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Compressor Manual PDF
Compressor Manual PDF
SKID TYPE
OPERATION AND
MAINTENANCE MANUAL
The operators charged with machines or equipment must pay steady attention
to any potential hazards.
They must be skilled and have both ability and tools to carry out the different
operations in the most proper way.
Do not use the machine nor carry out any lubrication, maintenance or repair
works before reading and understanding any information about how to use,
lubricate, maintain or repair the machine.
The basic precautions to be taken are detailed in section B "Safety" of this manual.
When a particular operation may involve specific hazards, additional safety notices are
added to the description of the same operation.
In this manual, the SAFETY NOTICES start with three different kinds of signal word.
This safety notice denotes an extreme hazard exists. If proper precautions are
not taken it is highly likely that you or others could be permanently injured
(or killed).
This safety notice denotes a hazard exists. If proper precautions are not taken
you or others could be seriously injured.
Additionally improper practices may result in damage to the machine and reduce
the safety standards for which it has been designed.
In the handbook, the message following the signal words may be either written or illustrated.
The manufacturer HANJIN D&B cannot foresee all possible circumstances which may result in
hazardous situations when using and operating the machine.
For this reason, the safety notices, contained in this manual or applied on the machine,
cannot include all possible situations of potential danger.
When, during work, you follow procedures, equipment or methods other than those expressly
recommended by HANJIN D&B, it is of the utmost importance that you do your job taking into
account the safety limits for your own as well as for everybody else's safety.
Additionally, you must be sure that the machine does not suffer from damage or become unsafe
due to operation, lubrication, maintenance or repair works you decide to carry out.
INTRODUCTION
---------------------------------------------------------
This manual is intended to provide you with all the information you need to use the machine
correctly and to carry out the principal maintenance operations.
IMPORTANT
It is essential that you read and understand this manual before using or operating
the machine and prior to carrying out any operations.
Section B is intended for the personnel who will operate the machine,
as well as for repair and maintenance personnel and site safety staff.
This section also contains machine personnel requirements and important safety information
which must be read carefully and fully understood.
Section C is intended mainly for the personnel who will operate the rig.
All the operation and control devices are explained in this section.
This section also contains operating information, ranging from assembly to storage
instructions.
Section D is specifically intended for the maintenance department and maintenance personnel.
It contains information on the periodic maintenance jobs and schedules, as well as useful
reference tables and specifications for servicing.
The sections are divided into chapters and paragraphs numbered in sequence.
However, the information you require can also be located by means of the key words used in
the title of the individual chapters.
IMPORTANT
The quickest way to locate the information you require is to consult the general table
of contents. After reading this manual, personnel must ensure that it is always within
reach when needed.
Should you have any doubts or difficulty in understanding this manual or any part of it,
we strongly recommendyou contact the HANJIN D&B customer service.
Addresses, telephone and fax numbers are provided on the cover page of this manual.
SECTION A
GENERAL INFORMATION
Safety symbols
Three safety warning symbols are used in this manual, corresponding the three different
levels of potential danger (residual risks)
Drawing your attention to situations and problems that might threaten the safety of
Drawing your attention to situations or problems connected with the eficiency of the
machine (or equipment) which as a result may threaten the safety of personnel
IMPORTANT
Drawing your attention to important information of which must be fully aware
These three sysbols are followed by a message which either explains or draws your attention
to particular operating procedures that must either be adopted or strictly avoided
IMPORTANT
Check the rig's serial number matches the number on the cover of this manual
Always specify the machine model, type and serial no. when is needed information or
technical assistance
The plates of all the main components not built by HANJIN D&B (Pump, Motor, etc.) are
