line
Oil containing air

Oil line
Control line

Loading

33 (55)

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COMPRESSOR & PNEUMATICS

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3. COLLARING (solenoid valve 25 not energized):

Flush valve (37) opens, ball valve (38) opens completely receiver pressure decreases
pressure of controller output increases flap opens bleed valve (13) closes minimum
pressure valve (14) opens consumer in operation (COLLARING) control air streams
via controller nozzle (24) and pressure relief valve for signal pressure (22).

23

37

36

30

20
19

21

22

24

46

50

31

38

14

15

3
25

4
2
I=2,825

CF1000H

16

51

8
CAT C-15

13

26
40

45

44

17

12
27

18
9

10

11
42
41

Air line
Oil containing air

Oil line
Control line

Collaring with low pressure

34 (55)

TITON 600
COMPRESSOR & PNEUMATICS

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COLLARING WITH REDUCED FLOW (Ball valve (38) partly closed, or consumer does not
require whole flow): receiver pressure increases pressure on controller output decreases
butterfly valve (4) closes by spring and remains in intermediate position bleed valve
(13) controlles pressure (15 bar) constantly and blows-off partially.

23

37

36

30

20
19

21

22

24

46

50

31

38

14

15

3
25

4
2
I=2,825

CF1000H

16

51

8
CAT C-15

13

26
40

45

44

17

12
27

18
9

10

11
42
41

Air line
Oil containing air

Oil line
Control line

Collaring with reduced flow

35 (55)

TITON 600
COMPRESSOR & PNEUMATICS

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4. HP-DRILLING (full loaded; solenoid valve (25) and flushing valve (36) opens):
Solenoid valve (25) sets control air to P-controller HP (30) suction control valve (4) opens
completely bleed valve (13) closes and pressure increases to 24 bar. Power increases significantly and air temperature rises.Thermostatic valve (8) directs oil increasingly to the oil
cooler until at 70C the full flow goes through the cooler.

23

36

30

20
37
19

21

22

24

46

50

31

38

14

15

3
25

4
2
I=2,825

CF1000H

16

51

8
CAT C-15

13

26
40

45

44

17

12
27

18
10

11
42
41

Air line
Oil containing air

Oil line
Control line

HP-Drilling

36 (55)

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COMPRESSOR & PNEUMATICS

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5. Flushing OFF - idling (Flushing valves (36,37) switches off):

Receiver pressure increases at once interrupt controller (15) [26 bar] activates rapidly the
bleed valve (16) and leads pressure out of servo cylinder (6) so that the butterfly valve (4)
may close rapidly ( the safety valve (12) in the separator otherwise will be activated) final
pressure is controlled by means of bleed valve(13) at 24 bar the control air streams via controller nozzle (23) and bleed valve (13).

23

37

36

30

20
19

21

22

24

46

50

31

38

14

15

3
25

4
2

51

I=2,825

CF1000H

8
CAT C-15

13

16

26
40

45

44

17

12
27

18
9

10

11
42
41

Air line
Oil containing air

Oil line
Control line

Flushing off (idling)

37 (55)

TITON 600
COMPRESSOR & PNEUMATICS

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6. Reduced pressure during tramming (tramming mode):

To reduce the power consumption of the compressor when the rig is in tramming mode, the
solenoid valve (20) is deengerized the control line to the bleed valve (13) is completely
bleeded so that the receiver pressure decreases to 10 bar, reducing fuel consumption on
the engine.
7. Shutting off from idling (always switch the low pressure controller before engine shutdown): Diesel engine stops solenoid valves(20,25) are deenergized non return valve
(18) closes oil stop valve (10) closes venting valve (19) opens air streams out of
receiver via bleed valve (13) and venting valve (19). Airend depressurization is done via the
suction side.
If engine is shut down during compressor is on full load, oil is ejected
in the air filter on suction manifold.
CAUTION

23

36

30

37

20
19

21

22

24

46

50

31

38

14

15

3
25

4
2
I=2,825

CF1000H

16

51

8
CAT C-15

13

26
40

45

44

17

12
27

18

10

11

42
41

Air line
Oil containing air

Oil line
Control line

Engine shut down

38 (55)

TITON 600
COMPRESSOR & PNEUMATICS

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6.

CONTROL INSTRUMENTS OF THE PNEUMATIC CIRCUIT

Compressor control switches on switch

panels 1 and 2
1.

