Вы находитесь на странице: 1из 90

D&B-980CP

SKID TYPE

OPERATION AND
MAINTENANCE MANUAL

DO NOT OPERATE THE MACHINE BEFORE READING


AND UNDERSTANDING THE INSTRUCTIONS OF THIS MANUAL

Electric Circuit Diagram ----------------------------------------------------------------

HANJIN D&B CO., LTD.


HEAD OFFICE
728-3 Anchung-dong, Kwangsan-gu, Kwangju-city, Korea
Telephone +82-62-9524564 - Telefax +82-62-9524565
IMPORTANT SAFETY NOTICE
Most accidents which occur while operating or maintaining operation machines or job site
equipment are caused by not complying with or neglecting the basic safety precautions and
the potential dangerousness of a specific situation before the accident occurs.

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.

Operating, lubricating, maintaining or repairing the machine in an improper way


may be highly dangerous and result in srious personal injury or even death.

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.

Special labels or warning plates are also applied to the machine.


They provide instructions on how to identify the hazards which, if under-estimated, may
result in serious injury or death.

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.

The manual is divided into four section:

Section A GENERAL INFORMATION


Section B SAFETY
Section C INSTRUCTIONS FOR USE
Section D MAINTENANCE

Section A contains general information which is very important for understanding


the machine and its main parts.
Exact identification data, specifications, etc. are also provided.

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

DO NOT OPERATE THE MACHINE BEFORE READING


AND UNDERSTANDING THE INSTRUCTIONS OF THIS MANUAL

HANJIN D&B CO., LTD.


A-1
CONVENTIONAL REFERENCES
--------------------------------------------------------
Symbols used in the manual

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

personnel, from the risk of injury to the risk of death

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

The message may also be accompanied by illustrations


A-2
IDENTIFICATION
---------------------------------------------------------
Manufactured

HANJIN D&B CO., LTD.


621-20 Dochun-dong, Kwangsan-gu, Kwangju-city, Korea
Telephone +82-62-9524564 - Telefax +82-62-9524565

Model and Type

D&B-980CP/SKID TYPE with HYUNDAI D6CE Engine.


D&B980CP/SKID TYPE is installed AIR COMPRESSOR 980CFM

Machine identification plate

The identification plate is located on the front of machine.


The identification plate is showed model & type, engine maker & no.,Serial no.,
& manufacturing year
Model

Model D&B - 980CP


Chassis No. D&B-980CPPHI17111613
Engine Model HYUNDAI D6CE
Engine No. D^CE GJ307821
Engine Type Turbo Charger, ECU SYSTEM
Power 520HP/1800RPM
Contact No. 82-62-953 4510 (T), 4520 (F)
Web-site www.hanjindnb.com
E-mail mail@hanjindnb.com

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

Identification plate of main component parts

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

DIMENSIONS & WEIGTH

Width 2100mm
Length 4050mm
Height 2168.5mm
Weight 6.8 ton

ENGINE

Model Hyundai D6CE


Rated power 520HP/1800rpm
Fuel Capacity 1100 liter
Cooling system water cooling (85 liter)

Max. Operating Speed 1800 rpm


Min. Operating Speed 1100 rpm

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

Inlet flange(ID) 165.6mm


Discharge flange(ID) 76mm

Fan Diameter 1200mm


Com. Oil Cooling System Air cooled
Oil Fill Capacity 100liter
Temperature of Outlet air 75~85°C
Air Outlet Port Size 3inch 1EA
A-3
DESCRIPTION AND SPECIFICATIONS
--------------------------------------------------------
Main dimensions

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

DO NOT OPERATE THE MACHINE BEFORE READING


AND UNDERSTANDING THE INSTRUCTIONS OF THIS MANUAL

HANJIN D&B CO., LTD.


