Safety, Operation and Maintenance PV-270 Series SECTION 6 — MAINTENANCE 6.6 - MAINTENANCE (50 HOURS OR WEEKLY) Read and understand Section 2 - Safety Precautions and Guidelines before you operate or perform any maintenance, service or repairs on the drill. ‘Safety should be the main concer for anyone working on or around the drill. Do not perform any function that could put someone in danger. Always wear correct safety gear while working on or around the drill. This includes an Approved Hard Hat, Safely Glasses, Steel Toe Shoes, Gloves, Respirator and Ear Protection. Do not wear loose fiting clothing that can become caught in rotating components. If you are not experienced with the drill’s controls and instruments, read and understand Section 4 - Operating Controls & Instruments. Unexpected drill motion or mo on the drill, \g parts can cut or crush. Shut down engine before working GENERAL INFORMATION The following operational hints should be observed: 1. Do not speed engine when it is cold ‘Always chock the tracks if there is a possibility of uncontrolled movement, . Do not lubricate the drill while the engine is running, Always perform safety checks prior to starting and using the dil Do not control propel speed using the engine speed control lever. Always operate the drill at full engine power when driling or tramming the drill. NOOnRON If drill is equipped with a remote control system option, always use it from a safe location when propelling on unstable surfaces where there may be a risk of overturning, or when loading onto a transporter where there is a risk of overturning. 8. Never propel or stop the drill on a slope or surface that is liable to collapse. 9. Never stop the drill against a high wall that is lable to collapse or cause a crushing risk. 10. Before starting engine, always check to see that the dril/propel mode selector is in the drill Position and both propel control levers and drill feed are at stop position and that the track brakes are applied. 11, Always sound the horn before moving the drill in either direction to alert personnel and allow sufficient time before putting the drill in motion. Dring Sottions 12004 Rev 000 | owsSafety, Operation and Maintenance PV-270 Series SECTION 6 ~ MAINTENANCE ee 6.6 - MAINTENANCE (50 HOURS OR WEEKLY) BATTERIES The following battery maintenance must be carried out as part of the 50 hour routine maintenance schedule. Batteries contain an acid and can cause injury. Battery fumes can ignite and explode. Skin and eye contact with battery fluid can cause injury. Do not smoke when observing battery fluid level. Avoid skin and eye contact with battery fluid. If contact occurs, flush area immediately with water. Electrolyte Level 1. Check the electrolyte level and keep the electrolyte level above the plates. 2. Refill with distilled water if necessary. A CAUTION Over filling can cause poor performance or early failure. BATTERIES Figure 6.6—1 Battery Terminals Keep the battery terminals clean and the connections tight. om 1200 Reva Dring SoatonsSafety, Operation and Maintenance PV-270 Series SECTION 6 - MAINTENANCE -—] 6.6 - MAINTENANCE (50 HOURS OR WEEKLY) PUMP DRIVE GEARBOX Oil Leaks Inspect the hydraulic pump drive gearbox for leaks as part of the 50 hour maintenance schedule. Follow the steps shown below. 1. Look for signs of oil on the case and around the bottom of the case. 2. If there are signs of oil leakage, clean the outside of the case and around the bottom, Verify signs of oil are from the case and not another source. 3. If a leak is verified, contact maintenance and take corrective action. Check Oil Level The type of service and the operating conditions will determine the maintenance interval. However, it is recommended that the oil level be checked as part of the 50 hour routine maintenance schedule. At the same time, check for oil leaks. Because the lubricant system is the heart of the unit, it is especially important that the oil be kept clean. Note: The ail in the pump drive gearbox should be changed whenever the oil shows traces of dirt or the effects of high temperature, evidenced by discoloration or strong odor. Hot oil or components can burn. Oil must be at normal operating temperature when draining. Avoid contact with hot oil or components. Do notallow used oil to drain into the ground. Dispose