located on the components themselves at the point where the manufacturers originally
placed them
A-3
DESCRIPTION AND SPECIFICATIONS
--------------------------------------------------------
A-3-1 Identification
Main compartment
9 5
13 11
4
5
8
7
2 1 3
10 12
14
No DESCRIPTION / CONDITION
1 Engine
2 Cooler&radiator ass'y
3 Compressor end
4 Separate Tank
5 Fuel tank
6 Engine end Air Cleaner
7 Compressor end Air Cleaner
8 Air Intake duct
9 Battery
10 Thermostat
11 Minimum pressure regulating valve
12 Valve block(Pressure regulating, Max pressure relief, Bypass, Blow-down)
13 RPM Position sensor & Air cylinder Assy
14 Oil drain valve
A-3
DESCRIPTION AND SPECIFICATIONS
--------------------------------------------------------
General Specification
D&B-1070CP
Width 2100mm
Length 4050mm
Height 2168.5mm
Weight 6.8 ton
ENGINE
Battery Quantity 2 EA
Battery Capacity 200AH
COMPRESSOR DATA
AIR-END HR-2.0
RPM 2100rpm
Capacity (CFM) 953cfm
Capacity (PSI) 362psi(27kg/㎠)
Power Range 315HP
Work configuration
A-3
DESCRIPTION AND SPECIFICATIONS
--------------------------------------------------------
Electric circuit diagram
A-3
DESCRIPTION AND SPECIFICATIONS
--------------------------------------------------------
Electric circuit diagram-Engine
A-3
DESCRIPTION AND SPECIFICATIONS
--------------------------------------------------------
Electric circuit diagram-Compressor
SECTION B
SAFETY
Most of the accidents that occur when working with machines and during their maintenance
and repair are caused by the failure to observe basic safety precautions
You must therefore be fully aware of potential hazards and must pay constant attention to
the consequences do what you are doing
IMPORTANT
If you recognise potentially dangerous situations, accidents can be avoided!
In this manual, for example, a special set of "safety warming symbols"(see SYMBOLS)
has been used to highlight potentially dangerous situations
Naturally, most of the safety rules contained in this section refer specifically to
machines designed for drilling, soil consolidation, etc
The instructions contained in this manual are those envisaged by HANJIN D&B;
it is possible that there are more convenient and equally safe ways to set up and operate
the machine and perform maintenance on it, especially when account is taken of space
requirements and auxiliary equipment available
If, however, you intend to adopt procedures different from the ones set out in this manual,
it is essential that you:
- make sure that the methods you intend to use are not prohibited;
- make sure that the methods are safe and that they comply with the rules set out in
Section B;
- make sure that the methods do not cause direct or indirect damage to the machine or
render it unsafe;
- contact the HANJIN D&B technical department for suggestions and the necessary approval
IMPORTANT
Remember that, if in doubt, it is always better to ask! Contact HANJIN D&B:
the company's Customer Service is there to help you in this respect too
Addresses, telephone and fax numbers are given on the cover and on page 1 of this manual
B-1
PERSONNEL REQUIREMENTS
--------------------------------------------------------
B-1-1 Fitness
The personnel using or operating the machine must be competent to do so, and must satisfy
the following requirements:
Physical Good eyesight, hearing, coordination, and the ability to perform safely
all the tasks needed to operate the machine
Mental Ability to understand and apply the regulations, rules and safety
precautions. You must be alert and must use your judgement to ensure your
own safety and that of others. You must want to carry out your job
correctly and responsibly
Emotional You must be calm and able to withstand stress, and you must be able to use
your judgement toassess your physical and mental condition
Training You must have read and studied this manual, as well as any associated
graphs and diagrams and the warning and danger plates
You must be skilled and qualified in all aspects of machine use and
maintenance
- Work overalls or other comfortable garments: these must not be too big and must be made
in such a way that they will not get caught in the machine's moving parts;
- Safety helmet
- Protective gloves
- Safety shoes
IMPORTANT
Use only type-approved accident-prevention material in good condition
You must also have the following equipment ready for use if necessary:
IMPORTANT
Use only type-approved accident-prevention material in good condition
B-2
DANGER SITUATIONS
--------------------------------------------------------
Generally speaking, the dangers that might arise when using machines and equipment are
connected with the mechanical, hydraulic and electrical power transmissions
There are also a series of specific hazards connected with the job technology and area of
application.