B
SAFETY
--------------------------------------------------------
Introduction

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

Licence If required by law

B-1-2 Work clothing


When working or carrying out repairs or maintenance jobs, you must use the clothing and
accident-prevention material listed below:

- 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

B-1-3 Safety equipment

You must also have the following equipment ready for use if necessary:

- Respirators (or dust masks)


- Ear plugs or headsets
- Goggles or masks to protect the eyes

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

B-2-1 List of hazards

A TRANSPORT (to and from site)


B SETTING UP/ASSEMBLY AND DISASSEMBLY (on site)
C JOB PERFORMANCE (on site)
D POSITIONING (from one job to another on site)
E PARKING OR OFF-DUTY (on site or in warehouse)

Type of danger Situations


Oil leaks A B C D E
Mechanical component failure B C D
Accidental dropping of drilling equipment A B C D
Risks connected with lifting and lowering of mechanical
parts (e.g.mast, rods)
B C D
Contact with hot or cold components B C D E
Contact with dangerous substances B C D
Pressure drops in the hydraulic system B C D
High pressure fluids and gases B C D
Electric shocks: - from contact with electric power lines B C D
- from contact with underground cables C
Falls from high positions A B C D E
Overturning or slipping of the machine B C D E
Cuttings thrown up by drilling tool C D
Whiplashing of hoses or ropes B C D
B-3
SAFTEY RULES
--------------------------------------------------------
B-3-1 Work area

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

- Study, if necessary, the best access route to the work area

- 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

B-3-2 Preparing for work

Before and during a job do not take alcohol, medicines or any other substance that may
impair your ability to operate machines

You must be properly prepared prior to starting work:

- 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

- It is forbidden to make emergency repairs simply in order to start work!


B-4
SAFTEY LABELS
----------------------------------------------------------

B-4-1 Read the Instruction Manual(ISO 7000-0419)

B-4-2 Hearing protection must be worn(ISO 3864)

B-4-3 Do not start(ISO 7000-0790)

B-4-4 Doors open, do not operate


B-4
SAFTEY LABELS
----------------------------------------------------------

B-4-5 Valve open before connecting air hose ban

B-4-6 Warnings for Hot Coolant

B-4-7 Automatic Control(ISO 7000-0017)

B-4-8 Dangerous heating plate(IEC 417-5041)


B-4
SAFTEY LABELS
----------------------------------------------------------

B-4-9 WARNING FOR ROTATION PARTS

WARNING

Rotating parts can cause personal injury


Keep away from fan and belt when engine is run-ning
Stop engine before servicing

B-4-10 Maintenance work in progress

B-4-11 Dangerous exhaust


B-4
SAFTEY LABELS
----------------------------------------------------------

B-4-12 HOT SURFACE

B-4-13 Coolant Injection(EN 61340-1)

B-4-14 HEATING SYSTEM THE MANUAL


B-4
SAFTEY LABELS
----------------------------------------------------------

B-4-15 The risk of electric shock(ISO 3864)

B-4-16 Start and stop device(IEC 417-5010)

B-4-17 Direction of rotation(ISO 7000-004)


B-4
SAFTEY LABELS
----------------------------------------------------------

B-4-18 Fuel fill(ISO 7000-0245)

B-4-19 Oil fill(ISO 7000-0248)

B-4-20 Coolant fill(ISO 7000-0524)


B-4
SAFTEY LABELS
----------------------------------------------------------

B-4-21 Lifting point(ISO 7000-1368)


B-5
SAFETY
----------------------------------------------------------------------
SAFETY

Always follow the safety instructions and be careful with your work

Service and adjustment procedures are only allowed to persons


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

Hazardous moving and rotating parts.


Do the service and repair workonly when the rig is not running.
Make sure that accidental starting or moving of the rig is
prevented during service

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.

Do not modify Compressor except with written factory approval


B-5
SAFETY
----------------------------------------------------------------------
Pressure Release

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

Fire and Explosion

1. Clean-up spills of lubricant or other cumbustible substances immediately, if such spills


occur.

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

3. Do not use flammable solvent for cleaning purposes

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.

8. Do not attempt to operate the Compressor in any classification of hazardous environment


unless the Compressor has been specially designed and manufactured for explosive
applications.

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

1. Do not use air from this Compressor for respiration (breathing)

2. Operate the Compressor only in open or well ventilated areas.

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

Death or serious injury may result from inhaling compressed


air without using proper safety equipment

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

1. Observe all safety precautions mantioned elsewhere in this manual.

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

√ Read the manual in detail and follow the instructions.

√ Clean the air compressor package regularly.

√ Keep the air filter clean.

√ Use only genuine Spares.

√ Maintain correct oil level.

√ Use proper tools.

√ Attend immediately to anything unusual with the air compressor.

DON'TS

X Neglect the routine attention.

X Allow any leakage in the system.

