CAT CUBEX QXR 1120 Surface Drill Maintenance Manual BI620146 – PDF DOWNLOAD
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CAT CUBEX QXR 1120 Surface Drill Maintenance Manual BI620146 – PDF DOWNLOAD
Language : English
Pages : 329
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
CAT CUBEX QXR 1120 Surface Drill Maintenance Manual BI620146 – PDF DOWNLOAD
General Safety Instructions:
1. Observe all safety procedures when operating and servicing the equipment.
2. Be completely familiar with the operating and maintenance procedures before inspecting,
operating, or servicing the drill or booster. You must read and understand all procedures
described in each manual.
3. Do not inspect or repair any components without properly shutting down the drill, water
pump, and air supply.
4. Keep all non-essential personnel away from the operator’s controls and the maintenance
area while service work is in progress.
5. Any modifications to controls or operating procedures must be noted clearly on equipment
and all operators must be advised of changes.
6. Inspect hoses, hose connection safety devices, fittings, and supply lines at frequent intervals
for indication of wear or damage. Repair or replace damaged components immediately.
7. Check all bolts, nuts, and adjustments frequently for proper tension. Check all fluids at
recommended intervals.
8. Do not stand under the mast at any time.
9. Disconnect the electrical power supply to the drill and booster before washing.
10. Wear protective gear when operating, diagnosing, or servicing the equipment.
11. Do not weld or grind near electrical wiring or supply lines.
12. Keep hands, clothing, rags, and tools away from moving parts.
13. Keep shields and guards in place. Do not operate equipment with the electrical panel door
open.
14. Keep safety and instruction decals clean. Replace them if they are not clearly legible.
TABLE OF CONTENTS:
CAT CUBEX QXR 1120 Surface Drill Maintenance Manual BI620146 – PDF DOWNLOAD
1.1 Operating/Maintenance Safety........................................................ 15 1.1.1 Drill Operation and Maintenance Safety........................................ 17 1.1.2 General Safety Instructions................................................... 17 1.1.3 Safety Instructions for Driving and Operating................................. 18 1.1.4 Safety Instructions for Servicing............................................. 18 1.1.6 Fluid and Filter Notices:..................................................... 22 1.1.7 Safety Reminders:............................................................. 22 2.1 Drill Assembly...................................................................... 31 2.2 Break-in Maintenance................................................................ 33 2.3 Preventative Maintenance Program.................................................... 35 2.3.1 Lubrication................................................................... 37 2.3.1.1 Rock Drill Grease....................................................... 37 2.3.1.2 Lubrication Points and Intervals........................................ 37 2.3.1.3 Lubrication Types....................................................... 38 2.3.1.4 Lubrication Cross-over.................................................. 39 2.3.1.5 QXR Automatic Lubrication System........................................ 40 2.3.2 Bolt Torque................................................................... 51 2.3.3 Drill Filtration Points and Intervals......................................... 53 2.3.4 Pipe Thread Grease Pump....................................................... 54 2.3.4.1 Safety.................................................................. 55 2.3.4.2 Maintenance............................................................. 56 2.4 Recommended Tools:.................................................................. 57 3.1 Track Adjustment.................................................................... 69 3.2 Final Drive......................................................................... 71 4.1 Mast Feed System.................................................................... 75 4.1.1 QXR Feed Chain Adjustment..................................................... 77 4.1.2 Slider Adjustment............................................................. 80 4.1.3 Carrier Block................................................................. 81 4.1.4 Feed Chain Block.............................................................. 82 4.1.5 Jib Boom...................................................................... 83 4.1.6 Triple Jaw Breakout (TJBO).................................................... 84 4.1.6.1 Overhaul procedure...................................................... 85 4.2 Top Drive........................................................................... 87 4.2.1 Using the Right Equipment..................................................... 88 4.2.2 Checking Bearing Pre-load..................................................... 89 4.2.3 Adjusting Bearing Pre-load.................................................... 90 4.2.4 Removing Top Drive............................................................ 90 4.2.5 Disassembly Procedure......................................................... 91 4.2.6 Assembly Procedure............................................................ 92 4.2.6.1 Lower Gear Housing Assembly............................................. 92 4.2.6.2 Upper Gear Housing Assembly............................................. 93 4.2.6.3 Driveshaft Assembly..................................................... 