Transcript
‘Whatever It Takes’
Operator’s Manual Ultimate Drilling Machine (UDM) Part Number: 1801409 (800) 321-5336
www.diamondproducts.com
ULTIMATE DRILLING MACHINE OPERATING SUMMARY STARTING: The function switch at the rear control panel must be in the center START / DRIVE position and the MASTER DISCONNECT switch must be on. Be certain both red STOP switches are pulled out. The engine throttle, choke and start key are all at the rear of the engine. MOVING: The self‐propelled function only works with the function switch in the START / DRIVE position. Gently raise or lower the lever on the drive valve mounted at the upper right rear of the machine. To steer the unit, lift the rear tires off the ground and pivot to the proper direction. The machine may also be moved manually by lifting the rear tires off the ground and pushing or pulling. Be certain the rear legs and front mast are raised up for maximum ground clearance. HYDRAULIC OUTLETS: The function switch must be in the lower HYDRAULIC OUTLETS position. It is best to attach the hoses before switching to this function or with the unit off. Flow to the outlet is controlled by a cartridge at the top of the main hydraulic manifold. This cartridge should normally be left in the OFF position until flow is required. Due to internal pressure loss, the pressure at the rear pressure manifold (quick connects) will be less than that at the gauge on the main manifold. DRILLING: The labels at the front controls summarize the typical drilling operation. Please read them and review the following additional information. After positioning the drill, put the function switch in the upper DRILL position. This activates the controls at the front panel. Be certain the circuit breakers at the rear electric outlet panel are on as AC power is needed for the vacuum pump.
The DRILL DOWN, DRILL UP, and TURBO switches are intermittent and must be held to operate. Holding UP or DOWN and TURBO will raise and lower the drill more rapidly for initial positioning or pulling a bit out of a hole. To adjust the speed of cylinder stroke hold the up or down switch and turn the small black knob at the top right of the main hydraulic manifold. This is also the maximum speed the drill can move while in the AUTO DRILL mode and should be set slow. With the drill set to the proper RPM, gently jog the DOWN switch to slowly start the hole. Once contact is made, switch to AUTO DRILL. Drilling will continue until the cylinder strokes to its maximum length or until the AUTO DRILL switch is turned off. The DRILL DOWN, DRILL UP, and TURBO switches will not operate when in the AUTO DRILL mode. TWO SPEED DRILL MOTOR: Set to high speed for drills up to 10” Diameter (Shift Clockwise) and low speed for drills greater than 10” (Shift Counter Clockwise). COUNTERWEIGHT: For smaller bits it should be removed and stored or mounted at the front frame position. The rear position is recommended for 16” bits and larger when the machine becomes front heavy.
IMPORTANT! A red emergency stop button is at the rear and side control panels. This will stop the engine and shut down all hydraulic and electric circuits. These buttons must be in the out position to start the engine
Table of Contents Safety Precautions .......................................................... 1 Safety Alerts................................................................ 1 Proposition 65 (California) .......................................... 1 Spark Arrester Requirement ....................................... 1 Respiratory Hazards ................................................... 1 General Safety ............................................................ 2 Battery and Electrical Safety....................................... 2 Drill Safety................................................................... 3 Fuel Safety .................................................................. 3 Engine Safety.............................................................. 3 Hydraulic Safety .......................................................... 3 Belt Safety................................................................... 4 Transporting Safety..................................................... 4 Lifting Safety ............................................................... 4 Introducing the UDM ....................................................... 5 Components................................................................ 5 Controls....................................................................... 6 Rear Control Panel ................................................. 6 Front Control Panel ................................................ 7 Dimensions ................................................................. 8 Specifications .............................................................. 9 Operating the UDM ....................................................... 10 Handlebars................................................................ 10 Adjusting and/or Moving the Handlebars ............. 10 Light Tower ............................................................... 10 Adjusting the Light Tower ..................................... 10 Counterweight ........................................................... 10 Lift Points .................................................................. 11 Fuel System .............................................................. 11 Fueling the Machine ............................................. 11 Fuel Shutoff Valve ................................................ 11 Adding Hydraulic Oil ............................................. 11 Master Battery Disconnect ................................... 11 Engine ....................................................................... 12 Starting the Engine ............................................... 12 Stopping the Engine ............................................. 12 Drive Mode................................................................ 12 Electrical Outlets and Circuit Breakers ..................... 13 Electric Switches ....................................................... 13 Hydraulic Outlet Mode .............................................. 13 Pressure .................................................................. 13 Hoses. ....................................................................... 14 Water System ........................................................... 14 Filling the Water Tank........................................... 14 Using the Water Supply ........................................ 14 Draining the system .............................................. 14 Vacuum System ........................................................ 15 Using the Vacuum ................................................ 15 Vacuum Gauge..................................................... 15 Drill Mode .................................................................. 15 Cylinder Pressure ................................................ 15 Cylinder Speed ..................................................... 16 Drill Motor Pressure .............................................. 16 Counterbalance Valve .......................................... 16 Raising and Lowering the Drill .............................. 16 Raising and Lowering the Frame and Mast ......... 16
Diamond Core Bits ................................................... 17 Inspecting the Core Bit ......................................... 17 Core Bit Speeds ................................................... 17 Installing a Core Bit .............................................. 17 Removing a Core Bit ............................................ 17 Helpful Hints Prior to Drilling ................................ 18 Tasks Prior to Drilling ........................................... 18 Drilling a Hole ....................................................... 18 Continuing a Partial-Hole ..................................... 18 Stuck Cores .............................................................. 18 Removing a Stuck Core ....................................... 18 Stuck Bits .................................................................. 19 Removing a Stuck Bit ........................................... 19 Maintaining the UDM .................................................... 20 Maintenance Overview ............................................. 20 Daily/Regularly ..................................................... 20 Part Lubrication ........................................................ 20 Hydraulic Pillow Block .......................................... 20 Rear Axle.............................................................. 20 Tires .......................................................................... 20 Replacing the Front Tires ..................................... 20 Replacing the Rear Tires ..................................... 21 Battery ...................................................................... 21 Battery Type ......................................................... 21 Servicing the Battery ............................................ 21 Electrical System ...................................................... 21 Fuse Panel ........................................................... 21 Circuit Breakers .................................................... 22 Hydraulic System...................................................... 22 Changing the Hydraulic Oil .................................. 22 Changing the Hydraulic Oil Filter ......................... 22 Belt System .............................................................. 22 Tensioning the Belt .............................................. 23 Replacing the Belt ................................................ 23 Roller Carriage ......................................................... 23 Disconnecting the Carriage .................................. 24 Adjusting the Shims ............................................. 24 Adjusting Rear Rollers/disconnected carriage: .... 24 To Connect the Carriage: ..................................... 24 Adjusting Rear Rollers on a connected carriage:. 24 Replacing the Rollers ........................................... 24 Engine ...................................................................... 25 Engine Throttle Screw .......................................... 25 Cleaning the Engine ............................................. 25 Storing ...................................................................... 25 Disposal .................................................................... 25 References.................................................................... 27 Appendix A ............................................................... 27 Serial Tags ........................................................... 27 Appendix B ............................................................... 28 Daily Maintenance Task Chart ............................. 28 Appendix C ............................................................... 29 Belt Tension Setting ............................................. 29 Appendix D ............................................................... 30 Troubleshooting ................................................... 30 Appendix E ............................................................... 31 Additional Resources ........................................... 31
Safety Precautions Operate the Ultimate Drilling Machine (UDM) and all of its components according to this manual. Failure to comply with and understand the following safety, operations, and maintenance instructions can result in serious injuries and/or death. All operators must be properly trained or supervised by experienced personnel prior to using the machine and should understand the risks and hazards involved. Improper or unintended machine usage is discouraged and Diamond Products cannot be held liable for damages.
Proposition 65 (California) WARNING Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and/or other reproductive harm.