X Keep any tools or loose items on the compressor / other modules.

X Meddle with any adjustments or settings.

X Use cleaning agents, when changing oil.

X Overload the compressor for a long period even though it is of continuous rating,
as we recommended intermittent use only.
SECTION C

INSTRUCTIONS FOR USE

DO NOT OPERATE THE MACHINE BEFORE READING


AND UNDERSTANDING THE INSTRUCTIONS OF THIS MANUAL

HANJIN D&B CO., LTD.


C-1
CONTROLS AND INSTRUMENTS
--------------------------------------------------------
Main control panel

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.

5 Indicate Lamp Show


Check eng
Water temp - Check overheating
Check battery charging
Check remain engine oil
Over speed
Pre-heat for Engine
Engine stop

Power
C-1
CONTROLS AND INSTRUMENTS
--------------------------------------------------------
Switchs

4 3

6 5
1

No. DESCRIPTION CONDITION


Key Box for Engine
pos. stop STOP
1
pos. on Ready to use all electronices
pos. start START
Engine rpm - Control
2 Clockwise Increase
C.Clockwise Decrease

3 Fuse 250V 15A

Engine auto stop


4 Auto : Engine stop after several minutes.
Manual : Manual engine off

5 Alarm On/Off alarm when main key on

6 Buzz The buzz notify the level of engin oil

7
C-1
CONTROLS AND INSTRUMENTS
--------------------------------------------------------
COMPRESSOR CONTROL PANEL

4
1

3
5

7 6
2

No DESCRIPTION POSITION CONDITION


WARNING SIGNAL LAMP OF OFF NORMAL
1
COMPRESSOR ON WARNING

2 FUEL LEVEL GAUGE SHOW

3 AIR PRESSURE GAUGE SHOW

COMPRESSOR OIL OUTLET


4 SHOW
TEMPERATURE
COMPRESSOR OIL INLET
5 SHOW
TEMPERATURE
DOWN OFF
6 AIR ON/OFF SWITCH
UP ON
DOWN OFF
7 LIGHT ON/OFF SWITCH
UP ON
COMPRESSOR OIL INLET
8 SHOW
TEMPERATURE
C-1
CONTROLS AND INSTRUMENTS
--------------------------------------------------------
DIAGRAM OF COMPRESSOR CIRCUIT
OPERATING PRINCIPLE OF COMPRESSOR CIRCUIT

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. Thermostat & Oil stop valve


• The thermostat directs the oil below 60oC past the oil cooler. The thermostat starts
opening when the oil temperature rises over 60oC, allowing part of the oil to flow
through the cooler. When the oil temperature is over 80oC the thermostat is fully
opened, and all the oil circulates through the oil cooler.

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 Pressure regulating valve


• The pressure regulator controls the inlet valve in accordance with air consumption,
maintaining the desired pressure. By adjusting the spring the compressor output
pressure can be regulated between 18 and 25 bar.
16 Throttle valve
• The throttle restricts the air flow in the air regeneration line.
17 Bypass valve
• The non-return valve prevents the oil/air mixture from going to the air end oil/air
receiver during the stopping. The screw unit remains pressurized until the pressure
in the oil/air receiver is released.
18 Blow-down valve
• The blow-down valve automatically releases the pressure from the oil/air receiver
when the air end is stopped. The pressure is released out through the valve.

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

21 RPM Position sensor


• The butter fly valve is opened and electric signal the electrical system
which in engine ecu raises engine rpm with step putting out automatic.
22 Air cylinder assy
• Opens the butter fly valve to use the air and the system which closes.
23 Air sol valve
• In air cylinder air supply and cutoff.

23

24 Max pressure relief valve


• It is a valve that adjusts the maximum pressure.

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.

Oil temperature between 60-80oC

The bimetallic spring in the thermostat valve starts opening the thermostat valve and
part of the oil flows through the oil cooler.

Oil temperature above 80oC

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

of the safety rules and information contained in Section B

If in doubt, read this section again; you should start work only when you have fully

assimilated its contents

C-4-1 Diesel engine start

Prior to starting engine, make sure that nobody & nothing is in near operating area

Main electric power

Before start your engine, turn the main power lever (No. 7) - ON.
C-4
DIESEL ENGINE START AND STOP INSTRUCTIONS
---------------------------------------------------------
Engine Start

The correct engine start-up precedure is as follows

- Main electric switch - On

- Leave control volume switch for engine R.P.M. at low speed position

- Turn starter key to start(right) position. Engine should be start in


approx.5 seconds

- After engine has started, release key. Key will rerurn to


normal(central) position

- Follow procedures in "Hydraulic system warm -up"

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.