94 4.2.6.4 Final Assembly..........................................................101 4.2.7 Top Drive Installation........................................................113 4.2.8 Saver Sub Field Procedures....................................................114 4.2.8.1 Removal.................................................................114 4.2.8.2 Installation............................................................116 4.2.9 Air Swivel Field Procedures...................................................117 4.2.9.1 Removing Air Swivel.....................................................117 4.2.9.2 Installation of Air Swivel..............................................118 4.2.9.3 Dismantling Air Swivel..................................................119 4.2.9.4 Assembly Procedure......................................................119 4.2.9.5 Inspection of Parts.....................................................120 4.3 Top Drive Motor.....................................................................121 4.4 Breakout Wrench.....................................................................125 4.5 Carousel Assembly...................................................................127 4.5.1 Carousel Adjustment...........................................................130 4.5.1.1 Pipe Clamp Adjustment...................................................130 4.5.1.2 Clamp Arm Adjustment....................................................131 4.6 Expander Pin System – Mast Boom.....................................................133 4.6.1 Torque and Maintenance Intervals..............................................135 4.6.1.2 Torque Schedule.........................................................136 4.6.1.3 Mounting/Dismounting Tools..............................................136 4.6.1.4 Installation............................................................136 4.6.1.5 Dismounting ............................................................139 5.1 Hydraulic Symbols...................................................................143 5.1.1 Hydraulic Schematic...........................................................144 5.2 Hydraulic Circuits..................................................................147 5.3 Hydraulic Pump......................................................................151 5.3.1 Installation..................................................................152 5.3.1.1 Pre Start-up............................................................152 5.3.1.2 Start-up................................................................152 5.3.2 Adjustments...................................................................154 5.3.2.1 System (Operating) Pressure Adjustment..................................154 5.3.2.2 Stand-by Pressure Adjustment............................................154 5.3.3 Testing the Pump..............................................................155 5.3.4 Troubleshooting the Pump......................................................157 5.3.5 Factors Affecting the Pump’s Life.............................................158 5.3.5.1 Contaminated Fluid......................................................158 5.3.5.2 Poor Suction Conditions.................................................159 5.3.5.3 Excessive Case Pressure.................................................160 5.3.5.4 Too Low an Operating Pressure...........................................160 5.3.5.5 Cavitation/Aeration.....................................................161 5.4 Hydraulic Cylinders.................................................................163 5.4.1 Double Acting Cylinders.......................................................164 5.4.2 Cylinder Inspection...........................................................164 5.4.3 Cylinder Overhaul.............................................................164 5.5 Control Valves – On/Off Types.......................................................165 5.5.1 Control Valves................................................................167 5.5.2 Relief Valve Adjustment.......................................................168 5.5.3 Valve Pressure Adjustment.....................................................169 5.5.4 Valve Flow Adjustment.........................................................169 5.5.5 Valve Overhaul................................................................169 5.5.6 Valve Sections................................................................171 5.5.7 Solenoid......................................................................171 5.5.8 Lever Section.................................................................171 5.5.9 Valve Assembly................................................................173 5.5.10 Inlet Section................................................................173 5.6 Manifold Blocks.....................................................................175 5.6.1 Servicing Cartridge Valves....................................................175 5.6.2 Troubleshooting Cartridge Valves..............................................175 5.6.3 Installation Torque Values....................................................182 5.7 Counterbalance Valves...............................................................183 5.7.1 Making Adjustments............................................................184 5.7.2 Troubleshooting...............................................................185 5.8 Hydraulic Filtration................................................................187 5.8.1 Change Hydraulic Fluid Every 2000 Hours.......................................188 5.8.2 Return Filters................................................................188 5.8.3 Pressure Filter Element.......................................................189 5.9 Proportional Valves.................................................................191 5.9.1 Proportional Valve Settings...................................................192 5.9.2 Flow Settings.................................................................193 5.9.3 Pressure Setting..............................................................194 6.1 Air Schematic.......................................................................199 6.2 Sullair Compressor..................................................................201 6.2.1 Compressor Unit Functional Description .......................................203 6.2.2 Compressor Discharge System Functional Description............................205 6.2.3 Compressor Cooling and Lubrication System Functional Description..............207 6.2.4 Air Inlet System Functional Description.......................................209 6.2.5 Lubrication Guide.............................................................210 6.2.6 Application Guide.............................................................210 6.2.7 Control System................................................................211 6.2.7.1 Purpose of Controls.....................................................211 6.2.7.2 Butterfly Inlet Valve Functional Description............................215 6.2.7.3 Closed Inlet Start Program..............................................216 6.2.7.4 