AOI Auto Driller

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Auto-DrillerInstallation, Operation,

and Maintenance Manual

TM-551


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4 TM-551 Auto-Driller Installation, Operation, and Maintenance Manual

Copyright 2004-2005 Acadiana Oilfield Instruments, Inc. All rights reserved.

AOI Instrumentation is a registered trademark of Acadiana Oilfield Instruments, Inc.

The AOI logo is a trademarks of Acadiana Oilfield Instruments, Inc.

All other brand names and product names are trademarks or registered trademarks

of their respective companies.

AOI Instrumentation

105 Bonin Road

Lafayette, Louisiana 70508 USA

www.aoiinstrumentation.com

Printed in the U.S.A.

Part Number Edition Date

TM-551 First September 2004January 2005


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Auto-Driller Installation, Operation, and Maintenance Manual TM-551 5

Contents

1 Introduction 9

Auto-Driller system components . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

System on/off control valve . . . . . . . . . . . . . . . . . . . . . . . . . 11

System control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Air motor/differential gearbox . . . . . . . . . . . . . . . . . . . . . . . 13

Drum rotation sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Flexible shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Spring assembly with chain . . . . . . . . . . . . . . . . . . . . . . . . . 16

Air hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2 Installation 19

Planning ahead: Placing the Auto-Driller components

on your rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Installing system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Step 1: Install the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SA101 wall-mounted controller . . . . . . . . . . . . . . . . . . . . . 21

SA102 console-mounted controller . . . . . . . . . . . . . . . . . . . 22

Step 2: Install the drum rotation sensor . . . . . . . . . . . . . . . . . . . 23

Step 3: Install the air motor/differential gearbox . . . . . . . . . . . . 25

Step 4: Adjust the cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Step 5: Install main air control and connect the system

air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Step 6: Install the spring assembly . . . . . . . . . . . . . . . . . . . . . . . 29

Step 7: Purge and pressurize the system . . . . . . . . . . . . . . . . . . 30
http://introduction.pdf/http://introduction.pdf/


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Contents

Speed of penetration control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Air pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Microflow valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Right-angle gear, wheel and hub . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Drum rotation sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Flexible shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Flex shaft couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Spring set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Air motor/differential gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Deadline Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Disconnect couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
http://-/?-http://-/?-


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8 Auto-Driller Installation, Operation, and Maintenance Manual


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1 IntroductionThe AOI Auto-Driller is an automated mechanical system (equivalent to the

SatelliteAutomatic Driller) that controls drilling by comparing deadline

tension with weight on bit.

When deadline tension exceeds a preset value, the Auto-Driller raises the

drawworks brake lever. The drawworks drum extends the drill line.

When a preset value for weight on bit is reached, the Auto-Driller lowers

the drawworks brake lever to slow or stop the extension of drill line.

Figure 1. AOI Auto-Driller operational overview diagram

DEADLINE

DIAPHRAGM

CONTROLLER

MODULE ASSEMBLY

AIR MOTOR &

DIFFERENTIAL GEAR

ROTATION

SENSORRIG AIR IN

Auto-Driller

As deadline tension increases, the

controlleroperates the air motor

to apply force to the differential

gear, which also responds to a

counter-rotational force from the

rotation sensor.

The differential gear's response

determines the rate of winding of

the lift line, which raises the drum

brake leverand allows drilling line

to be released.

When the pre-set

weight-on-bit is

reached, the

Auto-Driller

lowers the brake

leverto stop the

drum.

BRAKE

LEVER

SENSATOR

SENSATOR

WEIGHT

DIAPHRAGM

WEIGHT

or

DEADLINE ANCHOR

LIFTLINE


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Chapter 1. Introduction

The Auto-Driller is available in two models:

The SA101incorporates a wall mounted system controller that operateson rig air supply and is intended for use with deep-hole rigs. The SA101

uses hydraulic pressure measurements received from a deadline anchor

weight sensor.

Figure 2. SA101 wall-mounted Auto-Driller

The SA102is a console-mounted system with controller. It uses hydraulic

pressure signals from the deadline anchor. The systems hydraulic sensing

tube is connected to the consoles weight indicator manifold. The SA102

operates on the consoles internal air supply.