For example: use of pressurised drilling fluids; particular excavation tools or methods, etc
Always take account of the characteristics of the area in which you have to operate:
- Study the plans and, if necessary, the cross-sections of the work area and compare them
with the machine dimensions in its various configurations
Pay particular attention if you are working near gas pipelines or other underground lines,
or close to overhead power lines
- If you have to assemble all or part of the machine on site, prepare an area of
sufficient size with a firm, level surface and suitable equipment
- Mark off the work area, even if you are working on an already staked out job site
- When the machine is in operation, only skilled personnel may come within its operating
range, and only when strictly necessary
- During jobs keep the work area in order and carry out regular cleaning: do not let mounds
of soil or drilling mud prevent or make movements of personnel and machines hazardous
Before and during a job do not take alcohol, medicines or any other substance that may
impair your ability to operate machines
- First of all make sure that the maintenance jobs have been performed with the proper
care and attention and at the established maintenance times (Section D MAINTENANCE)
- Make sure that you have sufficient operating autonomy so as to avoid the risk of forced
machine stop, perhaps during a critical manoeuvre
- Thoroughly clean the instruments, the plates, the work lights and the cab windows
(where fitted)
- Check that all the safety devices on the machine and in the work area are functioning
correctly
- If there are problems of any kind, inform your superior immediately and do not start
work unless the necessary safety conditions are in place
WARNING
Always follow the safety instructions and be careful with your work
Hanjin designs and manufactures its products for smooth and safe operation. However, the
responsibility of safe operation rests with those who use and maintain these products.
Following safety precautions and devices are offered as guide and accessories respectively.
These when followed will minimise the accidents and failures through out the useful life
of the equipment
Only those who have been trained and delegated to do so and who have read and understood
this OPERATION AND MAINTENANCE MANUAL should operate the air Compressor. Failure
to follow the instructions, procedures and safety precautions given in the manual may
increase the possibility of accidents and failures.
Refer Operation and Maintenance Manual of Engine and follow the instructions as given
by the Engine Manufacturer.
Never start Air Compressor unless it is safe to do so. Do not attempt to operate the air
compressor with known unsafe condition. Tag the air compressor and render it in-operative
by disconnecting power supply so others who may not know of unsafe condition will not
attempt to operate it until the condition is corrected
This Hanjin Screw Compressor is not explosive-proof and not to be operated in explosion area.
1. Manually pop up the pressure relief valve when the Compressor is operating, at least
weekly, to make sure the pressure relief valve is not blocked, closed, obstructed or
otherwise inoperative.
2. Do not use tools that are rated below the maximum rating of this Compressor. Select
tools, air hoses, pipes, valves, filters and other fittings accordingly, Do not exceed
manufacturer's rated safe operating pressure for these items
3.Secure all hose connections by wire, chain or other suitably retaining devices to prevent
tools or hose ends from being accidentally disconnected.
4. Open oil filter cap only when compressor is not running and is not pressurised.
Shotdown the compressor and bleed the receiver tank to zero internal pressure before
removing the cap
5. Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug
connection or other component, such as filters.
6. Keep personnel out of line with and away from the discharge opening of hoses or tools
or other points of compressed air discharge .
7. Do not use air at pressure higher than 2.5 kgf/cm2 for cleaning purposes.
8. Do not engage in horseplay with air hoses as death or serious injury many result.
Most of the accidents that occur when working with machines and during their maintenance
and repair are caused by the failure to observe basic safety precautions
You must therefore be fully aware of potential hazards and must pay constant attention to
the consequences do what you are doing
2. Shut-off air compressor and allow it to cool. Then keep sparks, flames and other sources
of ignition away and do not permit smoking in the vicinity when checking or adding
oil/fuel
4. Keep electrical wiring and other terminals in good condition. Replace any wiring that
has cracked, cut, abraded or otherwise with degraded insulation; keep all terminals clean
and tight.
B-5
SAFETY
----------------------------------------------------------------------
5. Keep grounded conductive objects such as tools away from exposed live electrical parts
such as terminals to avoid arcing, which might serve as a source of ignition
6. Keep oily rags. Trash, dry leaves, litter or other combustibles out of and away from the
Compressor
7. Do not operate the Compressor without proper flow of cooling air/cooling water or with
inaequate flow of lubricant or with degraded lubricant.
Moving Parts
1. Keep hands, arms and other parts of the body and also clothing away from couplings,
fans and other moving parts.
2. Do not attempt to operate the Compressor when the fan guard, coupling guard or other
guards removed.
3. Wear snug fitting clothing and confine long hair when working around this Compressor,
especially when exposed to hot or moving parts.