Spark Arrester Requirement Machine modifications should be made by Diamond Products to ensure safety and design. Any modifications made by the owner(s) are not the responsibility of Diamond Products and void all warranties if a problem arises as a result of the modification. Refer to the UDM Parts List for additional information and part diagrams. Refer to the engine manual and manufacturer as the primary source for all safety, operations, and maintenance instructions regarding the engine. Prior to operating, record the machine’s serial number, and the engine’s model and serial numbers in Appendix A. Notice: The information in this manual may be updated at any time!
Safety Alerts DANGER Serious injuries and/or death will occur if these instructions are not followed.
WARNING Serious injuries and/or death could occur if these instructions are not followed.
CAUTION Mild and/or moderate injuries could occur if these instructions are not followed.
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WARNING In the State of California it is a violation of Section 4442 or 4443 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester, as defined in Section 4442, maintained in effective, working order or the engine is constructed, equipped, and maintained for the prevention of fire pursuant to Section 4443.
Respiratory Hazards WARNING Concrete drilling produces dust and fumes known to cause illness, death, cancer, respiratory disease, birth defects, and/or other reproductive harm. Safety protection techniques include, but are not limited to:
Wearing gloves. Wearing safety goggles or a face shield. Using approved respirators. Washing work clothes daily. Using water when wet cutting to minimize dust. Washing the hands and face prior to eating/drinking.
For additional safety and self-protection information, contact your employer, the Occupational Safety and Health Administration (OSHA), and/or The National Institute for Occupational Safety and Health (NIOSH).
General Safety
Read and understand all safety, operations, and maintenance instructions provided in this manual prior to operating or servicing the machine. Keep the machine clean and free of slurry, concrete dust, and debris. Inspect water hoses prior to operating the machine. Clean, repair, or replace damaged components. Repair the machine immediately if a problem arises. Replace machine decals if unreadable. Dispose of all hazardous waste materials according to city, state, and federal regulations. Always have a phone nearby, and locate the nearest fire extinguisher and first aid kit prior to operating the machine. Persons under the statutory age limit should not operate the machine. Operate the machine wearing flame resistant clothing. Always let the machine cool after operating to prevent serious burns. Replace all guards and access panels prior to operating the machine. DO NOT operate the machine around combustible materials or fumes to prevent fires/explosions. Fit blocks/jacks under the frame edges at the front and back of the frame for support when working under the machine. All non-routine maintenance tasks should be performed by an authorized service center.
DO NOT:
Drop equipment, supplies, tools, etc., when handling to prevent injuries. Lift and carry equipment, supplies, tools, etc., that are too heavy.
Operate the machine without using the appropriate safety equipment required for the work task.
Operate or service the machine with clothing, hair, or accessories that can snag in the machinery. Operate the machine using attachments not associated with or recommended for the machine. Operate the machine with anyone near the work area. Operate the machine until the work area has been cleared. Operate the machine with loose nuts, screws, and bolts. Operate the machine when ill or fatigued.
DO NOT (cont.): Operate the machine under the influence of drugs and/or alcohol. Operate the machine on steep slopes. Operate the machine with guards and access panels removed. Grease/lubricate the machine with the engine running unless stated otherwise. Touch hot components when operating the machine, or until the machine cools down. Leave the machine unattended until the engine is off. Place the machine into storage until it cools down. Service the machine until it cools down. Service the machine with the engine running unless stated otherwise.
Battery and Electrical Safety
Ignitable explosive gases are emitted from the battery. DO NOT expose the battery to sparks or open flames.
Keep the area around the battery well-ventilated. Keep the battery level when handling it. Use protective eyewear or a face shield and avoid contact with the skin when handling/servicing the battery. Use a proper battery tester when testing the battery strength. Always connect the battery cables to the proper terminal to ensure safety. Regularly inspect the battery, cables, clamps, and terminals for damages. Clean, replace, tighten, and grease components as necessary. Always keep the battery cable clamps away from the battery terminals when the battery is disconnected to avoid accidental connections. Immediately rinse your clothing, skin, or eyes with water if exposed to battery acid. Seek medical attention immediately! Turn off the master battery disconnect when servicing the machine. Disconnect the battery prior to servicing the machine unless stated otherwise. Remove the battery when storing the machine for longer periods. Disconnect external equipment connected through the electrical outlets prior to servicing the machine. Do not plug external equipment into the electrical outlets that requires more power than the outlets are rated for. Always use the correct size fuses (amps) .
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Disconnect the battery prior to servicing the electrical system unless stated otherwise. DO NOT use the electrical outlets for equipment that requires more power than the outlets are rated for.
When parking the machine on a slope, lower the rear legs and front mast or chock the tires to prevent rolling.
Fuel Safety Drill Safety
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Inspect all core bits prior to usage and discard damaged bits. Keep all body parts away from rotating core bits. Always use an appropriate size bit for the drilling task. The bit must fit tightly on the spindle shaft. Wear gloves and be alert to the surrounding environment when handling core bits. Always use the correct bit type for the material being drilled. Always start the engine with the function switch at Start/Drive. DO NOT exceed the core bit’s maximum recommended speed when drilling. DO NOT use damaged core bits when drilling to avoid harming yourself, others, or the machine. DO NOT activate the spindle shaft when installing a core bit by hand to avoid entanglement. Failure to properly secure the core bit to the spindle shaft may cause the bit to loosen or fall off the machine. Raise the core bit/pillow block assembly to a sufficient height when maneuvering the machine to provide proper clearance between the bit/spindle shaft and the ground. Remove all body parts from under the core bit when releasing the bit from the spindle shaft. DO NOT stand on the machine to act as an anchor. Use the vacuum pump to anchor the machine. Always make sure the mast is firmly touching the ground prior to drilling. Install the counterweight when using core bits 16” or larger to prevent front-end tipping. The work area should not contain buried or embedded electrical, gas, or water lines. Use extreme caution when drilling through floors. Another trained worker must clear the surrounding area on the lower floor prior to drilling in case the core falls to the lower floor. DO NOT allow any person, animal, or object in and around the work area when drilling. Use extreme caution when operating the machine on slopes, as it is more susceptible to sideways tipping/rolling over, especially with a full water tank. When driving the machine be alert to the surrounding environment to avoid harming yourself, others, or the machine.
Store all fuel in appropriate safety containers. DO NOT operate the machine with a fuel leak. DO NOT fuel the machine with the engine running. Let the engine cool prior to adding fuel. Refer to the engine manual for recommended fuels.
DO NOT smoke or expose fuel to open flames when filling the fuel tank or working with fuel.
Clean up spilled fuel prior to starting the engine. Move the machine away from the fueling area prior to starting the engine. Drain the fuel tank and fuel lines for longer storage periods. Refer to the engine manual for additional information.
Engine Safety
Refer to the engine manual as the primary source for engine safety. Always know how to turn off the engine for emergency purposes. DO NOT leave the engine running unattended.
Keep all body parts away from rotating machine parts with the engine running.
Always operate the machine in wellventilated areas. Concentrated engine exhaust can cause loss of consciousness and/or death.
Wipe down the engine’s exterior and oil cooler daily/regularly to prevent high operating temperatures. DO NOT spray the engine with water to prevent engine damage. DO NOT touch the engine/muffler assembly with the engine running, and always let the parts cool down prior to touching them or servicing the machine. Handle hot oil carefully when changing the oil.
Hydraulic Safety
Turn off the engine prior to servicing the hydraulic system. Turn off the engine prior to disconnecting hydraulic hoses. Pay attention to the hydraulic oil thermometer. The maximum recommended oil temperature is 180°F. Remove the core bit to reduce residual pressure in the cylinder circuit prior to servicing the machine.
DO NOT use external hydraulic equipment that requires a higher flow rate than what the machine is rated for. Always use a piece of cardboard or paper to check for hydraulic fluid leaks. Keep all body parts away from leaks and/or areas that may eject hydraulic fluid. Pressurized hydraulic fluid can penetrate the skin, causing serious injuries. Seek medical attention immediately!