Figure 3. SA102 console-mounted Auto-Driller

Auto-Driller

Auto-Driller

SPEED REGULATOR

0 - 100 PSI 0 - 100 PSI

CONTROLKNOB

PULL- ON

PUSH - OFF CAUTION CONTROLKNOB

SPEED PENETRATION

0


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Auto-Driller system components


Both models of the Auto-Driller include the following components:

System control valve

System control unit

Air motor/differential gearbox

Drum rotation sensor

Flexible shaft

Cable

Spring assembly

Air hose

Lubricator

Air filter

System on/off control valve

The system control valve starts and stops system operation. This push/pull

control is usually mounted on the drillers console.

When the system control valve is in the ON (pulled out) position, filtered

air under pressure is supplied to the system control unit.

When the knob is in the OFF (pushed in) position, it restricts airflow to

the system control unit and the system ceases operation.

knob


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System control unit

The system control unit includes knobs that control these functions:

Speed of penetration

Set-point for optimal deadline weight

Set-point for optimal weight on bit.

The system control unit provides:

Hydraulic connections for input from the load cell at the deadline anchor

Output to the air motor/differential gearbox

Output to the drum rotation sensor.

The system is powered by rig air, and is available in wall-mount (shown) or

console-mount models. Both models contain the same controls, but in slightly

different configurations.

A drilling knob controls rate of penetration (ROP). Drilling knob rotation

regulates the amount of air pressure made available to the air motor as a result

of changes in deadline tension. Counter-clockwise turns decrease the ROP;

clockwise turns increase the ROP.

A bit-weight control knob regulates the amount of weight on bit the system

maintains to optimize drilling.

Principle of operation:

A bourdon tube in the system control unit reacts to changes in deadline

tension by operating a flapper valve. The flapper valve regulates air flow

through an opening in the controller. This air flow opens a 3-to-1 valve that

regulates air pressure that drives the air motor/differential gearbox assembly.

Note

Controllers must match load sensing equipment in use on your rig. Rigs

having deadline anchors require controllers with 1000 PSI or 1500 PSI

bourdon tubes, depending on the type of anchor in use.

Auto-Driller

See Auto-Driller controls on

page 32for more information.


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The air motor/differential gearbox assembly winds and unwinds a cable thatmoves the spring-loaded drawworks drum brake lever.

An integral reel contains and transports the supplied cable. A push-pull knob

at the top of the assembly provides selection of fast or slow drilling speeds. A

shaft adjustment knob at the back of the assembly aids in gear

synchronization during speed changes.


Two opposing input forces govern the operation of the differential gearbox:

Input from the air motor causes the differential gearbox to unwind cable.

This engages the drawworks drum brake lever and slows or stops the

release of drilling line.

Input from the drum rotation sensor (via the flexible shaft) causes the

differential gearbox to wind up cable. This disengages the drawworks

drum brake lever and releases additional drilling line.


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During system installation, the drum rotation sensor is welded to thedrawworks rear drum shield. The drum rotation sensor contains an air

cylinder and a right-angle drive. A rubber friction wheel is mounted on the

right-angle drive.


During system operation, the air cylinder in the drum rotation sensor receives

air pressure from the system controller assembly. The air cylinder forces the

rubber friction wheel against the drawworks drum flange. As the rubber

friction wheel turns, it drives the attached flexible shaft.


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Spring assembly with chain

The spring assembly is attached to the drawworks brake lever by a chain, andis anchored securely to the rig floor.


The spring assembly provides a constant force on the drawworks brake lever.

It opposes the force applied by the air motor/differential gearbox, and tends to

keep the drawworks brake set.

When operation of the differential gearbox applies a force that exceeds

the force applied by the spring assembly, the drawworks brake is

disengaged.

As the force applied by the differential gearbox lessens, the springassembly causes the drawworks brake to engage.

Air hoses

Air hoses interconnect the components of both console and wall-mounted

systems.

1

2

3

8

1

4

inch

inch

inch

1/2-inch hose for supply to main air control

valve and controller.

3/8-inch hose for supply to the gearbox.

1/4-inch hose for supply to the right-angle drive.


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Lubricator

The lubricator supplies oil (SAE 10W-30) to the air motor during operation,and is mounted directly on the air motor.

Air filter

The air filter and its associated fittings are rated at 150 PSI (maximum). The

filter is installed between the rig air tap and the control valve, and provides

filtered air to all Auto-Driller system components. The air filter for the SA102

system is mounted in the drillers console.


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2 InstallationBefore the Auto-Driller can be installed, the installation site must be prepared.

The following conditions must be met:

The brake handle must have a hook to which the Auto-Drillers spring

assembly can be connected, and the spring assembly must be bolted or

welded onto the rig floor. Be certain that the spring assembly can be

firmly fixed to the floor, and that it will not cause a hazard.