4. Keep access doors, if any, closed except when making repairs or adjustments
5. Make sure all personnel are out of and / or clear of the Compressor prior to attempting
to start or operate it.
6. Disconnect and lock out all power at source and verify at the Compressor that the
circuits are de-energised to minimise the possibility of accidental start-up or operation,
prior to attempting repairs or adjustments. This is especially important when Compressor
is remotely controlled.
7. Keep hand, feet, floors, controls and walking surfaces clean and free of fluid, water or
other liquids to minimise the possibility of slips and falls.
Hot Surfaces
1. Avoid bodily contact with hot oil, hot coolant, hot surfaces.
2. Keep all parts of the body away from all points of air-discharge.
3. Wear personal protective equipment including gloves and head covering when
working in, on or around the Compressor
4. Keep a first aid kit handy. Seek medical assistance promptly in case of injury.
Don't ignore small cuts and burns as they may lead to infections.
B-5
SAFETY
----------------------------------------------------------------------
Toxic and Irritating Substances
3. Oils, coolants and lubricants used in this Compressor are typical of the industry.
Care should be taken to avoid accidental ingestion and/or skin contact. In the event of
ingestion, seek medical treatment promptly. Wash with soap and water in the event of
skin contact
Entrapment
1. Make sure all personnel are out of compressor before closing and latching enclosure doors.
2. If the compressor is large enough to hold a man, and if it is necessary to enter it to perform
service or adjustments, inform other personnel before doing so, or else secure the access door
in the open position to avoid the possibility of others closing and possible latching the door
with personnel inside
Jump Starting
2. Batteries may contain hydrogen gas, which is flammable and explosive. Keep flames, sparks
and other sources of ignition away.
3. Batteris contain acid, which is corrosive. Do not allow battery acid to contact eyes, skin,
fabrics, or painted surfaces as serious personal injury or property damage could result. Flush
areas thoroughly with water immediately. Wear an acid resistant apron and face shield, when
any contacted attempting to jump-start the compressor.
4. Remove all vent caps from the battery or batteries in the compressor. Do not permit dirt or
foreign matter to enter the open cells.
5. Check fluid level, if low, bring fluid to proper level before attempting to jump start.
6. Do not attempt to jump start if fluid is frozen or slushy. Bring batteries up to at least
4-degF(5degC) before attempting to jump start.
B-5
SAFETY
----------------------------------------------------------------------
7. Cover open cells of oil compressor batteries with clean dampened cloths before attempting to
jump start.
8. Attempt to jump start only with a vehicle with a negative ground electrical system with the
same voltage and that is equipped with a battery or batteries of comparative size or larger than
supplied with the compressor. Do not attempt to jump start using motor generator sets, welders
or other sources of DC power as serious damage may result.
9. Bring the starting vehicle alongside the compressor, do not permit metal to metal contact
between the compressor and the starting vehicle.
10. Set the parking brakes of both the compressor (if provided) and the starting vehicle or
otherwise block both sides of all wheels.
11. Place the starting vehicle in neutral or park, turn off all non-essential electrical loads and
start its engine.
12. Use only jumper cables that are clean, in good condition and are heavy enough to handle the
starting current.
13. Avoid accidental contact between jumper cable terminal clips or clamps and any metallic
portion of either the compressor or the starting vehicle to minimise the possibility of
uncontrolled arcing which might serve as a source of ignition.
14. Positive battery terminals are usually identified by a plug (+) sign on the terminal and the
letters POS adjacent to the terminal. Negative battery terminals are usually identified by the
letters NEG adjacent to terminal.
15. Check your connections. Do not attempt to start a 24V compressor with one 12V battery in
the starting vehicle. Do not apply 24V battery in the compressor.
16. Connect the other end of this same jumper cable to a clean portion of the compressor engine
block away from fuel lines, the crank case breather opening, and the battery.
17. Start the compressor in accordance with normal procedure. Avoid cranking more than 5
seconds continuously.
18. Remove and carefully dispose of the dampened cloths, as they may be contaminated with
acid, then replace oil vent caps.
B-5
SAFETY
----------------------------------------------------------------------
DO'S AND DON'TS
DO'S
DON'TS
X Overload the compressor for a long period even though it is of continuous rating,
as we recommended intermittent use only.