Please contact a HANJIN D&B distributor or service center for repairs.


C-4
DIESEL ENGINE START AND STOP INSTRUCTIONS
---------------------------------------------------------
Checking point after start

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

Normal checking points are :


TEMP. of ENGINE COOLANT GREEN ZONE
QUANT. Of FUEL SEE AND RE-FILL
TEMP. of ENGINE OIL GREEN ZONE
CHARGING VOLTAGE GREEN ZONE
QUANT. Of HAMMER OIL SEE AND RE-FILL
VIBRATION / NOISE USUAL
COLOR of EXAUST SMOKE NO COLOR / LIGHT BLUE
No color In good condition
Light blue In good condition
Black Incomplete combustion
White Engine oil is burned
Dark blue Engine oil is burned
COLOR of EXAUST SMOKE NO COLOR / LIGHT BLUE
C-4
DIESEL ENGINE START AND STOP INSTRUCTIONS
---------------------------------------------------------
C-4-2 Diesel engine stop

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

- Set engine speed control volume switch to low speed.

- Stop engine by turning key to stop (normal / central) position.

- Start switch - Off (No. 1 - KEY TURN OFF)

- Remove key from starter switch

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.

LEAK. of ENGINE COOLANT CHECK


QUANT. Of FUEL SEE AND RE-FILL
LEAK. of ENGINE OIL CHECK
FRONT ATTACHMENT ANY ABNORMAL APPEARANCES?
UNDERCARRIAGE SEE AND RE-FILL
ENGINE COMPARTMENT CLEAN / ANY FLAMMABLE MATERIAL?
OPERATOR'S COMPARTMENT CLEAN / ANY MUD, OIL?
SECTION D

MAINTENANCE

DO NOT OPERATE THE MACHINE BEFORE READING


AND UNDERSTANDING THE INSTRUCTIONS OF THIS MANUAL

HANJIN D&B CO., LTD.


D-1
OCCASIONAL MAINTENANCE
--------------------------------------------------------

Prior to beginning any operation or procedure described in this chapter you must be aware

of the safety rules and information contained in section B

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:

Diesel engine - insufficient oil pressure

Diesel engine - high water temperature

Stop the machine as soon as possible if one of the following lights comes on:

Hydraulic oil filter - clogged

Hydraulic oil radiator fan - in operation

When the indicator lights listed above are illuminated, stop the engine; leaving it running

might cause serious damage

Overheating of the hydraulic oil signals a malfunction in part of the hydraulic system,

generally clogged filters or obstructed heat exchanger

Do not ignore the indicator lights and continue work; if you do so a chain reaction might

be triggered, causing damage to other parts of the system

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

The filter must always be replaced and not cleaned

Fuse
- REPLACEMENT

The fuses are located in control panel

FUSE VALUE FUNCTION PROTECTED


1 10A Key box line
2 15A Battary line

When changing a fuse make sure that the rating of the new fuse is correct and that it

corresponds to the table

IMPORTANT
Take care never to let water, oil or dirt into the electrical panels When replacing the

covers take care not to damage cables or wiring


D-3
TABLES AND SPECIFICATIONS
--------------------------------------------------------
D-3-1 Refilling

Fuel tank 250


Hydraulic oil tank 100
Tramming reduction gears 1.5
Engine cooling system (water+antifreeze) 24+7 (approx. 30% antifreeze)
Air system lubricator 10
HD rotary 4
Winch 1.5
Diesel engine oil 15

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

to a maximum of 80% petroleum

Hydraulic oil

On delivery the rig is provided with same type hydraulic oil:


This is the only oil we authorise as it recorded the best result in a number of comparative
tests we performed. Always use the same make and type of oil when carrying out subsequent
periodic oil changes in temperate climates suited to multigrade oils

Do not mix oils different types and characteristics, as you risk causing malfunction in the

hydraulic system and component failure

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

The rig is provided with the following lubricating oils:

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

Do not mix oils of different types and characteristics!