Lifting Safety
Move yourself and all others away from the lifting area when hoisting the machine to prevent being crushed underneath.
Secure the appropriate hoisting cables, straps, and/or chains to the machine’s designated lift points on the frame prior to hoisting it. DO NOT attempt to lift the machine irresponsibly and/or improperly.
Belt Safety
Turn off the engine prior to servicing the belts. Let the belt cool down prior to servicing it. Regularly inspect the belt for fraying, stress cracks, and/or breakage and replace immediately when damaged. Over-tensioning the belt may damage the engine crankshaft. Under-tensioning the belt may cause slippage, shorter belt life, and poor generator performance. Make sure the belt is prior to operating the machine.
Transporting Safety
Close the fuel shutoff valve when transporting the machine. Drain the fuel tank when transporting the machine long distances. Use heavy-duty ramps that will support the weight of the machine and yourself when loading or unloading. The towing truck/trailer should be in good working condition. Avoid standing directly downhill of the machine when driving it up or down slopes or ramps. Always stand on the side of the machine or drive it forward down ramps and reverse up ramps. Never run the machine in reverse, downhill, directly toward yourself! Turn off the engine once the machine is loaded into the truck/trailer. Chock the wheels and secure the machine in the truck/trailer prior to transporting. Refer to the Department of Transportation (DOT) for additional information on proper transportation techniques and truck/trailer requirements.
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Introducing the UDM Components The UDM is a self-contained, self-propelled drilling machine with electric and hydraulic power outlets.
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5 24
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2 23
17 15
22 14
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18 12
21 13
11 7
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8 9 20
Figure 1: UDM Components
1. Handlebar 2. Handlebar Lock Pin/Knob 3. Water Tank 4. Front Control Panel 5. Light Tower 6. Heat Exchanger 7. Frame 8. Generator 9. Drill Base 10. Mast 11. Hydraulic Oil Tank 12. Main Hydraulic Manifold 13. Spindle Shaft
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14. Pillow Block 15. Roller Carriage 16. Hydraulic Cylinder 17. Rear Control Panel and DC Fuses 18. Engine 19. Front Tires 20. Vacuum Base 21. Rear Tires 22. Hydraulic Outlets 23. Drive Lever 24. Electrical Outlets and Circuit Breakers
Controls Rear Control Panel 2
3
4
1
5
6
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Figure 2: Rear Control Panel
1. Engine Tachometer/Hour Meter–Indicates engine rpm, total machine hours operated. 2. Strobe Switch–Turns strobe light on or off. 3. Spot Switch–Turns spotlight on or off. 4. Function Switch–Three position switch. Up is Drill mode, center is Start/Drive mode, down is Hydraulic Outlets mode. Make sure switch is at Start/Drive when starting engine.
5. Master Battery Disconnect–Connects or disconnects battery circuit. Note: Always disconnect when finished operating the machine. 6. Emergency Stop Button–Stops engine, hydraulic outlets, electrical outlets, and radiator. 7. Indicator Light–Indicates power when master battery disconnect activated.
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Front Control Panel 1
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2 4 3
16 5 6 17
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18 19 20
10 21
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Figure 3: Front Control Panel
1. Drill Up Pushbutton–Raises core bit. 2. Drill Down Pushbutton–Lowers core bit. 3. Turbo Pushbutton–Raises or lowers core bit
11. 3000 Psi Pressure Gauge–Indicates drive
at maximum speed. Turbo must be pressed while holding Drill Down or Drill Up to indicate direction. Turbo does not function in Auto Drill mode. 4. Auto Drill Switch–Locks the drill down function until cylinder reaches maximum length, or until switch is turned off. Drill Down, Drill Up, and Turbo do not work when this switch is activated. 5. Rear Lift Switch–Raises and lowers rear legs and tires. 6. Front Lift Switch–Raises and lowers front legs and tires. 7. Vacuum Switch–Turns vacuum pump on or off. 8. Water Switch–Turns water pump on or off. 9. Digital Readout–Indicates bit rpm. 10. Emergency Stop Button– Stops engine, hydraulic outlets, electrical outlets, and radiator.
core bit rpm. 13. Hydraulic Outlet Flow Cartridge–Increases or decreases flow to hydraulic outlets. 14. Cylinder Speed Knob–Increases or decreases core bit’s maximum raise and lower speed. 15. 500 Psi Pressure Gauge–Indicates cylinder pressure when drilling. 16. Cylinder Pressure Base End Valve–Adjusts the cylinder pressure. See operation section! 17. Main Relief Valve–Increases or decreases the system pressure. See operation section! 18. Vacuum Gauge–Indicates vacuum pressure. 19. Vacuum Valve–Holds or releases vacuum. 20. Water Valve–Starts and stops water flow. 21. Water Flow Valve–Set water flow to bit at desired level.
motor, drill motor or hydraulic outlet pressure.
12. Drill Rpm Cartridge–Increases or decreases
Dimensions
Figure 4: UDM Dimensions
Table 1: UDM Dimensions
A B C D E
Drill Height to Light Tower Drill Height to Hydraulic Cylinder Drill Length (Handlebars Out) Drill Length (Handlebars In) Drill Width
87.7” 86.1” 102" 77.4” 31”
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Specifications Table 2: UDM Specifications Core Bit Diameter Spindle Shaft Thread Belt Drive Core Bit Coolant Handlebars Drive Speed Electrical Power Electrical Outlets Hydraulic Power Supply Hydraulic Power Flow Control Hydraulic Quick Disconnects Fuel Capacity Water Tank Capacity Hydraulic Tank Capacity Engine Tachometer/Hour Meter Core Bit Rpm Tachometer Spotlight Strobe Light Uncrated Dry Weight
4”-24” 1-1/4-7” One belt Water Two-position, variable length 3.25 mph maximum 5,000 Watts 115V and 230V single-phase twist locks, 115V ground fault interrupt 2,000 psi maximum 14 gpm maximum 1/2” and 3/4” Nine gallons 44 gallons 12 gallons Standard Standard Standard Standard 1,100 lb (add 450 lb with water, oil, and fuel; add 50 lb for counterweight)
Table 3: Engine Specifications Manufacturer Model Fuel Type Air Filter Low Oil Alert Electric Start
Honda GX670 Unleaded gasoline Dual element Standard Standard
Note: Refer to the engine manual for additional engine specifications.
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Operating the UDM Handlebars The handlebars are held in position by a lock knob or pin, and may be used in an upper or lower position. When in the upper position, they may be slid into the frame when not in use. The lower position allows better leverage for lifting and steering if desired.
Figure 6: Light Tower and Lock Pin Figure 5: Handlebars in Upper Position
Counterweight Adjusting and/or Moving the Handlebars
1. Remove the handlebar lock pin or loosen the lock knob.
2. Slide the handlebar shaft out of the frame and into the second handlebar position (as desired).
3. Slide the handlebar forward or backward to adjust the position. 4. Replace the handlebar lock pin or tighten the lock knob to secure.
Light Tower Use the strobe light to alert others when operating the machine. Use the spotlight for additional lighting as necessary.
Figure 7: Counterweight at rear.
Adjusting the Light Tower
1. Remove the lock pin from the light tower. 2. Move the tower up or down to place the second tower hole just above the tower support tube. 3. Insert the lock pin into the light tower hole to secure. IMPORTANT! A red emergency stop button is at the rear and side control panels. This will stop the engine and shut down all hydraulic and electric circuits. These buttons must be in the out position to start the engine
The counterweight can be mounted at the rear of the machine on the lower handlebar supports. It is held in this position with one bolt on each end. This position is recommended when using bits 16” diameter and larger as they make the machine front heavy. For bits under 16”, the counterweight should be removed and stored or it can be hung vertically at the front end of the machine by resting the legs on the top rail of the frame and using a single bolt at the top end as in figure 8.