of properly. PUMP DRIVE (SHOWN IN POsiniON 2) MAGNETIC DRAIN PLUG Move the dill to a level surface. Stop engine before checking or adding oll Clean around the oil level and fil plug before checking or adding oil Check the oil level within the gearbox. The oil should be level with the oil level plug. necessary, add SAE 80WS0 oll and filo the correct level. Always use clean oil from clean containers. Do not overfil, This will cause overheating. See6.3 Lubricant Specifications for the recommended required oil specifications, 6. Check and clean the gearbox breather. gaena eyo ev ed onSafety, Operation and Maintenance PV-270 Series SECTION 6 - MAINTENANCE ————— ______ 6.6 - MAINTENANCE (50 HOURS OR WEEKLY) UNDERCARRIAGE Initial Break-In Maintenance New equipment requires the following initial one time break-in maintenance after 50 to 100 hours of operation. After this initial phase, the regular intervals listed in the maintenance schedule should be followed, Final Drive Mounting Bolts FILA LEVEL PORT DRAN PORT FINAL ORIVE ‘SHOWN AT ‘MOUNTING BOLT 800 0CLOCK POSITION Figure 6.6-3 1. Check the torque of the final drive mounting bolts with a torque wrench. The correct bolt torque is 420 + 50 fillbs (571 Nem). NOTE: new wheel nuts have been recently installed, they may require frequent checks untilthey seat properly. 2, Repeat same procedure for the other track drive. Oil Leaks Inspect the track final drives gearboxes for leaks. Look for signs of oilon the final drive gearbox case and around the bottom of the case. If there are signs of cil leakage, clean the outside of the gearbox case and around the bottom of the gearbox case. Verify that the signs of oil are from the gearbox case and not another source. Ifa leak is verified, contact maintenance and take corrective action. Oil Level The following gearbox maintenance must be carried out as part of the 50 hour routine maintenance schedule. Follow the procedure below to check the fluid level and to add fluid it level is low. NOTICE Care must be taken to ensure fluids are contained during any inspection or work performed on this component. Handle and dispose of fluids according to local regulations and mandates. on 102008 Rev on Drilling SolutionsSafety, Operation and Maintenance PV-270 Series SECTION 6 — MAINTENANCE 6.6 - MAINTENANCE (50 HOURS OR WEEKLY) Oil Level (continued) Hot oll or components can burn. Oil must be at normal operating temperature when draining. Avoid contact with het oil or components. Do not allow used oil to drain into the ground. Dispose of properly. 1. Move the drillto a level surface and position the track final drive, as shown in figure 6.63, with one port at the 6:00 o'clock position. Shut off the engine. 2, Besure that the planetary housings arenot toohot to touch. Ifthey are hot, give them time to cool down before proceeding. 3. Clean around the fil/level plug (figure 6.6-3) and remove it. 4. The final drive lubricant should be level up to the bottom of the fillevel plug hole. If the final drive gearboxes need oil, proceed with the following steps and add lubricant Do not overfill the final drive, damage may occur, 1. Add lubricant (ISO VG220) into the upper port until it is even with the threads. 2. Clean the port and plug threads, then replace the plug. 3. After all scheduled service is complete, start the engine and move the tracks to check for leaks. Listen for any unusual noises that might need attention. 4, Repeat this procedure for the other track drive, TRACKS Track Tension Tho following track maintenance must be carried out as part of the 50 hour routine maintenance schedule. One of the more critical factors in undercarriage wear is proper track adjustment. a. Tracks that are too tight will put extra stress on both the undercarriage and the drive train components, while wasting horsepower. , Tracks that are too loose create too much back bending, snaking and poor footing which ‘causes needless wear on the roller flanges, sprocket teeth and track guides. Proper track adjustmentwill vary with soil conditions and drill application. For example, packing ‘takes up slack, thus creating tight track. With excavator type chain, internal pin and bushing wear causes track to loosen and offset the tight track caused by packing. Proper track adjustment is important if long life and full track value are