SECTION C
Guages
No. DESCRIPTION
R.P.M. of Engine
This gauge displays engine rpm. At full load,
1
reading should be 2200-2400 rpm.
Full-load reading of less than 2100 rpm can cause overheating.
Temp. of Coolant
2 This gauge displays engine coolant temperature Check to ensure that
the coolant temperature is good standard indication is 75℃ to 95℃ or green zone.
Pressure of Engine Oil
3 This gauge displays engine oil pressure. At full load, readingshould be 3 to
5kgf/cm².At idle, reading should not drop below 1.5kgf/cm²
Charging Voltage
This gauge measures voltage in electric system.
4
Reading should be 24-27 volts with engine running.
If not, stop engine and Investigate.
Power
C-1
CONTROLS AND INSTRUMENTS
--------------------------------------------------------
Switchs
4 3
6 5
1
7
C-1
CONTROLS AND INSTRUMENTS
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COMPRESSOR CONTROL PANEL
4
1
3
5
7 6
2
General
The built-in air end produces the pressurized air used by the drilling rig.
The air flows from the air end into the oil/air receiver. where the oil is separated from the air.
According to the air consumption, the pressure regulator adjusts the butterfly valve that
regulates the inlet port. The temperature gauge indicates the output oil temperature.
Description of components
1. Air pre-cleaner
• The intake air gets into whirling motion inside the air filter housing, whereby the
centrifugal force separates the coarsest impurities from the air.
2. Air filter
• From the pre-cleaner the air flows through double filter unit.
3. Air filter service indicator
• The filter element must be changed always when the service indicator shows red.
The indicator must be checked daily by pressing the button on the top, whereby
the red warning colour must show.
1 2 3
4. Air end
• The filtered intake air is compresed by the rotating rotors. The oil in the rotor
housing cools the air, and simultaneously seals the clearances between the rotors
and the housing, and lubricates the unit.
4
5. Butterfly valve (or Intake valve)
• Suction opens the inlet valve when the air end is started. The intake valve also acts
as an air end underload valve by restricting the intake flow.
Whenever the outlet pressure is less than 18bar, the valve is always opened.
And the valve starts closing from over 19bar, and the valve is fully closed over 25bar
When the rotors are stopped, the valve acts as a non-return valve preventing the oil
in the rotor chamber from entering the intake duct.
6. Separator tank
• The unit serves the purpose of an air and oil receiver including an oil separator.
7. Separator filter
• The separator filter separates the oil mixed with the pressurized air.
8. Minimum pressure valve
• The minimum pressure valve keeps at least 13 bar pressure in the tank while the
compressor is running to ensure proper oil circulation in the system. The valve
closes when the pressure drops to 13 bar. The valve is closed by a spring (13 bar)
The pressure is adjusted with the pressure regulating valve.
9. Safety relief valve
• The valve restricts the maximum pressure in the receiver to 27 bar.
10
11 Oil cooler
• The unit includes cooling cells for the driving and drilling hydraulics, and for the
compressor oil.
12 Oil filter
• The oil filter is a full-flow in-line unit and a built-in by-pass valve.
The by-pass valve opens when the pressure difference over the unit exceeds 3.5 bar.
13 Temperature gauge
• The gauge indicates the temperature of the compressor output oil.
The sensor is located under the air end.
14 Minimum pressure regulating valve
• A regulator controls the pressure affecting at the minimum pressure valve.
Pressure setting is 13 bar, which can be checked from a measuring point with a
separate pressure gauge.
13 14
15 16 17
18
19 20
19 Pressure gauge
• Showing the air quantity which, is produced.
20 Oil drain valve
• The valve is sour the oil issue.
21 22
23
24
Air circulation
The pre-cleaned air flows through the air filter into the air end. The intake and non-return valve
on top of the compressor is controlled by the pressure from the pressure regulator.
The intake valve opens when the compressor starts.
After compression the oil/air mixture is led into the separator tank where the oil is separated.
As soon as the air pressure in the separator tank exceeds the opening pressure of
the minimum pressure valve, the clean, oil-free air starts to flow out to be used for air flushing,
shank lubrication and other pneumatic devices.