Otherwise you risk causing malfunctions and irregularities in the components

Grease

SHELL EP SUPER GREAES is used in the machine's lubrication points

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!

Bolt tightness valves


Refilling

Fuel tank 830


Hydraulic oil tank
Engine cooling system (water+antifreeze) 24+7 (approx. 30% antifreeze)
Air system lubricator 10
Diesel engine oil 26W

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

to a maximum of 80% petroleum

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)
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

1. Oil should be changed when hot to prevent build up of sludge deposits.


2. To change the oil in the receiver tank the machine must be set on level ground.
3. Place a pan for catching the spent oil under drain plug.
4. To facilitate oil drainage, unscrew the filler cap.
5. Remove drain plug and drain the oil.
Problem Causes Remedles
No fuel Check fuel level and add fuel if necessary
Clogged fuel filter Replace the element
Check electrolyte level and add water and
Low battery voltatge
recharge if necessary.
Loose battery cables Tighten cables
Dirty battery cables Clean thoroughly
Clogged air filter Clean or replace the element
Engine problem may have
1. Engine not starting Refer to your Engine manufacturer
developed
Defective engine oil
pressure switch,
compressor Replace the defective switch
dischargetemperature
switch
Check electrical continuity and replace if
Blow Fuse
necessary
Compressor discharge
temperature switch is open
a) Cooling air flow is
Clean cooler and check for proper ventilation
insufficient
b) Low oil level in receiver
Add oil
tank
c) Dirty oil Change oil
d) Clogged oil filter Change oil filter elements
Check for a short or open circuit to
2. Machine shuts down the fuel solenoid should this check out
Defective discharge
with air demand present normal,
temperature switch
it would be possible that the temperature
switch itself is defective
Engine water temperature
switch is open
a) Cooling air flow
Clean the radiator core
restricted
b) Low water level Fill the radiator with adequate water
c) Defective switch Replace
d) Blown fuse in wiring
Check continuity and replace if necessary
hamess
Air demand too great Check service lines for leaks or open valves
Check the filter indicator and change or
Dirty air filter clean
element if required
3. No building of line Adjust pressure regulator valve according to
Pressure regulator valve
pressure control adjustment instruction
out of adjustment
in the maintenance section
Defective pressure
Check diaphragms and replace if necessary
regulator
Defective minimum
Check and ensure piston in moving freely
pressure valve

Pressure regulating valve


Re- adjust
is set too high

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

DO NOT OPERATE THE MACHINE BEFORE READING


AND UNDERSTANDING THE INSTRUCTIONS OF THIS MANUAL

HANJIN D&B CO., LTD.


SEPARATE TANK HJST03
ITEM LEVEL P/NAME
1 2 P/NO REMARK
NO ASSY ENGLISH KOREA
1 1 HJST03-01 SEPARATOR TANK 세퍼레이트 탱크 바디
2 1 HJST03-02 SEPARATOR FILTER 세퍼레이터 필터
3 1 HJST03-03 TANK COVER 탱크 커버
4 1 HJST03-04 OIL RETURN FILTER TANK 오일 리턴필터 탱크
5 1 HJST03-05 OIL RETURN FILTER 오일 리턴필터
6 1 HJST03-06 O-RING 오링 P180
7 1 HJST03-07 RETURNBFILTER TANK COVER 오일 리턴필터 커버
8 1 HJST03-08 MINIMUM PRESSURE VALVE BODY 잔압유지벨브
9 1 HJST03-09 PISTON 피스톤
10 1 HJST03-10 SPRING 스프링
11 1 HJST03-11 O-RING 오링 G60
12 2 HJST03-12 VITON SEAL 바이톤 씰
13 1 HJST03-13 VALVE 밸브
14 1 HJST03-14 O-RING 오링 G115
15 1 HJST03-15 UPPER BODY 상부 바디
16 1 HJST03-16 SPRING 스프링
17 1 HJST03-17 SPRING 스프링
18 1 HJST03-18 O-RING 오링 G75
19 1 HJST03-19 VALVE COVER 밸브 커버
20 1 HJST03-20 GASKET 가스켓 125*77*3.2
21 1 HJST03-21 CHECK VAVLE 판 체크밸브 65A
22 1 HJST03-22 GASKET 가스켓 125*93*3.2
23 1 HJST03-23 OUTLET PIPE 토출 파이프
24 2 HJST03-24 SAFETY VALVE 안전변 3/4"
25 1 HJST03-25 AIR GAUGE 에어 게이지
26 1 HJST03-26 MINIMUM PRESSURE REGULATOR 저압 레귤레이터
27 1 HJST03-27 INLET COVER 오일 주입구 커버
28 1 HJST03-28 O-RING 오링 P60
29 3 HJST03-29 OIL LIMIT GAUGE BODY 유면게이지
30 1 HJST03-30 GASKET 가스켓 132*103*3.2
31 1 HJST03-31 CHECK VAVLE 판 체크밸브 80A
SEPARATE TANK HJST03
ITEM LEVEL P/NAME
1 2 P/NO REMARK
NO ASSY ENGLISH KOREA
32 1 HJST03-32 GASKET 가스켓 139*77*3.2
33 1 HJST03-33 INLET PIPE 흡입 파이프