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Fuel System
Figure 8: Hanging Counterweight
Lift Points Three lifting points are on the frame. Welded loops are on each side at the rear of the machine, and there is one shackle at the top of the front column. Secure the lifting cables, straps, and/or chains to these three points and adjust them so the overall lift point is near the front axle. Note: The empty center of gravity is just behind the front axle. This location will shift toward the rear slightly with a full water tank.
WARNING DO NOT operate the machine with a fuel leak. DO NOT fuel the machine with the engine running. DO NOT smoke or expose fuel to open flames when filling the fuel tank or working with fuel.
CAUTION Clean up spilled fuel prior to starting the engine.
Fueling the Machine
1. Turn off the engine and let the machine cool down. 2. Remove the fuel tank cap. 3. Fill the fuel tank with unleaded gasoline as necessary. Refer to the engine manual for fuel ratings and additional refueling information. 4. Replace the fuel tank cap. Fuel Shutoff Valve A fuel valve is located directly below the gas tank.
Adding Hydraulic Oil 1. Turn off the engine. 2. Remove the fill port cap at the front of the tank. 3. Fill to the sight port. Do not overfill as oil expands when hot 4. Replace the cap Monitor the hydraulic oil thermometer. The maximum recommended oil temperature is 180°F.
Master Battery Disconnect The master battery disconnect, at the rear panel, completes the battery’s circuit. When off, it eliminates slow battery discharge. The strobe light, spotlight, water pump, and raise/lower cylinders will operate with the engine off and master battery disconnect on. Be careful not to drain the battery when using these items with the engine off . The master battery disconnect must be on to start the engine. Figure 9: Lifting Machine
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Figure 10: Master Battery Disconnect
Figure 11: Engine Switch
8. Gradually open the choke as the engine warms up. 9. Increase the throttle on the engine to maximum. Engine
WARNING DO NOT leave the engine running unattended. Operate the machine in wellventilated areas. Concentrated engine exhaust can cause loss of consciousness and/or death.
Refer to the engine manual as the primary source for information regarding the engine.
Stopping the Engine
CAUTION DO NOT leave the machine unattended until the engine is off.
1. Turn off all switches/controls. 2. Decrease the throttle to Minimum. 3. Turn the ignition key to Off and remove the key.
Starting the Engine
1. 2. 3. 4.
Open the fuel shutoff valve below the gas tank. Pull out the emergency stop buttons. Move the function switch to Start/Drive. Close the choke at the rear of the engine (not required on warm engine). 5. Turn on the master battery disconnect. 6. Set the throttle to about 1/3. 7. Insert the ignition key, turn to Start, and release when the engine starts. If the engine doesn’t start, release the key and try again after 10 seconds. Note: Refer to the engine manual if the engine doesn’t start after several attempts.
Drive Mode
WARNING When driving the machine forward or backward, be alert to the surrounding environment to avoid harming yourself, others, or the machine.
The drive lever (Figure 12) moves the machine at variable speeds based on its position. The lever automatically returns to the center stop position when released. The maximum speed is ~3.25 mph. The unit may be moved manually by lifting the rear tires off the ground and pushing or pulling to the desired location
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Figure 12: Drive Lever
1. Move the function switch to Start/Drive. 2. Push the drive lever down to move the machine
Figure 13: Electrical Outlets and Circuit Breakers
forward.
3. Pull the drive lever up to move the machine in reverse. 4. Steer the unit by lifting the rear tires off the ground and pivoting to the desired direction.
Hydraulic Outlet Mode
WARNING Use extreme caution when operating the machine on slopes, as it is more susceptible to sideways tipping/rolling over, especially with a full water tank.
Electrical Outlets and Circuit Breakers
WARNING DO NOT use the electrical outlets for external equipment that requires more power than the outlets are rated for.
The electrical outlets are powered by a 5000 Watt generator when the engine is running. The outlets are single phase 115 and 230 Volt twist locks and a 115 volt GFI (ground fault interrupt). The circuit breakers provide system protection and can be left on at all times.
Electric Switches The STROBE light, SPOT light, WATER PUMP, REAR and FRONT raise/lower electric cylinders are all12 volt DC and will operate with the engine off and the Master Disconnect ON (Figures 2 and 3). Take care not to run down the battery if the engine is not running. The engine must be running for all other switches to operate
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Figure 14: Hydraulic Outlets
Flow is controlled by a cartridge at the top of the Main hydraulic manifold (Figure 3). This cartridge should normally be left in the OFF position until flow is required. Pressure: The Main Relief valve is typically set to 2100 psi on the front 3000 psi pressure gauge (Pressure higher than 2100 psi will stall the engine). Lower pressures may be set if required for a particular tool. To Adjust Pressure 1) The unit must be in the hydraulic outlet mode with no hoses attached. This will force the system pressure to maximum. 2) Move the flow control cartridge away from zero.
3) The pressure can now be adjusted by turning the knob on the main relief cartridge (Fig. 3) Note: Due to internal pressure loss, the pressure gauge located at the rear hydraulic outlets will show less pressure than the gauge at the main hydraulic manifold. Attaching External Tool: It is best to attach the external hoses to the UDM before switching to the hydraulic outlet function or with the unit off as even very low residual internal pressure can make attaching hoses difficult. Be certain connections are clean! WHEN FINISHED 1. Turn off the hydraulic tool or the flow adjuster on the tool. 2. Turn the flow cartridge off. 3. Move the function switch to Start/Drive. 4. Disconnect the external hoses. 5. Turn off the engine.
Figure 15: Water Tank
Filling the Water Tank Fill the water tank as required. The clear hose at the rear of the tank shows the water level. Left and right fill ports are provided for convenience. Using the Water Supply
Hoses: Large diameters and short lengths are preferred and offer the highest system efficiency. If one is operating 50 ft (15.2M) from the power source, there is also a 50 ft (15.2M) return for a 100 ft (35.5M) total hose length. With 12 GPM and oil at 100 deg. F (37.8C), this could result in a 300 psi (20.6 Bar) pressure loss with ½” hose and a 100 psi (6.9 Bar) loss with 5/8” hose. Pressure loss will change dramatically with oil temperature.
1. Open the supply valve directly under the tank center (Not the large drain valve, near the side of the tank). 2. The master disconnect switch must be on. 3. Turn on the water switch at the front panel. The spray hose will now function. For drilling
4. Open the manual valve mounted in the front control panel (Figure 3).
5. Adjust the adjacent ball valve to increase or
WARNING Keep all body parts away from areas that may eject hydraulic fluid. Pressurized hydraulic fluid can penetrate the skin, causing serious injuries. Seek medical attention immediately!
Water System The water system consists of the stainless water tank, a 12 volt DC water pump and various hoses, fittings and valves. The primary purpose is to cool the core bit and flush slurry from the hole. Note: Always test the water supply for adequate pressure and flow prior to drilling.
decrease flow to the bit. This valve may be left in this position. 6. After drilling, shut off the manual valve. 7. Turn off the Water switch. NOTE: Too much water makes the slurry look clear and wastes water. Insufficient water makes the slurry thick and pasty and could result in a core sticking in the bit. Draining the system 1. Be certain the area is safe for dumping water. 2. Open the large valve below the water tank and accessible through the side cover plate. 3. Repeat steps 1-7 to drain water from the drill circuit and spray hose (if required). 4. For complete drainage, remove hoses from the water pump. Sliding tabs at the pump ports will quickly release the hoses. Complete drainage is only required if freezing may occur or for long term storage.
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NOTE: Poor vacuum may indicate loose hose fittings, loose water trap jar, worn vacuum base seal, or the base may be on a cracked or scored surface where vacuum is not possible. Water Jars These jars are mounted adjacent to the vacuum pump and help keep water and other contaminants from being sucked into the pump. Visually inspect and empty these jars on a regular basis. The jars unscrew by hand. Failure to empty these two jars will result in vacuum pump damage. Figure 16: Water Release Valve
Vacuum System
WARNING DO NOT stand on the machine to act as an anchor.