Compressor on/off switch

2.

Compressor, 15/24 bar switch

Warning lights on the engine control panel

3.

Compressor first stage over-pressure. If pressure in the first stage of

the compressor rises over 10 bar, the
warning light is lit and the engine stops
automatically.

4.

Compressor temperature.
If compressor temperature rises above
the max. factory adjusted temperature
(max. 130 C); indicator light in the
control panel is lit.

5.

Clogged compressor air filter

6.

Clogged compressor oil filter

7.

Thermostat valve controls the flow of

compressor oil through the oil cooler.
The valve opens when temperature of
the oil is 55 C and lets the oil flow into
the cooler.

8.

Electronic pressure difference

switches monitor the pressure difference in the compressor oil and air filters. When the filter is clogged, the
pressure difference grows over the
adjusted limit and signal to light up
warning light on the control panel is
given.

39 (55)

TITON 600
COMPRESSOR & PNEUMATICS

tm 600 07 0-1 en 0107

Pneumatics control panel

9.
9

10

11

12

13

14

Compressor second stage temperature gauge. Compressor cooler fan

starts when temperature is 55 C. The
engine is shut down if temperature
rises above max. temperature, which
is adjusted according to ambient temperature (temperature range 110 - 130
C)

10. Compressor first stage temperature

gauge. The engine is shut down if
temperature rises above the max. temperature, which is adjusted according
to ambient temperature (temperature
range 110 - 130 C)
11. Compressor oil injection pressure
gauge
12. High pressure regulator
13. Low pressure regulator
14. Pressure relief valve for the servo
cylinder. Limits pressure in the servo
cylinder (max. 8bar).

40 (55)

TITON 600
COMPRESSOR & PNEUMATICS

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7.

ADJUSTMENTS
1.

Low pressure regulator

There are two ways to adjust the low pressure regulator:

If the adjustment is done in a place where it
is not possible to drill with the rig, the
adjustmet is done the following way:

4
1

Open the lock nut (3)

Close the pressure regulator by opening
the adjusting screw (4) completely
Close the half flushing ball valve
Switch half flushing on
Switch low pressure on
Start flushing
Turn the adjusting screw in until the pressure gauge in the cabin is showing 15
bar.
Open the half flushing ball valve a little,
just enough to let small amount of air
flow through it and the pressure drops a
little.
Adjust the pressure to 15 bar with the
adjusting screw.
Lock the adjusting screw with the lock
nut
When adjusting the pressure during drilling, the operator must be drilling with the
rig, and flushing, dustcollector and low
pressure must be on.
Loosen the lock nut (3)
Turning the adjusting screw (4) clockwise
increases, and counterclockwise
decreases the pressure. Adjust the pressure with the adjusting screw until the
flushing air pressure gauge in the cabin
is showing 15 bar.
Tighten the lock nut.

41 (55)

TITON 600
COMPRESSOR & PNEUMATICS
2.

tm 600 07 0-1 en 0107

High pressure regulator

There are two ways to adjust the high pressure regulator:

If the adjustment is done in a place where it
is not possible to drill with the rig, the
adjustmet is done the following way:

Open the lock nut (3)

Close the pressure regulator by opening
the adjusting screw (4) completely
Close the half flushing ball valve
Switch half flushing on
Switch high pressure on
Start flushing
Screw the adjusting screw in until the
pressure gauge in the cabin is showing
24 bar.
Open the half flushing ball valve a little,
just enough to let small amount of air
flow through it and the pressure drops a
little.
Adjust the pressure to 24 bar with the
adjusting screw.
Lock the adjusting screw with the lock
nut
When adjusting the pressure during drilling, the operator must be drilling with the
rig, and flushing, dustcollector and high
pressure must be on.
Loosen the lock nut (3)
Turning the adjusting screw (4) clockwise
increases, and counterclockwise
decreases the pressure. Adjust the pressure with the adjusting screw until the
flushing air pressure gauge in the cabin
is showing 24 bar.
Tighten the lock nut.
NOTE: If 24bar is not achieved during drilling, despite proper setting of the pressure
regulator (2), the hammer consumes more
air than is available.

42 (55)

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COMPRESSOR & PNEUMATICS

3.