Oil circulation
While the compressor is running, the minimum pressure valve keeps at least 13 bar pressure
in the separator tank. This pressure forces the oil from the separator tank into the oil circuit.
The oil circulation is based on the pressure difference between the separator tank and
the inlet side of the compressor.
The oil flows to the thermostat through the connection at the bottom of the separator tank.
Oil temperature below 60oC
The cold oil flows directly through the thermostat valve into the oil filter, and then
into the air end.
The bimetallic spring in the thermostat valve starts opening the thermostat valve and
part of the oil flows through the oil cooler.
The thermostat valve is fully opened, and all the oil flows through the oil cooler.
From the oil cooler the oil flows to the oil filter. The filter has a built-in by-pass valve
which lets the oil flow past the filter if the filter is plugged or if the oil is too thick while
it is not yet in operating temperature. The opening pressure of the by-pass valve is 3.5
bar.
From the filter the oil flows into the lubricating ducts at the inlet side of the air end.
At the beginning of the single phase compression, oil is injected onto the rotors to cool down
the air and to seal the clearances between the rotors and the housing.
Oil flows also through the other ducts to lubricate the bearings and the shaft gasket.
After compression, the pressurized oil/air mixture flows from the screw compressor into
the spiral duct of the separator tank where most of the oil is separated from the air to
the bottom of the separator tank. The rest of the oil mixed with the air is separated when the air
flows through the oil separator element. The oil from the bottom of the separator chamber is
forced through the pipe to the inlet side of the compressor unit.
The pipe includes an orifice plate
Before starting
The system is not pressurized. The air end is not running and the intake valve is
closed preventing oil from the compressor from entering the intake line.
The minimum pressure valve at the top of the separator tank is also closed.
Starting
After starting, it creates suction that opens the spring-loaded intake valve) letting air enter the
unit. At the same time air end sucks oil from the separator tank.
The rotating screws compress oil and air into a mixture which is led to the separator tank
where oil is separated from air by means of separator filters. During starting the pressure
in the separator tank is below the opening pressure of the minimum pressure valve which
remains closed.
Delivery
The intake valve is fully open, and pressure in the separator tank starts rising. When
pressure reaches 13 bar in the tank, the minimum pressure valve of the separator tank
opens because the pressure regulating valve is adjusted to increases the opening pressure
with 7 bar. When the valve is open, air flows to the pneumatic circuit.
The pressure regulator is used to adjust desired output pressure.
The intake valve will operate steplessly between 19 and 25 bar. The oil that
escapes through oil separators is led to air end unit by a regeneration line which contains
a restrictor, non-return valve.
Throttling
When the system pressure reaches the pressure setting of regulator this opens,
letting air enter into intake valve. Air pressure pushes the piston forwards and closes
the air intake partly, thus restricting air flow to compressor. At the same time air flows to
compressor trough non-return valve. Although the intake valve is fully closed, the compressor
gets the extra air through the hole (dia 5mm) on intake valve; this prevents noise caused by
reduced intake air flow into compressor.
Intake valve operates steplessly in 19 bar area.
Pressure setting for system is normally 19 bar but it is adjustable between 19 to 25 bar.
Idling
This is the situation when air consumption is less than compressor delivers. It only differs
from 'throttling' in the part of intake valve which is now completely closed. Only oil and
air from substitution air valve circulate in compressor circuit.
Stopping
When compressor stops rotating, it also stops suction of air. Lack of suction makes intake
valve close by the spring. Because of the pressure in separator tank, air end becomes
pressurized through the delivery line. The line from air end to blow down valve
gets pressurized opening the valve. Blow down valve is pressurized in both lines but
because of different diameters in valve spools, the pressure from compressor can push
the other spool open releasing separator tank.
Non-return valves in oil regeneration line prevent air/oil mixture from entering the system.
When the system pressure drops below the pressure setting of minimum pressure valve
it gets closed.
C-4
DIESEL ENGINE START AND STOP INSTRUCTIONS
---------------------------------------------------------
Prior to beginning any operation or procedure described in this chapter you must be aware
If in doubt, read this section again; you should start work only when you have fully
Prior to starting engine, make sure that nobody & nothing is in near operating area
Before start your engine, turn the main power lever (No. 7) - ON.