A 8 HJST03-34 NUT 너트 M20


B 3 HJST03-35 FITTING 니플 1 1/2"
C 8 HJST03-36 BOLT 육각 볼트 M20X140L
D 1 HJST03-37 FITTING CLOGGING 메꾸라 1/2"
E 4 HJST03-38 NUT 너트 M10
F 4 HJST03-39 BOLT 육각 볼트 M10X25L
G 8 HJST03-40 NUT 너트 M10
H 8 HJST03-41 BOLT 육각 볼트 M10X50L
I 2 HJST03-42 FITTING SWIVEL 스위벨 1/2"
J 2 HJST03-43 FITTING 니플 1/2" X 3/4"
K 1 HJST03-44 FITTING CLOGGING 메꾸라 3/4"
L 2 HJST03-45 HIGH PRESSURE T 고압 T 3/4"
M 2 HJST03-46 FITTING ELBO 90도 니플 3/4"
N 1 HJST03-47 FITTING 니플 1/4" X 3/8"
O 1 HJST03-48 FITTING 니플 1/4" X 3/8"
P 1 HJST03-49 FITTING SWIVEL 스위벨 1/4"
Q 1 HJST03-50 HIGH PRESSURE T 고압 T 1/4"
R 1 HJST03-51 FITTING 니플 1/4"
S 1 HJST03-52 FITTING BUSING 붓싱 1/2" X 3/4"
T 4 HJST03-53 BOLT 육각 볼트 M16X45L
U 4 HJST03-54 NUT 너트 M16
V 4 HJST03-55 BOLT 육각 볼트 M16X110L
W 20 HJST03-56 BOLT 육각 볼트 M16X60L
COMP PARTS HJDT04
ITEM LEVEL P/NAME
1 2 P/NO REMARK
NO ASSY ENGLISH KOREA
1 1 HJDT04-01 COMP DOUBLE BLOCK BODY 콤프더블블록바디
1 HJDT04-02 THERMOSTATE BASE 써모스탯 베이스
2 1 HJDT04-03 THERMOSTATE COVER 써모스탯 커버
3 1 HJDT04-04 OIL STOP PISTON 오일차단밸브 피스톤
4 1 HJDT04-05 OIL STOP VALVE HOUSING 오일차단 하우징
5 1 HJDT04-06 OIL STOP VALVE 오일차단밸브
6 1 HJDT04-07 OIL STOP VALVE COVER 오일차단밸브 커버
7 1 HJDT04-08 OIL STOP VALVE SEAT 오일차단밸브시트
A 1 HJDT04-09 BOLT M12X15L
B 1 HJDT04-10 O-RING G65(실리콘)
C 1 HJDT04-11 THERMOSTATE 써모스탯
D 1 HJDT04-12 O-RING G90(실리콘)
6 HJDT04-13 BOLT M10X65L
E 1 HJDT04-14 O-RING G40(실리콘)
F 4 HJDT04-15 BOLT M10X20L
1 HJDT04-16 SEAL USH50(바이톤)
1 HJDT04-17 O-RING P11
1 HJDT04-18 NUT M10
1 HJDT04-19 O-RING G50(실리콘)
G 4 HJDT04-20 BOLT M8X20L
H 1 HJDT04-21 O-RING G60(실리콘)
I 1 HJDT04-22 O-RING G65(실리콘)
J
COMP PARTS HJCP05