Caution Install signs or use some other method to warn personnel who

will be working near the spring assembly.

The rubber wheel on the drum rotation sensor must make good contact

with the drum flange as the drawworks drum turns. Keep the drum flange

clean, dry, and smooth while the Auto-Driller is operating.

For console-mounted installations, make sure that the air filter, controlvalve and the connecting hoses can be incorporated into the console.

After you have reviewed these conditions, proceed with the most important

part of installation: planning ahead (see Planning ahead: Placing the Auto-

Driller components on your rig on page 20).


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Chapter 2. Installation

Planning ahead: Placing the Auto-Driller components on your rig

Planning ahead: Placing the Auto-Driller components on your rig

Trial-fit all major components of the Auto-Driller before they are installed.

Figure 4illustrates the most significant component placement relationships.

Figure 4. Orientation of system components in a typical installation

Begin installation by placing the system components in their approximate

installation locations. Pay particular attention to these two critical factors:

When installed, the flexible shaft must bend in a single smooth curve

between the drum rotation sensor and the air motor/differential gearbox.

The cable mounted on the air motor/differential gearbox must be alignedwith the drawworks brake lever path of travel.

DRAWWORKS


with cable attached

Flex-shaft connects drum

rotation sensor (inside the

drawworks shell) and the air

motor/differential gearbox.

See Figure 7 on page 23.

Spring assembly is

bolted or welded to

the rig floor.


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Step 1: Install the controller Installing system components

Installing system components

Step 1: Install the controller

SA101 wall-mounted controller

The SA101 controller is shipped mounted on a plywood base, with all integral

tubing attached.

a. Secure the SA101 controller to a solid wall in a place close to the

drillers position that is protected from the weather. Mount the

controller so that it is easy to view its gauges and operate its controls.Figure 5shows the SA101 controller mounted in the doghouse.

Figure 5. Mounting the SA101 controller in the doghouse

b. Fill the bourdon tube and the hydraulic plumbing leading to it with

AOI hydraulic fluid (p/n A-11).

Auto-Driller

Secure lines

together.

Cut a

smooth hole.

Doghouse floor

approximately

54 inches

Mounting

surface must

bear weight of

the controller.


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Installing system components Step 1: Install the controller

SA102 console-mounted controller

The console-mounted controller ships pre-installed in the SA102 model. Thecontrollers bourdon tube arrives at your site vacuum-pumped and filled

along with the weight indicator.

To install the SA102, connect it to system air and hydraulic lines as shown in

Figure 6.

Figure 6. SA102 air and hydraulic lines

INSTRUMENTREGULATOR

INSTRUMENT

PRESSURE

BLOCK

SPEED

REGULATOR

MICROVALVE

SPEED

GAUGE

AIR BLEED

PORT (SA101)

LOAD CELL

INPUT PORT

NOT USED

AIR MOTOR GAUGE

PRESSURE TO

3:1 REGULATOR

INSTRUMENT

AIR (20 PSI)

INSTRUMENT

SUPPLY PRESSURE

LOAD

PRESSURE TO BOURDON

TUBE

INSTRUMENTOUTPUT

PRESSURE


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Step 2: Install the drum rotation sensor Installing system components

Step 2: Install the drum rotation sensor

a. Read Step 3 on page 25to determine whether placement of thedifferential gearbox will affect how you must install the drum rotation

sensor.

b. Hold the drum rotation sensor inside the drum guard to determine its

optimum mounting position. Two factors determine its placement:

The flexible shaft that will be attached to the drum rotation sensor

must form a smooth curve when the shaft is attached to the

differential gearbox.

The drum rotation sensor must be mounted so that its friction wheel

will contact a point near the drum spool rim, and the friction wheel

is 0.75 inch (19 mm) from the surface of the drum spool. Thefriction wheel mounting bolt allows a maximum 1-inch adjustment

after the drum rotation sensor has been installed.

Figure 7. Drum rotation sensor placement

The flex shaft must conform to

a single smooth curve when

connected between the drum

rotation sensor and the differential

gearbox.

Base of sensor is welded to the drum guard.

air cylinder

drum guard

drum

flange

friction

wheel

0.75 inch

Flex shaft

connects to

gearbox.

drill line on drum


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Installing system components Step 2: Install the drum rotation sensor

c. When you have determined the best position on the drum guard for

the drum rotation sensor, mark the place on the drum guard where you

will weld it. Draw a line around the drum rotation sensors base plate;then remove the sensor.

d. Detach the air cylinder and slide it and the friction wheel components

out of the base plate.

e. Weld the base plate to the location you marked on the drum guard.