The vacuum system is only used during the drilling operation when the base is firmly on the ground. It adds stability to the system and should be used whenever possible. Cleaning and wetting the surface with the garden hose helps create a good seal.
Figure 18: Water Jars
Drill Mode Introduction and Initial Settings: The following items can only be used or adjusted with the function switch in drill mode. The recommended pressure settings are maximum limits. They will typically only be reached intermittently if rebar or hard spots are encountered while drilling.
Figure 17: Vacuum Base
Using the Vacuum
1. 2. 3. 4.
Turn on the circuit breakers as 115V is required. Close the vacuum valve at the front panel (Fig. 3). Turn on the Vacuum switch. To release the vacuum, open the valve and turn off the Vacuum switch.
Vacuum Gauge The vacuum gauge indicates that the vacuum system is working. Vacuum pressure should range up to ~25” Hg.
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Cylinder Pressure The pressure at the base end (top) of the cylinder controls how hard the bit is pushed into the ground. This is limited so the machine can provide sufficient down force yet never lift itself of the ground. The pressure is monitored on the 500 psi gage at the front of the main manifold (Figure 3). This pressure is adjustable with an Allen wrench at the relief cartridge at the front of the main manifold. It is factory set to 200 psi and should rarely need adjustment.
1. The unit must be in the drill mode. 2. Set the drill RPM to zero. 3. Fully extend the cylinder without contact or push against the ground (drill down switch) as if trying to lift the machine off the ground. This will force the cylinder pressure to maximum.
4. The pressure cartridge can now be adjusted with an Allen wrench while holding the drill down switch. 5. Retract the cylinder with the drill up switch. NOTE: Use caution and judgment if increasing the pressure beyond 200 psi as the machine may drill faster, but the possibility of jammed bits increases. If drilling without vacuum, do not exceed 200 psi. Cylinder Speed While holding the drill down switch, turn the small black knob at the top right of the main hydraulic manifold (Figure 3). This sets the maximum speed the drill can move (unless in turbo mode) and should be set to the slow end of adjustment. Slow speed is particularly important at initial drill to ground contact. This setting should rarely need adjustment. Drill Motor Pressure This pressure generates the torque to spin the bit. It is controlled by the main relief cartridge at the front of the manifold and is monitored by the 3000 psi gage. This pressure should be set above 1500 psi for drilling and it is adjusted exactly as if setting hydraulic outlet pressure. Setting it below 1500 psi could result in stalling the drill motor. It can typically be left at 2100 psi at all times. 1. The unit must be in the hydraulic outlet mode with no hoses attached to set this pressure. This will force the system pressure to maximum. 2. The pressure can now be adjusted by turning the knob on the main relief cartridge (Figure 3). 3. Switch out of the Hydraulic Outlet mode. Drill Motor Pressure Switch A non-adjustable pressure switch monitors the drill motor pressure and will automatically shift the cylinder to neutral (stops pushing) if it senses the drill motor pressure rising above 1500 psi (hard spots). The cylinder will thus automatically cycle on/off as the drill works through rebar or other hard spots. Counterbalance Valve A counterbalance valve is in the cylinder circuit to hydraulically lock the cylinder in position when the machine is off. This prevents the weight of larger core bits from slowly extending the cylinder. If the counterbalance valve is not properly adjusted it may try to lock the cylinder during normal operation, resulting in a rapid on/off cycle as the cylinder extends. If this occurs, screw out (clockwise) the adjustment on the bottom of the counterbalance valve until a smooth cylinder motion is achieved. This adjustment is factory set and should not normally need attention.
Figure 16: Counterbalance Adjustment
Raising and Lowering the Drill The DRILL DOWN, DRILL UP, and TURBO switches are intermittent and must be held to operate. Holding UP or DOWN and TURBO will raise and lower the drill more rapidly for initial positioning or quickly pulling a bit out of a hole. These switches will not work when in the AUTO DRILL mode. Raising and Lowering the Frame and Mast To establish a more solid base, the pneumatic tires are raised off the ground. This same action places the vacuum base firmly on the ground. Electric cylinders at the front and rear of the machine are controlled by intermittent switches at the front control panel (Figure 3). The frame should be raised until the front and rear tires just clear or barely touch the ground. Independently adjusting the front or rear control allows slight leveling of the machine.
WARNING
DO NOT exceed the core bit’s maximum recommended speed when drilling.
DO NOT use damaged core bits when drilling to avoid harming yourself, others, or the machine.
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Diamond Core Bits Using the proper core bit (size and type) preserves the bit and improves drilling and operator efficiency, resulting in lower costs. Refer to www.diamondproducts.com for additional drilling and core bit information. Inspecting the Core Bit Inspect each core bit prior to installation and discard all damaged bits. Inspect all core bits for:
Cracks, nicks, and dents on barrel Darkness and/or discoloration near edge of bit Uneven wear Missing segments Bent segments Segment cracks
a) Place the bit under the spindle shaft and align it with the shaft threads. b) Start the engine. c) Set the Drill Rpm very slow. d) Set the Cyl Speed knob to a very slow speed. e) Press the Drill Down button to slowly lower the spindle shaft until the threads are engaged with the hub. CAUTION: Proper hub and shaft alignment is critical to avoid cross threading. Stop immediately and readjust the bit if the shaft and hub are not aligned when installing the bit. When aligned, the shaft will screw itself into the hub and lift the bit off the ground. If required, apply light resistance to the bit to prevent spinning, which will allow the shaft to screw itself completely into the bit. f) Set drill RPM to zero. 5. Raise the core bit to provide clearance between the bit and the ground.
Core Bit Speeds Refer to the chart on the machine for the recommended core bit speeds when drilling. DO NOT exceed the maximum recommended drilling speed.
Installing a Core Bit
WARNING Be extremely careful when installing a core bit by hand with the spindle shaft rotating. Avoid entanglement! Failure to properly secure the core bit to the spindle shaft may cause the bit to loosen or fall off the machine. Figure 20: Core Bit Attached
CAUTION Wear gloves and be alert to the surrounding environment when handling core bits. Install the counterweight at the rear of the unit when using core bits 16” or larger to prevent front-end tipping.
1. Select the correct core bit size and type for the drilling task. 2. Raise the spindle shaft to provide room to install the core bit. 3. For smaller core bits: Hold the bit with both hands and screw it onto the spindle shaft until it bottoms out on the shaft. Make sure the bit is secure (the bit will tighten further once it enters the concrete). 4. For larger core bits:
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Removing a Core Bit
CAUTION Move all body parts away from the core bit when releasing the bit from the spindle shaft.
1. Lower the core bit very close to the ground. 2. Grasp the flats near the top of the spindle using the wrench provided. Hold the wrench in place to stabilize the spindle shaft and use another appropriate tool to grasp the core bit hub. 3. Turn the tool clockwise, as viewed from above, to loosen the core bit.
4. When the bit is near the end of the threads. A. Remove smaller bits by hand. B. Allow larger bits to release and fall to the ground. Keep the bit close to the ground to minimize impact and help prevent segment damage. Dropping the bit onto wood or other soft surfaces will further reduce impact.
WARNING
Lowering the bit too quickly into the concrete surface can cause bit breakage, resulting in serious injuries and/or death.
Use extreme caution when drilling through floors. Another trained worker must clear the surrounding area on the lower floor prior to drilling in case the core falls to the lower floor.
Helpful Hints Prior to Drilling Keep the following in mind for better efficiency while drilling:
Avoid drilling excessively deep to preserve the core bit and reduce costs. For proper vacuum, make sure the drilling surface is clean and solid (no cracks, dents, etc.). Wetting the surface can help the vacuum seal. Use a proper water flow to prevent damaged and stuck bits. Using too much water when drilling will make the slurry look clear. Not using enough water will make the slurry look thick and pasty.