Normal Operation........................................................217 6.2.7.5 Modulation..............................................................217 6.2.7.6 Unload..................................................................218 6.2.7.7 Compressor Start Up Mode and Running Mode Low Air Pressure..............218 6.2.7.8 Manual Unload Mode......................................................220 6.2.7.9 Running Mode 350 psi Air Pressure.......................................221 6.2.7.10 Running Mode 500 psi Air Pressure......................................222 6.2.7.11 Instrumentation and Protection.........................................223 6.2.7.12 Start Up and Shutdown Procedures.......................................225 6.2.7.13 Adjustment Procedures..................................................227 6.2.8 Compressor Maintenance........................................................228 6.2.8.1 Main Fluid Filter Service...............................................228 6.2.8.2 Thermal/Bypass Valve....................................................229 6.2.8.3 Separator Element Replacement...........................................230 6.2.8.4 Running Blowdown Valve Maintenance......................................232 6.2.8.5 Shutdown Blowdown Valve Maintenance.....................................233 6.2.8.6 Minimum Pressure/Check Valve Maintenance................................234 6.2.8.7 Discharge Check Valve Maintenance.......................................235 6.2.8.8 Safety Valve............................................................236 6.2.8.9 Pressure Regulator (Low / High Air Pressure Regulator)..................237 6.2.8.10 Fluid Stop Valve.......................................................239 6.2.9 Screw Compressor..............................................................240 6.2.9.1 Screw Compressor Arrangement............................................240 6.2.9.2 Compressor Operator Daily Checklist.....................................241 Compressor Operator Daily Checklist.............................................241 6.2.9.3 Maintenance Schedules...................................................243 6.2.9.4 Compressor Lubrication Crossover........................................244 6.2.9.5 Compressor Troubleshooting..............................................245 6.3 Water Pump..........................................................................247 6.3.1 Pump Speed Adjustment.........................................................248 6.3.2 Preventative Maintenance......................................................249 6.3.3 Troubleshooting the Water Pump................................................250 6.3.4 Service Procedures............................................................255 6.3.5 Water Pump Coupling Annual Maintenance........................................263 6.3.5.1 Periodic Lubrication....................................................264 6.4 Grease Injection....................................................................265 6.4.1 To Fill Reservoir.............................................................267 6.4.2 To Prime System...............................................................267 6.4.3 Operation.....................................................................267 6.4.4 Adjusting Flow Rate...........................................................268 6.4.4.1 Setting for a 4” Hammer.................................................268 6.4.4.2 Setting for a 6” Hammer.................................................268 6.4.5 PanelView Settings for QXR....................................................270 7.1 Electrical Circuits.................................................................273 7.2 Electrical Components...............................................................275 7.2.1 Electrical Panel..............................................................276 7.2.2 Control Panels................................................................276 7.2.3 Replacement Parts.............................................................276 7.3 On/Off Valve Activation.............................................................277 7.4 Types of Valves.....................................................................279 7.5 Testing of Valve Solenoids..........................................................279 7.6 Testing On/Off Valves...............................................................281 7.7 Proportional Valves.................................................................283 7.8 Fault Monitoring System.............................................................285 7.8.1 Testing Proportional Valves...................................................285 7.9 Accra-Feed Control System...........................................................287 7.9.1 Accra-Feed Operation..........................................................287 7.9.2 Accra-Feed Components.........................................................287 7.9.3 PLC Operation.................................................................288 7.9.4 Maintenance of PLC in Accra-Feed System.......................................288 7.9.5 Troubleshooting Guide.........................................................289 7.10 Operator Interface PanelView 1000..................................................293 7.10.1 Maintenance of PanelView Terminal............................................293 7.10.2 Troubleshooting PanelView Terminal...........................................294 7.10.3 Alarm Messages on the Terminal...............................................296 7.11 QXR Canbus Electrical System.......................................................297 7.11.1 Components...................................................................297 7.11.1.1 Cab Control Panel......................................................297 7.11.1.2 Rear Control Panel.....................................................298 7.11.1.3 PanelView..............................................................298 7.11.1.4 Joysticks..............................................................299 7.11.1.5 Mast Sensor Junction Box...............................................299 7.11.1.6 Carousel Junction Box..................................................300 7.11.1.7 10-Channel Low-Pass Filter Module......................................300 7.11.2 Canbus Components............................................................301 