Make sure you have the base plate oriented in the proper direction.

f. Carefully apply a liberal amount of machine grease to the base plate

slide.

Note

Do not allow grease to spill onto any other parts, particularly the

friction wheel surface.

g. Slide the friction wheel/air cylinder components onto the base plate,

and attach the air cylinder to the base plate.

h. Adjust the friction wheel so that it rolls at a right angle to the drum

spools axis of rotation. The friction wheel should roll smoothly as the

drum spool turns. Tighten the friction wheels mounting locknut.

i. Cut a hole through the cover of the drum guard through which the

flex-shaft will pass. Ensure that the edges of the hole are smooth and

will not cut or abrade the flex-shafts outer jacket.


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Step 3: Install the air motor/differential gearbox Installing system components

Step 3: Install the air motor/differential gearbox

Follow these guidelines as you carefully position the air motor/differential

gearbox:

The flex-shaft must form a smooth curve when it connects the differential

gearbox to the drum rotation sensor.

The cable attached to the air motor/differential gearbox reel will pull the

brake handle in line with the brake handles path of travel. You can use

pulleys to guide the cables direction of pull.

The air motor/differential gearbox must be mounted onto a strong and

stable surface, such as the top cover of the drum guard.

straightpull

You can thread the cable through

sheaves that are securely mounted

to surfaces that will not be moved

when tension is applied to the cable.

Keep pulley runs close to walls and

away from traffic areas.


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Installing system components Step 3: Install the air motor/differential gearbox

Figure 8. Mounting the air motor/differential gearbox

a. Weld the base plate supplied with the air motor/differential gearbox to

the mounting surface. The mounting surface can be a short length of

heavy-gauge pipe, or you can construct a sturdy bracket to adjust the

installed placement of the gearbox.

Note

However you choose to mount the air motor/differential gearbox,the

base plate must be kept level to ensure proper lubrication in the

gearbox.

b. Install the free end of the flex-shaft to the differential gear assembly.

c. Use the mounting bolts supplied with the system to bolt the air motor/

differential gearbox assembly to its base plate that you welded in

position in part aof this step.

d. Unreel the cable on the gearbox reel to its full length.

e. Attach the free end of the cable to the fully-engaged drawworks brake

lever. Make sure it will not slip on the brake lever during system

operation.

2-inch heavy-gauge pipe

(or equivalent material).weld

Base plate must

be kept level.

Do notuse the gear

box as a grounding

electrode during

welding.

Solid, stable surface on rig - such as drawworks housing.

Viewport for

checking oil level.

If unit is not level,

oil level cannot be

checked

accurately.


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Step 4: Adjust the cable Installing system components

Step 4: Adjust the cable

a. Make sure you have already attached the cable to the drawworksbrake lever.

b. At the air motor/differential gearbox, pull slack cable through the

hole in the reel.

Figure 9. Loading the gearbox with cable

c. Loosen the cable clamp and move it towards the reel until it is 3 feet

from the outside of the reel. Tighten the clamp in this position.

d. Cut off the excess cable (cable beyond the reel and clamp).

e. Load the cable onto the reel, winding it in a counterclockwise

direction.

Caution Minimize job hazards by keeping your cable installation away

from high traffic areas, and make sure it is well marked.

Cut off excess cable.

Make sure that

one end of the

cable is already

attached to the

brake lever.

Cable feeds off reel this way.

Wind cable counterclockwise.


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Installing system components Step 5: Install main air control and connect the system air supply

Step 5: Install main air control and connect the

system air supply

Note:Whenever possible,

route air supply hoses beneath

the rig floor.

a. Install the main air control valve (sometimes called the drill knob)

in the drillers console. Refer to the figure below to complete the

system connections to the main air control valve.

Figure 10. Connecting the drill knob and system air supply

Auto-Driller

weightsignal

sourceoptions

rig air

air motorvalve main air

control valve

drum rotation

sensor

Auto-Driller

controller

air filter

Air motor/

differential gearbox


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Step 6: Install the spring assembly Installing system components

b. Connect the air line from the air motor to the air motor valve on the

Auto-Driller controller.

c. Connect rig air to the system through the air filter to the air inlet

fitting on the main air control valve.

d. Connect the air hose from the main air control valve to the drum

rotation sensors air cylinder.

Step 6: Install the spring assembly

a. Weld or bolt one end of the spring assembly to the rig floor as shown

in the following illustration.