6. Adjust the Drill Rpm based on the bit size. Refer to the chart on the machine for the recommended core bit speeds. DO NOT exceed the maximum recommended RPM. 7. Turn on the Water switch. 8. Open the water valve and adjust the water flow valve to increase or decrease the water flow. 9. Use the Drill Down button and Turbo to lower the bit close to the ground. Using only the Drill Down button, gently jog the bit to start the hole. Once ground contact is made, release the Drill Down button and turn the Auto Drill switch to On/Drill. The bit will continue drilling until the cylinder fully extends or until Auto Drill is turned off. 10. At the required depth, turn off the Auto Drill switch. 11. Press the Drill Up button to raise the bit out of the hole. Pressing the Turbo and Drill Up buttons together will raise the bit quickly. 12. Set RPM to zero. 13. Turn off the water valve and Water switch. 14. If used, turn off the Vacuum switch and open the vacuum valve to release the vacuum. 15. Lower all tires to the ground. Raise the mast and rear legs fully up for maximum ground clearance. 16. Move the function switch to Start/Drive. Continuing a Partial-Hole
1. Inspect the drill hole and remove, if possible, items that may cause the bit to stick (lost core bit segments, broken concrete). 2. Carefully align the bit with the existing hole and slowly lower the spinning bit back into the hole. 3. Finish drilling the hole following the directions directly above.
Tasks Prior to Drilling Complete the following tasks prior to drilling:
Stuck Cores
1. 2. 3. 4.
Clearly mark the drilling area. Be sure the work area does not contain any buried electrical, gas, water or other utility lines.
Drilling a Hole
1. Position the machine and core bit. 2. Move the function switch to Drill. 3. Lower the front mast and rear legs. All tires should just clear or barely touch the ground.
4. Turn on the Vacuum switch and close the vacuum valve. Check the vacuum gauge for pressure; stop to determine the problem if vacuum fails. Skip this step if the vacuum cannot be used when drilling. 5. Set the drill motor to high speed for bits up to 10” and low speed for bits larger than 10”.
Removing a Stuck Core Remove the bit from the machine. Move the bit away from the work area. Lay the bit on the ground. Option 1: a) Place a metal spike through the hub and drive the core out of the bit. b) Inspect the bit for damages and clean or replace as necessary. 5. Option 2: a) Thread a piece of threaded rod (1-1/4-7) through the hub until it contacts the concrete. b) Place two hex nuts on the rod end and lock them against each other.
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c) Holding the bit in place, grasp both nuts with a wrench and screw the rod into the bit to drive the core out. d) Inspect the bit for damages and clean or replace as necessary.
DO NOT hammer on the bit! This will dent the tube, which can result in additional problems and increased hang-ups.
Stuck Bits A bit can become stuck for several reasons:
An insufficient water supply allows slurry to accumulate, causing the drill to seize. Pushing the drill down too hard can cause the machine’s frame to shift slightly (more susceptible when not using the vacuum). If drilling completely through a slab, segments may catch at the bottom edge of the hole when raising the bit. Partially cutting through a piece of rebar with just the outer edge of the bit (mooning) can deflect the bit, causing it to jam. Slowly cutting through rebar or hard spots can reduce this effect.
Removing a Stuck Bit
1. Turn off the Auto Drill switch. Press the Drill Up or Drill Down button and Turbo to attempt freeing the bit. It is best to keep the bit spinning if possible. If the bit is not spinning, turn the Drill Rpm cartridge on and off to try and get the bit to spin (system pressure will go to maximum as it tries to spin the bit). Continue with step 2 if this attempt fails.
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2. Determine if the bit is still centered in the hole. If the bit has shifted toward the rear of the hole, slightly extend the rear legs (raise tires) to attempt to realign the bit. If the bit has shifted toward the front of the hole, retract the rear legs slightly (lower tires) to attempt to realign the bit. Use the Drill Up and Drill Down button while slightly raising and lowering the rear legs or front mast in an attempt to find the break-free position. Continue with step 3 if this attempt fails. 3. If steps 1 and 2 fail, the UDM must be disconnected from the bit, moved out of the way, and the bit extracted manually. 4. Turn the Drill Rpm cartridge to off. 5. Move the function switch to Start/Drive. 6. Turn off the engine. 7. Grasp the flats near the top of the spindle using the wrench provided and turn the spindle counterclockwise, as viewed from above. This will disconnect the spindle shaft from the bit (about 10 turns are required). 8. Move the machine away from the bit. It may be necessary to raise the drill motor for clearance. 9. Insert a piece of threaded rod (1-1/4-7) through the hub until it contacts the concrete. 10. Place two hex nuts on the rod end and lock them against each other. 11. Grasp both nuts using a wrench and turn to push the rod against the concrete. This will pull the bit out of the concrete. 12. Inspect the bit for damages and clean or replace as necessary.
Maintaining the UDM DO NOT attempt to perform maintenance on the machine if you are not properly trained for it, or are not supervised by an experienced person. Refer to the Diamond Products’ Parts List for additional information and part diagrams when performing maintenance tasks. Refer to the engine manual and manufacturer as the primary source for all safety, operations, and maintenance instructions for the engine. All non-routine maintenance tasks should be performed by an authorized service center. Contact the machine and/or engine manufacturers with any additional questions.
Maintenance Overview Complete the following tasks as required. DO NOT delay maintenance! Print the Daily Maintenance Task Chart from Appendix B to keep track of maintenance tasks completed.
Part Lubrication
Lubricating parts on schedule increases the machine’s efficiency and life. Use NLGI No. 2 premium lithiumbased grease when lubricating parts. Hydraulic Pillow Block Lubricate the pillow block grease fitting every 40 hours of operation. Rear Axle Lubricate both rear axle bearing grease fittings annually.
Tires
Daily/Regularly
Inspect belts for tension and wear. Replace or retension as necessary. Inspect machine for damages. Tighten loose nuts, screws, and bolts. Check all fluid levels and fill as necessary (fuel, water, hydraulic oil, engine oil). Wipe down and clean machine to remove dust, debris, and slurry from components (especially fans). Wipe down engine’s exterior and oil cooler. Look for fluid leaks. Check hydraulic oil filter gauge and replace filter as necessary. Check water trap jars and clean as necessary. Check tire pressure and add air as necessary. Clean air cleaner (see engine manual). Inspect hydraulic hoses, couplings, and fittings for leaks. Clean quick disconnects prior to connecting hydraulic hoses. Inspect the roller carriage and adjust as necessary.
Note: Refer to the engine manual and manufacturer for daily engine care and maintenance tasks.
WARNING DO NOT grease parts with the engine running.
WARNING Fit blocks/jacks under the frame edges at the front and back of the frame for support when working under the machine.
Inspect the tires regularly for damages and wear and replace as necessary. Fill the tires with air (check tire sidewall for recommended tire pressure) as necessary.
Figure 21: Front and Rear Tires
Replacing the Front Tires
1. 2. 3. 4. 5. 6. 7. 8.
Raise the front tires slightly off the ground. Remove the dust cap. Loosen the setscrew in the set collar. Remove the collar and tire from the front tire shaft. Place a new tire onto the shaft. Place the set collar against the tire on the shaft. Tighten the setscrew in the collar to secure the tire. Replace the dust cap.
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Replacing the Rear Tires Raise the rear tires slightly off the ground. 9. Loosen the setscrew in the set collar. 10. Remove the set collar and tire from the rear axle shaft. 11. Place a new tire onto the shaft. 12. Place the set collar against the tire on the shaft. 13. Tighten the setscrew into the set collar to secure the tire.
Battery
WARNING Ignitable explosive gases are emitted from the battery. DO NOT expose the battery to sparks or open flames, and keep the area around the battery wellventilated. Always keep the battery cable clamps away from the battery terminals when the battery is disconnected to avoid accidental connections.