7.11.2.1 Vansco Multiplexing Module (VMM) 1210 Multiplexing Module..............301 7.11.2.2 Pocket Gateway Module (PGM)............................................302 7.11.3 Operation....................................................................303 7.11.4 VMM 1210 Hardware and Software...............................................305 7.11.4.1 Hardware...............................................................305 7.11.4.2 VMM 1210 Software......................................................307 7.11.4.3 Updating the VMM1210 Software..........................................308 7.11.4.4 PC Software Installation...............................................308 7.11.5 Functions....................................................................309 7.11.5.1 QXR Input/Output List – Cab Control Panel – VMM1 PLC22.................309 7.11.5.2 QXR Input/Output List – Cab Control Panel – VMM2 PLC62.................309 7.11.5.3 QXR Input/Output List – Cab Control Panel VMM3 PLC102..................310 7.11.5.4 QXR Input/Output List – Rear Control Panel VMM4 PLC222.................310 7.11.5.5 QXR Input/Output List – Rear Control Panel VMM5 PLC262.................311 7.11.5.6 QXR Input/Output List – Rear Control Panel VMM6 PLC302.................311 7.11.5.7 QXR Input/Output List – Rear Control Panel VMM7 PLC342.................312 7.11.5.8 QXR Input/Output List – Rear Control Panel VMM8 PLC382.................312 7.11.5.9 QXR Input/Output List – Rear Control Panel VMM9 PLC422.................313 7.11.5.10 QXR Input/Output List – Mast Valve Junction Box VMM10 PLC482..........313 7.11.5.11 QXR Input/Output List – Mast Valve Junction Box VMM11 PLC522..........314 7.11.5.12 QXR Input/Output List – Mast Sensor Junction Box VMM12 PLC582.........314 8.0 Troubleshooting.....................................................................317 8.1 Troubleshooting the Tram Drive......................................................317 Crawler Does Not Run but Tramming Motors Are Operating..............................317 Crawler Does Not Move and Tramming Motor Does Not Run...............................317 Crawler Does Not Tram Straight......................................................317 8.2 Troubleshooting the Hydraulic System................................................318 Pump Does Not Deliver Oil...........................................................318 Pump is Running Hot.................................................................318 Cavitation or Pump Noise............................................................318 Insufficient Pressure...............................................................318 Slow Rotation at Top Drive..........................................................318 No Rotation at Top Drive Assembly...................................................318 Slow or No Feed.....................................................................319 Mast Does Not Rotate................................................................319 Actuator Allows Mast to Move After Being Set........................................319 8.3 Troubleshooting the Water Injection Pump............................................320 Discharge Pressure is Too Low.......................................................320 Cavitation Problems.................................................................320 No Water Discharge..................................................................320 Excessive Pump Noise................................................................320 8.4 Troubleshooting the Air Driven Oil Injection Pump...................................321 Air Motor Does Not Operate..........................................................321 Air Seepage from Air Exhaust While Pump is Not Working..............................321 Loss of Pressure, Volume, or Continuous Operation of Pump when Not in Normal Use....321 Excessive Amount of Air in Lubricant or Excessive Amount of Lubricant in Air........321 8.5 Troubleshooting the Air Driven Grease Injection.....................................321 Air Motor Does Not Operate..........................................................321 Grease Is Not Delivered to the Drilling Air Line....................................321 8.6 Troubleshooting the Air Delivery System.............................................322 Air Pressure Builds too Slowly......................................................322 Compressor Shuts Down with Air Demand Present.......................................322 Compressor Does Not Build-Up Full Discharge Pressure................................322 Compressor Unloading with an Excessive Pressure Build-Up............................322 Excessive Compressor Fluid Consumption..............................................322 Compressor Overheating..............................................................323 8.7 Troubleshooting the Hammer..........................................................324 Tool Does Not Start.................................................................324 Tool Stops Operating................................................................324 Operating Pressure is Lower than Specifications.....................................324 Low Penetration Rate................................................................324 Galling of Internal Parts...........................................................325 8.8 Troubleshooting the Drill Bit.......................................................326 Abrasive Wear.......................................................................326 Loss of Carbides in Bit.............................................................326 Bit Breakage and Carbide Failure....................................................326 Carbide Breakage....................................................................326 Uneven Wear Conditions..............................................................327 8.9 Troubleshooting Depth Laser.........................................................328 Laser appears not working. No red light is coming out of aperture. .................328 Laser appears working; red light is pulsing in even intervals, no output signal.....328 Laser appears working, red light is pulsing but in un-even intervals................329 General notes:......................................................................329
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