ITEM LEVEL 1 2 P/NO P/NAME REMARK


NO ASSY ENGLISH KOREA
1 1 HJCP05-01 VALVE BODY 밸브 바디
2 1 HJCP05-02 NIDDLE 니들
3 1 HJCP05-03 PISTON 피스톤
4 1 HJCP05-04 SPRING 스프링
5 1 HJCP05-05 SPRING SHEET 스프링 시트
6 1 HJCP05-06 VALVE COVER 밸브 커버
A 1 HJCP05-07 O-RING 오링 P9
B 2 HJCP05-08 BACK UP-RING 백업링 Ø30
C 1 HJCP05-09 QUTOR RING 씰 Ø 25X3.53T
D 6 HJCP05-10 BOLT 볼트 M8X30L
COMP PARTS HJCP06
ITEM LEVEL P/NAME
1 2 P/NO REMARK
NO ASSY ENGLISH KOREA
1 1 HJHT06-01 BUTTERFLY VALVE 버터플라이 밸브
2 1 HJHT06-02 SERVO CYLINDER BRACKET 서보 실린더 브라켓
3 1 HJHT06-03 BUTTERFLY VALVE BRACKET 버터플라이 밸브 고정브라켓
4 1 HJHT06-04 SERVO CYLINDER PIN 서보 실린더 고정핀
5 1 HJHT06-05 SERVO CYLINDER 서보 실린더
6 2 HJHT06-06 SPRING 스프링
7 1 HJHT06-07 BUTTERFLY CYLINDER 버터플라이 실린더
8 1 HJHT06-08 BALL JOINT 볼 조인트
9 1 HJHT06-09 THROTTLE SENSOR 스로틀 센서
10 1 HJHT06-10 THROTTLE SHAFT 스로틀 회전축
11 1 HJHT06-11 THROTTLE ROTATION BRACKET 스로틀 회전 브라켓
12 1 HJHT06-12 SPRING BRACKET 스프링 고정 브라켓
13 1 HJHT06-13 THROTTLE SENSOR BRACKET 스로틀 센서 브라켓
14 1 HJHT06-14 SPRING 스프링
15 1 HJHT06-15 SPRING 스프링
16 1 HJHT06-16 SPRING BRACKET 스프링 브라켓
17 1 HJHT06-17 BUTTERFLY ROTATION BRACKET 버터플라이 회전 브라켓
18 1 HJHT06-18 BRACKET 브라켓

A 2 HJHT06-19 WRENCH BOLT 렌치볼트 M8X40L


B 4 HJHT06-20 BOLT 육각볼트 M8X15L
C 4 HJHT06-21 BOLT 육각볼트 M8X15L
D 2 HJHT06-22 WRENCH BOLT 렌치볼트 M6X10L
E 2 HJHT06-23 BOLT SCREW 무드볼트 M5
F 4 HJHT06-24 BOLT 육각볼트 M8X20L
G 4 HJHT06-25 NUT 너트 M8
H 1 HJHT06-26 WRENCH BOLT 렌치볼트 M6X35L
I 1 HJHT06-27 NUT 너트 M6
J 1 HJHT06-28 WRENCH BOLT 렌치볼트 M6X20L
K 1 HJHT06-29 NUT 너트 M10
L 1 HJHT06-30 BOLT 육각볼트 M10X45L
M 2 HJHT06-31 NUT 너트 M6
N 2 HJHT06-32 WRENCH BOLT 렌치볼트 M6X20L
0 1 HJHT06-33 BOLT 육각볼트 M10X30L
COMP PARTS HJCP07
ITEM LEVEL P/NAME
1 2 P/NO REMARK
NO ASSY ENGLISH KOREA
1 1 HJCP07-01 HIGH PRESSURE REGULATOR 고압 레귤레이터
2 2 HJCP07-02 FITTING 니플 1/4"
3 1 HJCP07-03 FITTING SWIVEL 스위벨 1/4"
4 1 HJCP07-04 FITTING CLOGGING 메꾸라 1/4"
5 1 HJCP07-05 ELBO FITTING 90도 니플 1/4"
6 1 HJCP07-06 BLOCK 유압 블록
7 2 HJCP07-07 SAFETY VALVE 안전변 1/4"
8 2 HJCP07-08 FITTING CONNECT 양 연결 니플 1/4"
9 1 HJCP07-09 LINE CHECK VALVE(SUS) 라인체크밸브
10 1 HJCP07-10 AIR SOL VALVE 에어 솔밸브
11 1 HJCP07-11 FITTING 니플 1/4" X 3/8"
12 1 HJCP07-12 ELBO FITTING 90도 니플 1/4" X 3/8"
13 1 HJCP07-13 FITTING SWIVEL 스위벨 3/8"
14 1 HJCP07-14 THROTTLE CONTROL VALVE 유량 조정 밸브
15 1 HJCP07-15 FITTING 니플 3/8"
PANEL HJPN-CP01
ITEM LEVEL P/NAME
1 2 P/NO REMARK
NO ASSY ENGLISH KOREA
1 1 HJPN-CP01-01 R.P.M METER 회전 속도게이지
2 1 HJPN-CP01-02 WATER TEMP GAUGE 냉각수 온도 게이지
3 1 HJPN-CP01-03 OIL PRESSURE GAUGE 오일 압력 게이지
4 1 HJPN-CP01-04 BATT. VOLT GAUGE 배터리 볼트 게이지
5 1 HJPN-CP01-05 STARTER KEY ASS'Y 시동키 앗세이
6 1 HJPN-CP01-06 AIR GAUGE 에어 게이지
7 2 HJPN-CP01-07 OIL TEMP GAUGE 오일 온도 게이지
8 1 HJPN-CP01-08 FUEL GAUGE 연료 게이지