to be received Dring Solutions F208 Rev 000 onSafety, Operation and Maintenance PV-270 Series SECTION 6 — MAINTENANCE ua 6.6 - MAINTENANCE (50 HOURS OR WEEKLY) ‘Track Tension (continued) 1. The drill should be in its working environment. Propel the drill through mud and allow dirt to ack the tracks, 2. Propel the dil in the direction of the idlers. Stop with one track pin directly over the front carrier roller (the one closest to the idler) as shown in Figure 6.6-4. Figure 6.6-4 IDLER 3. Place a straight edge on top of the shoe grousers between the front cartier roller and the. idler (see figure 6.6-5). STRAIGHT EDGE, Figure 66-5 4, The correct SAG (distance from the bottom of the straight edge to top of the track shoe) is 3-4% of the distance between the top of the idler and the carrier roller. 5. The track requires retensioning when the top of the track sag between the top carrier rollers exceeds 1-1/2” (38 mm). ‘Track Adjustment Ifthe track is too loose, the track must be tightened by adding grease to the track adjuster. If the track is too tight, grease must be removed from the track adjuster. om 208 Revo Dring SolutionsSafety, Operation and Maintenance PV-270 Series SECTION 6 - MAINTENANCE 6.6 - MAINTENANCE (50 HOURS OR WEEKLY) Track Adjustment (continued) 1. Clean the single grease fitfing (A), shown in Figure 6.6-6. 2. Inject MPG-EP2 grease, with a high pressure grease gun, until the required track tension is obtained. See Refill Capacities/Lubricants/Fuel Specifications for recommended grease requirements. Figure 6.6-6 s Toreduce track tension, slightly unscrew the cover plug (B). The internal butferspring will relax and grease will be ejected. ‘To readjust, secure cover plug (B) and inject grease at grease point (A) until correct track tension is effected, Repeat the same procedure for the other track drive. » o AUXILIARY HOIST Do not climb a raised tower. Climbing a raised tower can cause severe injury or death, Lower the tower to the horizontal position to service the winch. Never lift or transport personnel with the winch. Do not use the winch in any manner of ‘operation which may endanger any individual. & CauTION Stay at least 10 feet (304.80 cm) away from cable while itis under tension. Cable should be inspected whenever unwound and replaced when broken strands are noted. Cable clamps are not designed to hold rated winch load. At least 5 wraps of cable must remain on the drum at all times. Dring Solaions 12004 Rev oon 6-75Safety, Operation and Maintenance PV-270 Series SECTION 6 — MAINTENANCE 6.6 - MAINTENANCE (50 HOURS OR WEEKLY) Periodic Inspection The following jib hoist maintenance must be carried out as part of the 50 hour routine maintenance schedule. Figure 6.6-7 1. Inspect rigging, winch and hydraulic hoses at the beginning of each work shift. Any defects should be corrected immediately. 2. Be certain that at least 5 {ull wraps of cable remain on the drum at al times; otherwise, the cable clamps may not hold the load, 3. Replace cable that has kinked or broken strands because it may fail without warning at low loads. 4. Inspect drive lugs on clutch and drum for rounding or cracking. 5. Inspect gear teeth for excessive wear. Wear should not exceed 1/16”. Refer to Feed Cable & Wire Rope information in 6.4 “Maintenance As Required’ for additional information on wire rope and wire rope clamps. Wire Rope Winch ropes, including their anchorage and other load carrying components of the travelling block and winch system, e.g. sheave bearings, rope sheaves and drill hooks, shall be checked at least once a week Wire rope used in driling operations becomes unusable because of wear and wire breakage and should be discarded in accordance with 3.5 of ISO 4309:1990. In table 3.5 of ISO 4309:1990, classification groups M1 and M2 shall be used. On drill igs with normal hook load of more than 1000KN, the winch rope shall be regularly paid out and shortened according toa plan laid down by the manufacturer on basis of experience. 1, Replace when four (4) randomly distributed broken wires are found in one lay. 2. Replace when the wire rope shows wear of one third (1/3) of the original diameter of the outside wire. 3. Replace when evidence of any heat damage from any cause is found. 4. Replace when any kinking or cracking occurs. 0-76 1/2004 Rev 00 Dring Sotutions