C-4
DIESEL ENGINE START AND STOP INSTRUCTIONS
---------------------------------------------------------
Engine Start
- Leave control volume switch for engine R.P.M. at low speed position
IMPORTANT
The engine speed control system had been set at the factory and should not require adjustment as part of routine maintenance.
if the engine rpm is being manually adjusted, the equipement can not function in its optimum capacity.
After "Hydraulic system Warm-up" procedures , check all operating indicators to make sure that all engine systems (oil
pressure, coolant, etc.) are in the normal operating range
lf any problems are noticed, stop the engine
Run engine under idle position for 3~5 min. prior to stop the engine. If not allowed to idle,
heat surge may develop which will damage the engine. Allow the engine to idle
1
C-4
DIESEL ENGINE START AND STOP INSTRUCTIONS
---------------------------------------------------------
C-4-3 Checking point after stop
After operating procedures , check all as possible as you can. If any problems are noticed, repair that.
MAINTENANCE
Prior to beginning any operation or procedure described in this chapter you must be aware
If in doubt, read this section again; start work only when you have fully assimilated its contents
By occasional maintenance is meant all those operations that may become necessary from time
to time without it being possible to schedule them on a regular basis
Indicator - CHECKING
The steps to be taken when the warning lights are illuminated obviously depend on the type
of problem involved
Generally speaking, the engine must be stopped whenever the following lights come on:
Stop the machine as soon as possible if one of the following lights comes on:
When the indicator lights listed above are illuminated, stop the engine; leaving it running
Overheating of the hydraulic oil signals a malfunction in part of the hydraulic system,
Do not ignore the indicator lights and continue work; if you do so a chain reaction might
When the machine has been turned off the cause of the malfunction must be identified; if it
is not possible to locate or remedy it, contact a HANJIN D&B SpA customer centre or the
company direct (the full address is given on the cover and on page one of this manual)
D-1
OCCASIONAL MAINTENANCE
--------------------------------------------------------
Filter
- Clogging check
Usaully, if the filter replacement times are properly observed, this should not occur
If, however, clogged filter does come on, stop the machine and immediately replace the
filter
Air filter
- cleaning / replacement
In order to do corrective action, please do check diesel engine air filter catridges
Fuse
- REPLACEMENT
When changing a fuse make sure that the rating of the new fuse is correct and that it
IMPORTANT
Take care never to let water, oil or dirt into the electrical panels When replacing the
D-3-2 Consumables
Fuel
Use only vehicle diesel fuel,i.e. fuel with a sulphur content of less than 0.5%, as per the
specifications contained in the diesel engine instruction book
When the ambient temperature is below -20˚C use only "Artic" diesel fuel, or petroleum and
vehicle diesel fuel mixes whose composition varies according to the ambient temperature, up
Hydraulic oil
Do not mix oils different types and characteristics, as you risk causing malfunction in the
Depending on the season and the temperature you should use the appropriate hydraulic.
Please refer to the table below;
Type if hydraulic Normal Viscosity Viscosity range(cSt@40°c)
ISO VG 22 22 19.8~24.2
ISO VG 32 32 28.8~35.2
ISO VG 46 46 41.4~50.6
ISO VG 68 68 61.2~74.8
※The more low-viscosity, low freezing weather is good to use.
IMPORTANT
If you use types of oil different from our authorised oil, the periodic oil change times
(except for the first change after 500 hours) must be shortened from 2000 to 1500 hours
When you change hyd. oil, do clear the oil tank
D-3
TABLES AND SPECIFICATIONS
--------------------------------------------------------
Diesel engine oil
Use the oil specified by the diesel engine manufacturer (SAE15W40, API CH-4/SJ, ACEA E2)
(Consult the instruction booklet included with the machine documentation)
Lubricating oil
Type Use
Rockdrill Oil ISO 320 grade Reduction gears in general
Mobile Company : ALMO525 (for winter), ALMO527 (for spring & autumn) & ALMO529 (for summer)
Caltex Company : Rock Drill Lubricant 46 (for winter), 100 (for spring & autumn) & 320 (for summer)
Vaseline oil Air system lubricator
Grease
Do not mix greases of different kinds The use of lubricants with inferior characteristics
is not recommended
Corrosion-inhibiting products
To treat the machined surfaces of metal mechanical parts which would otherwise be subject
to ageing and corrosion, we recommend you use CHESTERTON HEAVY DUTY RUST GUARD or other
products with equivalent characteristics that leave a thin and long-lasting protective film
on the surfaces treated
The use of these products is essential in order ot preserve spare parts and dismantled
mechanical parts when the drilling rig is in storage
If the parts treated with these products are then used in contact with seals or packings
Do not use these products on rubber components!