Pressure relief valve for the servo

cylinder
Disconnect the other end of hose (1)
which connects the valve plate and
servo cylinder. Connect a pressure
gauge between the hose and pressure
line. Adjust the pressure to 6 bar with
the adjustment screw (2) of the pressure regulator.

CAUTION

4.

The pressure must not be

adjusted higher than 8 bar to
avoid damaging the diaphragm inside the servo cylinder.

Temperature switches

Compressor cooler fan starting temperature and engine shut down temperatures
for high and low pressure compressors can
be adjusted with the adjusting key (3). The
green pointers inside the gauges show
adjusted pressure limits.
Green pointer = Compressor cooler fan
starting temperature
Red pointer = Engine shut down temperature
3

Insert the adjusting key into the

keyhole in the middle of the gauge
to be adjusted.
Press the key to move pointers
inside the low pressure gauge
over desired temperature value.
The pointer inside the high pressure gauge can be moved without
pressing the key.

CAUTION

The factory adjusted settings should be adjusted

only if the operating conditions change significantly.

43 (55)

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COMPRESSOR & PNEUMATICS

5.

tm 600 07 0-1 en 0107

Suction throttle valve

If the airend is emitting a dark sound after

replacement of an intake control valve, the
vacuum is too high. Connect a vacuum
pressure gauge to the connector (1) on
intermediate flange, and loosen locknut at
the cylinder rod. Put a pin or a small screw
driver through the hole in the cylinder rod.
The butterfly valve can be opened or
closed a few mm by one or two turns of the
cylinder rod to adjust the suction pressure
to 0,1 bar and the sound stops.
Maintenance
Check function of moving parts and closed
position at air filter inspection intervals.
When mounting the throttle valve, alignment and free butterfly plate movement
must be verified.

44 (55)

TITON 600
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8.

COMPRESSOR & PNEUMATICS

FLUSHING VALVES

37

36

The flushing valves (36 and 37 in the pneumatic circuit diagram) control the DTH hammer
flushing air.
Description of operation:
Valve is closed by spring power when not energized. When energized, the solenoid will
open/free the pilot chamber and the valve will open directly or servo assisted by the pressure differential (p) of the flow medium. A pressure differential (p) is not required for the
operation.

45 (55)

TITON 600
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8.1. Adjusting
The flushing valves have a default setting
for a soft closing of the valve. The closing
speed of the valve can be adjusted with the
muting screw (1):

1.

Start the engine

2.

Switch compressor on

3.

Switch full flushing on

4.

Close the valve by turning the muting

screw completely in (clockwise).

5.

Turn the screw counterclocwise. The

valve opens and starts to close. Stop
turning when the valve starts to close.
Make sure there is no air going
through the valve.

Variable close muting:

Turning the screw clockwise (+): valve
closes slower.
Turning the screw counterclockwise (-):
valve closes faster.

46 (55)

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9.

COMPRESSOR & PNEUMATICS

USING IN EXCEPTIONAL OPERATING CONDITIONS

9.1. High temperature and humidity (tropical conditions)

The compressor temperature must always exeed the dew-point of the actual operating conditions. This is made sure by reducing the amount of oil injected into the air end. A throttle
valve must be installed in front of the main oil injection port.

Install the throttle valve (1) (PN.:688723)

before the front of the main oil injection
port.
1

Additionally
The use of synthetic compressors oils (polyalphaolefine) with a viscosity of minimum 65 cSt is necessary.
The thermostatic valve inside valve number 8 in the circuit diagram of the oil cooling circuit has to be changed to PN.:692201, which opens in 83 C ( 181,4 F).
Temperature shut down switches (26),(27) must be adjusted to 130 C (266 F).
Despite of these measures the receiver must be drained more frequently than under normal
conditions (min. 1 times / shift).