Servicing the Battery
1. Turn off the master battery disconnect. 2. Remove the negative battery boot and disconnect the negative cable lead from the negative terminal. Note: Always disconnect the negative cable first. 3. Remove the positive battery boot and disconnect the positive cable lead from the positive terminal. 4. Remove the battery clamp assembly. 5. Carefully remove the battery from the frame. 6. If replacing the battery, carefully place a new battery onto the frame. 7. If cleaning the battery, inspect the terminals, clamps, and cables for damage and corrosion. Clean the terminals and clamps using a wire brush, or use another approved technique for cleaning. Use acidfree, acid-resistant grease to grease the battery clamps and terminals. 8. Reconnect the positive cable lead to the positive battery terminal and replace the battery boot. Note: Always reconnect the positive cable first. 9. Reconnect the negative cable lead to the negative battery terminal and replace the battery boot. 10. Replace the battery clamp assembly. 11. Turn on the master battery disconnect as needed.
Electrical System
CAUTION Use a proper battery tester when testing the battery strength. Use protective eyewear or a face shield, and avoid contact with the skin when servicing the battery.
Battery Type 12 Volt, Group U1
WARNING Disconnect the battery when servicing the electrical system unless stated otherwise. Always use the correct size fuses (amps) to prevent fires. Disconnect external equipment connected through the electrical outlets prior to servicing the machine.
Refer to the UDM Parts List for electrical diagrams. Fuse Panel Inspect fuses (behind rear electrical panel) if switches or controls are not working properly and replace as necessary. If the fuses fail frequently, determine the cause and repair immediately.
Figure 22: Battery
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clean, dry, and is operated at moderate temperatures it may last for several years. With no analysis program, changing the oil every 200 hours is recommended.
1. Place an oil drain tray under the hydraulic tank’s drain plug.
2. Remove the drain plug and drain the oil from the
Figure 23: DC Fuses behind Rear Panel
Circuit Breakers Reset the circuit breakers as necessary. If the circuit breakers trip or fail frequently, determine the cause and repair immediately.
tank. Replace the plug when completely drained. Dispose of the used oil according to city, state, and federal regulations. 3. Fill the tank to the sight port. DO NOT overfill as oil expands when hot. Use a high quality, petroleum based hydraulic oil with the following properties: a) b) c) d) e)
Anti-wear Low foaming Rust and oxidation inhibitors Wide temperature range Fluid viscosity: 8-1,000 Centistokes (52-4,600 SUS). Note: The machine is shipped with an ISO 46 viscosity grade (8 Cs/52 SUS @ 212°F/100°C and 46 Cs/210 SUS @ 104°F/40°C). 4. Replace the cap. Changing the Hydraulic Oil Filter Check the hydraulic filter gauge daily and replace the filter once the needle enters the red range.
1. Place an oil drain tray under the hydraulic filter. 2. Unscrew the filter and hold it over the tray to catch Figure 24: Circuit Breakers
Hydraulic System
WARNING Always use a piece of cardboard or paper to check for hydraulic fluid leaks. Keep all body parts away from leaks and/or areas that may eject hydraulic fluid. Pressurized hydraulic fluid can penetrate the skin, causing serious injuries. Seek medical attention immediately! Remove the core bit to reduce residual pressure in the cylinder circuit prior to servicing the machine.
Inspect the hydraulic hoses and fittings daily for leaks. Replace damaged components immediately. Changing the Hydraulic Oil An oil analysis program is recommended to determine the oil’s condition and when to change it. If the oil is kept
falling oil. Dispose of the used filter and oil according to city, state, and federal regulations. 3. Lightly oil the new filter’s rubber gasket with clean oil. 4. Tighten the new filter according to the directions on the filter. 5. Inspect the seal for leaks.
Belt System WARNING
Turn off the engine prior to servicing the belts.
Always let the belts cool down prior to servicing them.
CAUTION
Inspect the belt daily for fraying, stress cracks, and/or breakage and replace immediately when damaged. DO NOT exceed the manufacturer’s belt tension settings when tensioning belts. Note: Over-tensioning the belt
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may damage the engine crankshaft. Under-tensioning the belt may cause slippage, shorter belt life, and poor generator performance.
1. Loosen the nut on the four screws (under the frame) securing the generator to the frame.
2. Loosen the nut on the belt adjustment shaft. DO
Figure 25: Engine to Generator Belt
Tensioning the Belt
1. Test the belt tension. Refer to Appendix C. If adjustments are necessary, continue with step 2.
2. Loosen the nuts on the four screws (under the frame) securing the generator to the frame.
3. Turn the belt adjustment shaft nut clockwise to tighten the belt. Retest the tension and readjust the nut as necessary to reach the required tension setting. DO NOT exceed the manufacturer’s setting.
NOT remove the nut. 3. Slide the generator toward the engine to loosen the belt. 4. Remove the belt from the generator sheave. 5. Remove the two screws securing the hydraulic pump to the pump mount. Pull the pump out and set aside. There is no need to remove hoses from the hydraulic pump. 6. Remove three of the four screws securing the pump mount to the engine. The fourth must be loosened. 7. With pump mount loose, guide belt around sheave and coupler and pull out through the pump end. 8. Insert loop of new belt through rear opening and out the side of pump toward the generator. Guide belt around the coupler and into position on the engine sheave. 9. Reattach the pump mount to the engine. 10. Reinstall the hydraulic pump, aligning it with the coupling and pump mount. 11. Loop and align the belt around the generator sheave. 12. Slide the generator toward the side of the machine to tension the belt. 13. Turn the belt adjustment shaft nut clockwise to tighten the belt. Test the belt tension and readjust the nut as necessary to reach the required setting. (Appendix C). DO NOT exceed the manufacturer’s recommendation. 14. Retighten the four nuts (under the frame) to secure the generator. 15. If required, the belt alignment can be adjusted by loosening the sheave on the generator shaft and repositioning it.
Roller Carriage Figure 26: Belt Adjustment Shaft and Nut
4. Retighten the four nuts (under the frame) to secure the generator. Replacing the Belt The pump must be removed and the pump mount loosened to access the sheave on the engine shaft. It is not necessary to remove the hoses from the pump. The best way to remove the old belt is to simply cut it and pull it out. Otherwise, follow the steps below.
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The roller carriage moves the core bit up and down the mast. The carriage must be snug on the mast to support the bit and prevent unwanted motion. A consistent small gap should be visible between the mast and the top inner edges of the carriage. If a twisting or fore and aft rocking motion is visible while drilling, the carriage has become loose and required adjustment. This same twisting motion can be checked by gently pushing and pulling sideways on the pillowblock. The fore and aft rocking motion can be simulated by manually lifting up on the pillowblock. The normal weight of the pillowblock, drill motor and bit tends to tip the carriage forward slightly.
If only the rocking motion is visible, only the rollers at the rear of the carriage need adjustment. If the twisting motion is visible, both the side shims and rollers may need adjustment.
Adjusting the Rear Rollers on a disconnected carriage:
1. Loosen the setscrews at both ends of the upper and lower rollers.
2. Simultaneously turn both hex heads on one roller until you feel the roller contact the mast. The dimples on the hex heads should remain aligned. 3. Tighten the two setscrews on the adjusted roller. 4. Repeat steps 2–3 to adjust the second roller. 5. Check the carriage motion and repeat if required. To Connect the Carriage:
1. Realign the roller carriage with the spacer/pillowblock assembly. 2. Insert and tighten the four bolts removed previously..
Adjusting the Rear Rollers on a connected carriage:
1. Lift up on the pillowblock to balance the normal Figure 27: Roller Carriage, side shims & rear rollers.
The shims and rollers may be adjusted on a fully assembled machine. However, it is best to detach the carriage from the spacer block so it can be manually moved up and down the mast. If the carriage falls down the mast by its own weight it is too loose. If the carriage cannot be moved by moderate hand force, it is too tight.
weight of the pump, pillowblock and bit. 2. Proceed with steps 1 thru 5 above. Replacing the Rollers Over time, the rollers can wear to the point that adjustment is no longer possible. To replace the rollers, the cylinder assembly must be removed from the top of the mast and the carriage must be slid completely off the mast.