Consumables
Fuel
Use only vehicle diesel fuel,i.e. fuel with a sulphur content of less than 0.5%, as per the
specifications contained in the diesel engine instruction book
When the ambient temperature is below 20˚C use only "Artic" diesel fuel, or petroleum and
vehicle diesel fuel mixes whose composition varies according to the ambient temperature, up
Use the oil specified by the diesel engine manufacturer (SAE15W40, API CH-4/SJ, ACEA E2)
(Consult the instruction booklet included with the machine documentation)
Corrosion-inhibiting products
To treat the machined surfaces of metal mechanical parts which would otherwise be subject
to ageing and corrosion, we recommend you use CHESTERTON HEAVY DUTY RUST GUARD or other
products with equivalent characteristics that leave a thin and long-lasting protective film
on the surfaces treated
The use of these products is essential in order ot preserve spare parts and dismantled
mechanical parts when the drilling rig is in storage
If the parts treated with these products are then used in contact with seals or packings
Do not use these products on rubber components!
Compressor Oil
4. Improper unloading
with an excessive
pressure build up
Problem Causes Remedles
Leak in the control system
4. Improper unloading causing Check control lines
with an excessive loss of pressure signal
pressure build up Defective diaphrams in the
Replace diaphragms(kit available)
causing pressure relief actuator
valve to open Inlet valve jammed Repair/replace the valve
Check all control lines and components and
Restriction in the control
remove the foreign particles clogging the
system
system
Jammed controil linkage Free the jammed portion of the linkage and
Clogged air/oil separator adjust if necessary. Replace separator
element element
Clean or replace the element
Clogged air filter Replace separator element and also change
5. Insufficient the compressor oil and oil
air delivery Clogged air /oil separator Filter at this time
Faulty pressure regulator Adjust or repair
Engine speed too low Re-adjust engine speed
Clogged return line Clean oil return strainer and orifice
Defective blow down valve Replace diaphragm
6. Excessive Leak in the lubrication
Check all pipe connections and components
compressor system
Separator element
oil consumption
damaged or not functioning Change separator element
properly
Excessive oil in the
Drain to correct element
Reciever Tank
Loose or broken fan belt Tighten or change belt
Dirty oil cooler core Clean core thoroughly
Clogged oil cooler tubes
Clean tubes thoroughly
(internally & externally)
7.Compressor Low receiver tank oil level Fill up to max. level
overheating Clean or change the main oil filter and
Clogged oil filter
bearing oil filter
Clogged oil return line Clean oil return strainer and orifice
Drain and flush the system thoroughly.
Wrong grade of oil
Use recommended grade of oil
Loose or broken fan belt Tighten or change belt
Dirty radiator core Clean thoroughly
Faulty engine thermostats Replace thermostats
8. Engine overheating
Clogged radiator Clean thoroughly
Low oil level Refill
Other engine problems Refer to engine manual
Check oil stop valve, service if necessary
9. Back flow of oil through
Check discharge check valve
SECTION E
SPARE PARTS
1 2 3
5 6 7
FILTER
OIL
3 HYDRAULIC PUMP OIL ISO VG 46 (Hyd. Oil) EACH 1000HOURS (FIRST 50HOURS)
5 ROTARY GEARBOX OIL SAE 15W40 or SAE 80W 90 EACH 1000HOURS (FIRST 50HOURS)
6 COMP. OIL ISO VG 32/46/68 (Mobil Rarus SHC 1025 - ISO VG 46) EACH 1500HOURS (FIRST 50HOURS)
7 GREASE SGB (EP2)
8 WATER INJECTION PUMP OIL SAE 15W40, API CH-4/SJ, ACEA E2