Service Training Manual CM 765/785

Air System

Compressed air for operation of the down hole hammer as well as the
dust collector and thread greasing system is provided by an HR2
compressor in the CM 765 and an HR2.5 in the CM 785. The CM
765 supplies 636 CFM at a maximum pressure of 350 PSI (24 Bar).
The CM 785 supplies 855 CFM at a maximum pressure of 350 PSI
(24 Bar).

The compressor on each of these units is fitted with a normally open

inlet valve. A normally open solenoid valve is used to load the
compressor. This valve is energized to the closed position only when
the drill/tram mode switch is placed in the drill mode. This means that
the compressor will remain at low pressure, 40-60 PSI (2.5-4 Bar)
during warm up and during tramming.

Startup

The unloader allows the engine to start with the compressor

unloaded. This provides for easier starting, especially in cold
weather. This gives the engine time to achieve stable operation and
establish full oil flow through the engine and compressor. Allow
several minute of idle run time before operating any system on the
machine. This allows the engine to warm up before putting it under
load. The engine can only be started only with the drill/tram switch in
the neutral or center position. The compressor is unloaded at this
time. During the warm up time period, the compressor receiver tank
will slowly build up to 40-60 PSI (2.5-4 Bar) This normally takes
about10-15seconds.

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Running Loaded

When the drill/tram selector switch is placed in the drill position, the
load and unload solenoid valve is energized to the closed position.
The receiver tank will build up to the maximum pressure setting of the
inlet unloader. There is a low-high pressure switch on the left-hand
joystick that allows the operator to select either setting. The low
pressure setting is 220 PSI (15 Bar) and the high-pressure setting is
370 PSI (25.5 Bar). The compressor pressure will build up to the
pressure setting that is selected. A second normally open solenoid
valve when energized (closed), will set the compressor control
system to the high position. If the switch in the cab is set for high
pressure, it can be switched at any time to the low setting. Receiver
tank pressure will then begin to drop to the low-pressure setting. If
the unit is still in the drill mode, the main air valve can be opened to
speed up the dropping of air pressure from high to low. The dust
collector pulse system will also do this but the time involved will be
longer. The dust pulsing system method may take a minute or more.
It may in some cases, be desirable to collar the hole at the low setting
to prevent excessive blowout of the top of the hole. The air control
switch on the left side of the left control handle, is a momentary
switch on all later model machines. This means that the operator can
momentarily depress the switch at the top and limit the amount of air
that is allowed to pass to the hammer. Holding the switch down for
several seconds will fully open the air control valve. To turn the air
off, it is necessary to depress the bottom of the switch for several
seconds to shut off the air.

Shutting down

When the unit is to be shut down, it should be allowed to run for

several minutes with the compressor in the low-pressure mode before
stopping the engine. In an emergency the unit can be stopped with
the compressor in any operating mode. In any shutdown situation,
the compressor will blow down through the inlet valve. The noise
during blow down is much less noticeable than with other unloader
systems so be sure that the pressure has dropped to 0 PSI before
disconnecting any lines on the air system. To be absolutely safe,
open the manual blowdown on the top of the receiver tank.

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The HR2 & HR2.5 use synthetic fluid in its operating cycle. The unit
is shipped with Atlas Copco XHP605 fluid from the factory. Do not
use any other fluid that may not be compatible with the recommended
fluid. Other type fluids will cause excessive foam of the fluid and lead
to overheating problems.

PRINCIPAL OF OPERATION:

Up to this point we have discussed the control principals of the HR2 &
HR2.5 system. Air is allowed to enter the primary or low-pressure
stage of the compressor through the open inlet sleeve valve. The air
enters because the rotating compressor rotors create a vacuum at
the inlet of the compressor This causes a vacuum and the inlet valve
opens. The primary stage handles a large volume of incoming air.
The incoming air is trapped by the rotors and carried forward between
the rotors and the compressor housing to the outlet of the primary
unit. At this point the air from the primary rotors is supplied to the
secondary rotors. The air is compressed further and delivered to the
receiver tank. When the machine is drilling, the high-pressure air
from the receiver tank is supplied to the DHD and other functions
requiring air. When no air is required as during pipe changes, the
air pressure in the receiver tank increases until it reaches the setting
of the pressure regulator. At this point the inlet valve will close. It is
also important to note that the HR 2 & HR2.5 are equipped with a
positive displacement oil pump. During operation, oil is injected into
the compressor rotors where it mixes with the air. The oil is injected
at the point in the cycle where compression begins. The oil helps
seal the clearances between rotors as well as between the rotors and
the compressor housing as well as providing lubrication to internal
parts and bearings. The oil pump can also operate as an oil stop
valve, this prevents to much oil to be cycled through the compressor.
The oil also helps to take the heat from compression of the air to the
compressor oil cooler. The mixture of air and oil is supplied to the air
receiver tank. The air/oil mixture enters the air receiver from the
compressor through a discharge check valve. This check valve
prevents the air pressure in the receiver tank from forcing oil
backward through the compressor at shutdown. The air receiver tank
contains a large filter element that separates the incoming air/oil
mixture. Most of the oil drops to the bottom of the tank while the air
passes to the inside of the filter. Air from the inside of the filter

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supplies all of the air demands of the machine. The oil that drops to
the bottom of the receiver tank is partially forced by the air pressure
and partially drawn by the oil pump from the tank. From the receiver
tank the oil is directed to the thermal bypass valve. The temperature
of the oil reaching thermal bypass valve determines whether the oil is
directed to the oil pump and filter or through the cooler before being
directed to the pump. There is also a bypass check valve to protect
the cooler from excessive pressure when the oil is cold. A safety relief
valve set at 425 PSI protects the air receiver tank. The main air
discharge line contains a minimum pressure valve that is set at 140
PSI. If the air pressure in the system drops below the minimum
pressure valve setting the valve closes and stops airflow in the main
air line. If the air pressure is allowed to drop too low, the oil flow to
the cooler and pump will be reduced which can cause compressor
overheating.