Disconnecting the Carriage
1. Place a reliable support under the spacer/pillow block assembly. 2. Support the roller carriage. NOTE: It may be easiest to fully extend the hydraulic cylinder and thus place the pillowblock and carriage at or near ground level.
3. Remove the four bolts between the spacer and carriage. The carriage is now free to move independently. 4. Roll the carriage up and down the mast to test its movement. The carriage should move easily with light force applied and should not fall to the ground. Adjust the shims and rear rollers as necessary.
1. Disconnect the carriage following the instructions in the previous section.
2. Remove the clevis pin from the cylinder rod end. 3. Remove the large bolt at the top of the mast. 4. The cylinder assembly and guide block can now
5. 6. 7.
Adjusting the Shims
1. Remove the four side roller housings. 2. Remove an equal number of shims from all side roller housings to tighten the carriage. Add an equal number of shims to all side roller housings to loosen the carriage. 3. Replace the side roller housings and secure. 4. Check the carriage motion and repeat if required.
8.
9.
slide up and off the guide rail. Be prepared to safely support the cylinder. There is no need to remove the hoses. Slide the carriage off the mast. REAR ROLLERS: loosen the four setscrews. The hex head adjusters will now pull out and release the rollers. Install new rollers and reassemble. SIDE ROLLERS: remove the four bolts in each of the side roller housings and pull out the assemblies. Drive out the pin from each housing to release the roller. Install new rollers and reassemble. FRONT ROLLERS: remove the upper cover plate and loosen the setscrews on the upper and lower shafts (no cover plate on lower roller). Drive out the shafts to release the rollers. Install new rollers and reassemble. Place the carriage onto the mast and adjust the shims and rear rollers for proper movement.
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10. Carefully slide the cylinder assembly and guide
Disposal
block onto the guide rail and mast. 11. Replace and tighten the large bolt at the top of the cylinder bracket/mast. 12. Install the clevis pin through the cylinder rod end and spacer/pillow block assembly. 13. Reconnect the carriage following the instructions below.
Connecting the Carriage
1. Realign the roller carriage with the spacer/pillow block assembly.
2. Insert and tighten the four bolts previously removed.
Engine
WARNING Let the engine cool down prior to servicing the machine. DO NOT service the machine with the engine running unless stated otherwise.
Refer to the engine manual and manufacturer for a full maintenance schedule and additional maintenance information. Engine Throttle Screw The engine throttle screw (located at the top of the engine) is factory set at 3,550 rpm. The screw regulates the maximum no-load engine rpm. Occasionally check the setting on the rear control panel tachometer and adjust the screw as necessary. Cleaning the Engine Wipe down the engine’s exterior and oil cooler regularly to help prevent high operating temperatures. DO NOT spray the engine with water to prevent engine damage.
Storing Complete the tasks listed below prior to storing the machine for longer time frames:
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Drain the water tank, hoses, and pump. Turn off all switches and controls (including the master battery disconnect). Clean and wipe down the machine. Refer to the engine manual for engine tasks and fuel recommendations. Store the machine in an area protected from outdoor elements, and out of reach from children.
Drain all fluids and dispose according to city, state, and federal regulations. Remove the battery, reuse, recycle or dispose of properly. Transport the machine to a salvage yard or recycling facility.
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References Appendix A Serial Tags Record the machine’s serial number below for future reference and customer service purposes. Serial Number
Record the engine’s model and serial numbers below for future reference and customer service purposes.
Model Number Serial Number
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Appendix B Daily Maintenance Task Chart
Table 4: Daily Maintenance Task Chart Date
1.
Inspect belts for tension and wear. Replace or re-tension as necessary.
2.
Inspect machine for damages.
3.
Tighten loose nuts, screws, and bolts.
4.
Check all fluid levels and fill as necessary (fuel, water, hydraulic oil, engine oil).
5.
Wipe down and clean machine to remove dust, debris, and slurry from components.
6.
Wipe down engine’s exterior and oil cooler.
7.
Look for fluid leaks.
8.
Check hydraulic oil filter gauge and replace filter as necessary.
9.
Check water trap jars and clean as necessary.
10. 11.
Check tire pressure and add air as necessary. Check air cleaner (see engine manual).
12.
Inspect hydraulic hoses, couplings, and fittings for leaks.
13.
Clean quick disconnects prior to connecting hydraulic hoses.
14.
Inspect roller carriage and adjust as necessary.
15.
Refer to engine manual and manufacturer for daily engine care and maintenance tasks.
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Appendix C Belt Tension Setting
Table 5: Belt Tension Setting Model
Engine Type
Deflection
Deflection Force
Ultimate Drilling Machine (UDM)
20.5HP Honda GX670 to 5000 W Generator
.10”
69 lb
.
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Appendix D Troubleshooting
Table 6: Troubleshooting Symptom
Problem
Solution
2. Machine will not move
Engine off? Function switch in Drill mode? Engine off?
Start engine. Move function switch to Drill. Start engine.
forward/backward.
Function switch in Drill mode?
Move function switch to Start/Drive.
Engine off? Circuit breaker off? Blown fuse? Function switch out of Drill mode?
Start engine. Activate circuit breakers; replace fuses; move function switch to Drill.
Master battery disconnect off? Function switch in Hydraulic Outlets mode?
Turn on master battery disconnect. Move function switch to Hydraulic Outlets. Activate circuit breakers; check reset button on ground fault outlet.
1. Core bit will not raise/lower.
3. Controls/buttons/switches do not work.
4. Hydraulic outlets do not work. 5. Electrical outlets do not work.
Circuit breaker off? Broken engine belt? Vacuum valve open? Surface cracked/scored? Vacuum line leak?
6. No vacuum. Circuit breaker off? Loose or missing bolts thru top of vacuum pad? Broken engine belt? Loose belt causing slippage? Sheaves misaligned?
7. Short belt life.
(Refer to engine manual and manufacturer for additional engine troubleshooting information.)
Tighten or replace fasteners. Replace engine belt. Check belt tension. Use straightedge to check sheave alignment.
Overheating of belt? Emergency stop button down? Master battery disconnect off?
Check for groove wear and replace as necessary. Check belt tension. Pull up emergency stop button. Turn on master battery disconnect.
Fuel shutoff valve closed?
Open fuel shutoff valve.
Worn sheave grooves?
8. Engine does not start.
Replace engine belt. Close vacuum valve. Check surface and readjust; vacuum may not be possible. Tighten fittings and water jars; replace bad hoses. Turn on 40 amp circuit breaker; check reset button on ground fault outlet.
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Appendix E Additional Resources
1. Diamond Products (www.diamondproducts.com)
Ultimate Drilling Machine Parts List; Ohio, 2009 A Guide for Professional Concrete Cutters Training Manual–Introduction to Diamond Blades, Bits, and Equipment Diamond Products’ Equipment Catalog Diamond Products’ Website (www.diamondproducts.com)
2. Honda Motor Company (www.honda-engines.com)
Owner’s Manual; GX610, GX620, GX670; Japan, 2007
3. Concrete Sawing and Drilling Association (CSDA) (www.csda.org)
The CSDA has many helpful concrete cutting publications available to members and non-members.
4. Association of Equipment Manufacturers (AEM) (www.aem.org)
The AEM has a variety of safety and technical manuals available for various types of equipment, along with a list of industry-standardized safety symbols.
5. Occupational Safety and Health Administration (OSHA) (www.osha.gov)
OSHA provides information on work-related safety and health practices.
6. The National Institute for Occupational Safety and Health (NIOSH) (www.cdc.gov/NIOSH)
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NIOSH provides information on work-related safety and health practices.
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333 Prospect Street, Elyria, Ohio 44035 (440) 323-4616 (800) 321-5336 Fax (440) 323-8689 www.diamondproducts.com Printed in U.S.A.