A 1 HJPN-CP01-09 ENGINE PANEL ASS'Y 엔진 판넬 조립품


B 1 HJPN-CP01-10 COMP PANEL ASS'Y 콤프 판넬 조립품
FUEL TANK HJFT-01
ITEM LEVEL P/NAME
1 2 P/NO REMARK
NO ASSY ENGLISH KOREA
1 1 HJFT-01 FUEL TANK 연료 탱크
2 1 HJFT-02 FUEL TANK COVER 연료 탱크 커버
3 1 HJFT-03 FUEL SECTION 오일 압력 게이지
4 1 HJFT-04 FUEL CAB 배터리 볼트 게이지
5 1 HJFT-05 FUEL STICK 연료봉
COMP COOLER HJCC 01
ITEM LEVEL P/NAME
1 2 P/NO REMARK
NO ASSY ENGLISH KOREA
1 1 HJCC01-01 COOLER BRACKET(UPPER) 쿨러 고정 브라켓(상)
2 1 HJCC01-02 COMP OIL COOLER 오일 쿨러
3 1 HJCC01-03 INTER COOLER 인터 쿨러
4 1 HJCC01-04 RADIATOR 라디에이터
5 1 HJCC01-05 COOLER BRACKET(LOW) 쿨러 고정 브라켓(하)
6 1 HJCC01-06 COOLER COVER 라디치마
7 4 HJCC01-07 COVER 라디치마 커버
8 1 HJCC01-08 LOW COVER 냉각수 드레인 커버
9 1 HJCC01-09 FAN FLANGE 팬 후렌지
10 2 HJCC01-10 SUB OIL COOLER 오일보조쿨러
11 2 HJCC01-11 SUB OIL COOLER COVER 쿨러 커버
FILTERS FILTERS / OIL-COMP(D6CE)

1 2 3

5 6 7
FILTER

NO NAME IDENTIFICATION REMARK


1 FUEL FILTER HYUNDAI #31945-84400
2 ENGINE OIL FILTER HYUNDAI #26320-84300
3 WATER SEPARATE FILTER HYUNDAI #31945-7L002
4 COMP.OIL SEPARATE FILTER IR 900
5 COMP. OIL RETURN FILTER 26300-7H000
6 AIR CLEANER FILTER(ENGINE,AIR END) 28130-8S500
7 AIR END OIL FILTER IR-36860336
8
9
10

OIL

NO NAME IDENTIFICATION REMARK


1 FUEL DIESEL
2 ENGINE OIL SAE 15W40, API CH-4/SJ, ACEA E2 EACH 250HOURS (FIRST 50HOURS)

3 HYDRAULIC PUMP OIL ISO VG 46 (Hyd. Oil) EACH 1000HOURS (FIRST 50HOURS)

4 ENGINE GEARBOX OIL SAE 80W 90 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