There is another circuit to discuss. That is the scavenge circuit. As

the air passes through the receiver filter element a small percentage
of oil passes through also. This is called oil carry over. This oil
collects in the bottom of the filter element. A small line with a drop
tube to within 1/8 of the bottom of the separator/filter scavenges the
oil back into a lower pressure area of the rotors. There is a .11 orifice
located in the scavenger line near the receiver tank to limit the
volume of air passed through the line.
separate
NOTE: If the scavenger line is plugged up or the separater element
is damaged, this will result in excessive oil carry over. This will mean
that the operator will frequently have to add fluid to the receiver tank.
This will also push oil through the air stream to the toll somewhat
diluting the desired rock drill oil.

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Tier III Compressor Inlet Valve Assembly

Tier 3 units are fitted with the inlet valve and regulation system that is
shown on the following pages. Many older unit in the field have been
retrofitted with this system

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System PSI Air Filter

X Gauge Port Inlet Valve
High Pressure
Regulator

Load/Unload Unload PSI

Solenoid Test Port X

Compressor
Low Pressure Inlet
Regulator

High/Low
Selector Solenoid

Dry Air from

Receiver Tank
New Style Inlet Valve

Adjusting the unloader controls.

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view of compressor unloader control panel

This picture shows the various components that are used to control
the compressor inlet valve. Both of the solenoid valves are normally
open. The load/unload solenoid closed when the machine is placed
in the drill mode otherwise it is open. If it is open, the compressor will
not build any more pressure than standby. This pressure will be from
40-70 PSI. Once in the drill mode, the operator has the option via the
high/low switch on the feed lever to switch the compressor from low
pressure to high pressure.

The low pressure setting should be around 220 PSI

The High pressure setting should be 370 PSI.

When setting the high pressure it is necessary to blow off the air
several times to check for pressure overshoot. The relief valve in the
receiver tank is set for 400 PSI.

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The low pressure solenoid is also normally open. Energizing closes it

and the regulation air is required to pass through the high pressure
regulator before reaching the inlet valve.

When putting a new unit into service it might be beneficial to put

some blue loctite on the 4 small cap screws that sandwich the
regulators together. Experience has shown that the screws loosen
up in service and allow the regulator diaphragm to rupture or squeeze
out of the regulator.

The solenoid valves are subject to moisture collection. This will

sometime cause them to stick in either the open or closed position.
This can cause failure to load or to shift into high pressure or cause
the compressor to load immediately upon start up of the engine.

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This is the same regulator as used on the L-6 Atlas Copco drill. If
parts are hard to obtain from Allen try Roanoke parts dept.

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Down hole drill Lube system:

The CM 785 and CM 765 units are equipped with a pressurized

lubrication system. The rock drill oil is found in a pressurized lube
tank. The tank is a pressure vessel. Drill air pressure is used to
apply pressure on the tank only when the main air valve is opened to
supply air to the DHD. When the tank is pressurized, rock drill oil is
forced through the needle valve and into the throat of the venturi. As
drill air passes through the venturi, a low-pressure area is created in
its throat allowing the rock drill lubricant to enter the air stream. The
lubricant is atomized so that it is evenly dispersed within the tool.
The needle valve is used to regulate the amount of oil supplied to the
DHD.

Venturi Tube
Air Flow to
Down Hole Drill
The lubrication tank
is pressurized only
when the hammer
air is turned on.

Lube oil
needle valve
Lube Tank
Caution: Do not try to open the oiler reservoir unless the unit is
shut down and all air pressure has been bled off!

The normal setting for the needle valve is 1 ½ to 2 turns from fully
closed. When starting a new system, the valve should be opened
more to assure rock oil gets all of the way through the system before
turning the valve down.

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Service air circuits:

Pilot Pressure
from Blow Air
Pressure
Blow hose
valve

Grease Pump
Solenoid Valve

Water Pump
Pilot Valve

5 PSI

Hyd Tank
pressure
regulator
(Preset)

110 PSI Service Air Dust Collector

7.5 Bar Regulator Regulator

The dust collector regulator should be set at 50 PSI and no higher

than 60 PSI. Over pressure may rupture the air tank that supplies the
pulsing valves.

The water used in the water tank should be as clean as possible.

There is a small strainer between the tank and the water pump and it
should be cleaned regularly to prevent pump failure.

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Thread Greasing Circuit

Grease
Nozzle

80 Grease Pilot
PSI
Valve

Pressure
Regulator

Service Air
110 PSI (7.6 Bar)
Grease container Grease Valve
and pump

It is important that the main regulator found on top of the receiver

tank be set at 110 PSI. The setting for the greaser regulator is 80
PSI. The grease regulator is found in the enclosure behind the
operator s cab.

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