47 (55)

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9.2. High altitudes

The expected air volume of 28 m/min (776 cfm) is only available up to 1000 m (3281 ft)
above sea level. On higher altitudes follow the correction table.
ALTITUDE CORRECTION TABLE
Atitude feet

Altitude meters

Correction factor

4000

1200

0,86

5000

1500

0,82

6000

1800

0,79

7000

2100

0,76

8000

2400

0,73

9000

2700

0,7

10000

3000

0,68

11000

3400

0,65

12000

3700

0,63

Use the table for estimating the realistic operating pressure with a certain DTH hammer on
higher altitudes. The information of the hammer is provided by the hammer manufacturer.
Example:

Sea level 2100 m (6890 ft)

Compressor output 28x0,76=21,28 m/min (590 cfm)
Operating pressure with XL5/BC = 19 bar (275 psi)

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COMPRESSOR & PNEUMATICS

9.3. Cold ambient temperature

In conditions near 0C (32F) and exessive humidity, drain water / condensate daily to avoid freezing and pneumatics system clogging.
CAUTION

In arctic and cold conditions air line filteration may be required to separate condensation moisture in the dry air supply lines.
A lubricator (50) is connected in the pressure line before the air regulated components, right after the water separator (46).
Drain water separator daily.

Air in

50
46
Sight glass
Adjusting screw

Killfrost 400 (BPI No. 504726) must be

filled at temperatures below 0C (32F).
The adjustment screw must be adjusted
so that 1-2 drops of killfrost per minute
(sight glass) are injected into the compressed air, to prevent the icing-up the
pneumatic control.

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10.

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COOLER FAN SPEED TEST

The correct fan speed guarantees effective cooling. If there are any cooling problems, one
of the first things is to check the fan speed. The fan rotation direction is clockwise and the
air is pressed through the cooler body.
Rotating fan blades can cause serious injury or death! Be careful when
testing cooling fan speed to prevent any body part contacting the fan
blades.
WARNING

1
2
1
2

Shut down the engine

Place a piece of reflective tape on the fan
hubs (1). It may be necessary to prepare
the fan hubs with non reflective paint.
Make sure there are no screws or other
objects on the rotation circle of the tape
(they may cause errors).
Start the engine.
Use a hand held photo tachometer to
measure the rotation speed of the fans.
Correct fan speed is 2300 rpm.
If the fan speed is not sufficient, check
the pressure and the efficiency of the
hydraulic fan motor and the hydraulic
pump.
The hydraulic pressure can be measured
from the connectors (2). Correct pressure at engine speed 1800 rpm is 180
bar.

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11.

COMPRESSOR & PNEUMATICS

COMPRESSOR MAINTENANCE

The basic maintenance tasks (checking and changing oil) are described in maintenace
manual of the rig.

11.1. Compressor drive shaft seal changing

Dismantling

bolt torque 69 Nm (51lbf.ft)

GHH-Compressor

Rubber coupling

bolt torque 340 Nm

(251 lbf.ft)

bolt torque 35 Nm (26 lbf.ft)

3 +/- 0,2 Control dimension

Disconnect the compressor from the engine by undoing the mounting bolts
Remove the rubber coupling.

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5
7

6
4

Disconnect gear cover (1) by undoing screws (2). Remove the gear cover with driving
shaft out of the compressor
Unscrew M10x20 screws (3) and push the driving shaft out of the gear cover.
Remove sealing housing (4) by losing screws M6x12 (5).
Knock both old shaft sealing rings (6) out from the housing.
Take off the driving ring (7), sealed with Loctite 241, from the driving shaft
Clean and degrease all parts

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COMPRESSOR & PNEUMATICS

Assembly
Using a hammer or applying high forces to the driving shaft during
installation may damage the bearings.
CAUTION

CAUTION

When installing new or remanufactured compressor, it is recommended to add 5 liters (1,25 gallons) of oil into the open compressor
inlet prior to starting the unit.

Fit new driving ring (7) with Loctite 241 on the shaft. Driving ring has to be warmed up to
80-100 C (176-212 F) before fitting it on
Push new shaft sealing ring (6) by using a press into the seal housing.
Seal shaft sealing rings (6) with loctite 542 on the outer diameter.
Fill the space between the sealing lips up to 2/3 with Shell Darina-grease 2
Put the driving shaft back into the gear cover by using screws (1) and new O-ring (8)
Connect the gear cover with screws
Put a protective sleeve (a special tool) for the shaft seal on the drive shaft. Push the seal
housing in place without tilting it. Apply Loctite 241 on the screws (5) and connect the
seal housing to the gear cover with them. Remove the protective sleeve.
Mount the rubber coupling and connect the compressor to the engine.
spare parts:
sealing kit for the compressor CF 1000, PN:504646
following parts are included in the kit:
-1 driving ring
-2 radial shaft sealing rings
-1 O-ring

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12.

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TROUBLESHOOTING
Symptom

Machine shuts down

demand present

Probable cause
with

Action

air Air end high air/oil temperature Check air/oil discharge temperaswitch (2B5+2B6) may be defec- ture switch on discharge tube
tive
Pressure switch between stages Check intermediate pressure shut
defective (2B4)
down switch between 1. and 2.
stage of unit / 2.stage seized
Airflow through coller 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 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

Machine will not build up full dis- Air leaks

charge pressure
Dirty air filter

Check service lines for external

leaks, open valves and/or bad
hoses in control circuit
Check air intake filters, change if
needed

Pressure regulator(s) low or high Check pressure regulator diapressure

phragm(s) for damage,repair and
adjust if needed
Machine will not build up full dis- Defective pressure regulator
charge pressure (cont)
Faulty minimum pressure valve

Repair or replace regulator

Remove and inspect minimum
pressure valve for movement,
check seal and repair as needed

Bleed valves

Remove, inspect and repair as

needed

Venting valve

Remove, inspect and repair as

needed

Air demand greater then supply

Down the hole hammer not sized

correctly or not blanked

Stuck inlet valve

Check free movement, stroke

adjustment and setting of inlet
valve
Check orifice in bleed muffler on
control cylinder

Compressor oil dumps out air filter Improper shutdown procedure

during shutdown

Machine shut down with compressor at HIGH - setting. Must be set

in LOW - position and engine at
low idle for proper shutdown
Machine shutting down at high idle
RPM during drilling at high pressure
Faulty oil stop valve

Compressor components

Faulty discharge check valve

Foaming oil
Oil level in sump over full

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COMPRESSOR & PNEUMATICS

Symptom

Probable cause

Improper unloading with exess Pressure regulator(s)

pressure buildup causing tank
Air inlet
safety relief valve to open
Interrupt controller (15)

Action
Check pressure regulator(s) setting. Repair or adjust as needed
Check adjustment and setting of
inlet valve
Check adjustment of interrupt controller and venting valve
Servo cylinder sticking or defective
or spring is broken

Insufficient air delivery

Excess oil consumption

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, or no throttle bore
in the butterfly valve

Intake filter

Check filter and change as

needed, check difference pressure indicator

Separator filter

Plugged air/oil separator, change

as needed

Pressure regulator

Check, adjust
needed

Engine

Check speed

Inlet valve

Check inlet adjusting. Inlet valve

may be stuck closed

Bleed valves

Check, clean, rebuild as needed

Control line

Check for plugged, loose or leaking control line(s)

Separator element

Plugged scavenge line strainer or

fixed orifice

or

replace

as

Damaged saparator element

Damaged gaskets on separator
element
Oil

Incorrect oil
Foaming of oil
Oil level too high
Contaminated oil, drain, flush and
refill complete system per procedure

Excessive condensate building in Increase the compressor temperathe receiver due the high dew ture through reducing the oil injecpoints
tion or reduced cooler air flow
Compressor system will not shift to Control circuit
different pressure settings
Electric solenoid control

Defective solenoid valves or dirt in

valves (25)
Defective high/low toggle switch
Defective wiring from switch to
solenoids
Pressure regulator adjustment
Defective inlet control cylinder,
linkage or mounting

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COMPRESSOR & PNEUMATICS

Symptom
Compressor overheating

Probable cause
Oil cooler

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Action
External surface dirty
Plugged or partially plugged with
dirt build-up

Weather

Oil jelling in cooler due the cold

weather conditions. Cooler may
need cover or a oil viscosity correction for the ambient conditions

Thermostats

Broken or incorrect temperature

rating for ambient condition
Worn out, replace as needed

Oil

Low sump oil level - fill up

Incorrect oil for ambient condition
Oil contaminated with water or
other matter
Mixing of two different oils

Cooling fan

Low fan speed, check RPM

Low fan system pressure, check
relief valve setting
Fan oil flow to fan motor low check flow controller
Bad fan motor - replace
Worn out fan blades - replace
Engine RPM low - adjust
Fan direction is CCW acting as a
sucker - correct
Fan shrouding on cooler letting air
around fan blade slip - correct
Faulty hydraulic hoses from fan
pump to fan motor
Faulty oil stop valve

Compressor

Plugged bearing injection lines

Collapsed hose or restriction in oil
cooling hosing