Figure 11. Installing the spring assembly

b. Attach the other end of the spring assembly to the drawworks brake

lever. The brake lever must have a hook or hole to which the spring

assembly can be attached. The spring assembly must not slide when it

is connected to the brake lever.

DRAWWORKS


with cable attached

Flex-shaft connects drum

rotation sensor (inside the

drawworks shell) and the air

motor/differential gearbox.

See Figure 7 on page 23.

Spring assembly is

bolted or welded to

the rig floor.


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Installing system components Step 7: Purge and pressurize the system

Step 7: Purge and pressurize the system

Caution This purging procedure is for hydraulic sensor systems only. Do

not attempt to charge air sensor systems with hydraulic fluid

because damage to equipment will result.

The SA101 Auto-Drillers hydraulic line and controller are pre-charged with

hydraulic fluid and tested at the factory.

After connecting the hydraulic line to the deadline anchor, the system should

be purged of air and re-charged as necessary to maintain accurate deadlinetension measurement.

1. Without any tension on the deadline,charge the system according tothe applicable weight indicator manual.

2. Loosen the fitting at the base of the Auto-Driller controller assembly

bourdon tube and bleed any air out of the system.

3. Tighten the bourdon tube fitting when all air has been bled from the

system.


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3 OperationThe Auto-Driller operates after drilling has begun, with a minimum of 10,000

pounds of bit weight registered on the weight indicator.

Warning Damage to equipment can occur if you operate the Auto-Driller

for extended periods of timewhen you are not actually drilling.Operate the system only after drilling has begun. Disengage the

system immediately when drilling stops.


32/94


Chapter 3. Operation

Auto-Driller control locations

Auto-Driller control locations

When the system has been fully installed and checked, review Figure 12 to

familiarize yourself with the location of controls and their operation.

Figure 12. Auto-Driller controls

Figure 13. Main air control valve (Auto-Driller system main control).

Auto-Driller

Air Supply gauge,

regulated to 20 psi.

Speed Regulator gauge

indicates pressure availableto run the air motor.

Bit Weight

Control knob.

Air Output gauge

indicates control

pressure flow to

operate air motor

valve. (3-5 psi)

Air Motor gauge

indicates pressure

to the air motor when

operating. This is

equivalent to a

measure of speed.

Speed Penetration

Control knob sets air

pressure made available

to the air motor.

ON OFF

pull push

In console systems, (SA102)

the main air control valve

that controls system on/off is

mounted in the console.

In wall-mounted systems(SA101) the main air control

valve is typically mounted in

the drillers console, or as

close to the drillers console

as is possible.


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Starting the Auto-Driller system


1. Make sure the spring is holding the drawworks brake lever in its fully-engaged position, and that the main air control valve is closed (pushed in).

Figure 15. Operating the main air control valve (drill knob)

2. Rotate the Bit Weight Control knob clockwise several turns to disengage

the controller.

Figure 16. Auto Driller controls and gauges

ON OFF

pull push

Auto-Driller

Air Supply gauge,

regulated to 20 psi

Speed Regulator gauge

indicates pressure available

to run the air motor.

Bit Weight

Control knob.

Air Output gauge

indicates control

pressure flow to

operate air motor

valve. (3-5 psi).

Air Motor gauge

indicates pressure

to the air motor when

operating. This is

equivalent to a

measure of speed.

Speed Penetration

Control knobsets air

pressure made available

to the air motor.


35/94




3. Open (pull out) the main air control valve. This supplies air pressure to

power the system.

4. Turn the Speed Penetration Control knob clockwise, until the speed

regulator gauge indicates 30 psi.

5. Balance the air pressure from the hydraulic sensor with the air pressure

from the controller:

a. Slowlyturn the Bit Weight Control knob counterclockwise to the

point where the Air Output gauge indicates that air output pressure is

sufficient to trigger the air motors internal control valve.

b. Turn the Bit Weight Control knob clockwise until the Air Output

gauge reads below 3 psi (approximately 1/4 turn).

This balance corresponds to the current weight on bit. As bit weight falls

below the level you have set, the controller activates the air motor in the

differential gearbox. The differential gearbox turns the cable reel and lifts

the brake handle, permitting the drawworks drum to release drilling line.

6. Set the gearbox speed:

Pull the gearbox shift knob out for fast operation.

or

Push the gearbox shift knob in for slower operation.

Figure 17. Gearbox speed adjustment.

Pull shift knob out

for fast operation.

Push shift knob in for

slow operation.

Turn this

knob to help

mesh gears.


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Stopping the Auto-Driller system

Caution When shifting to slow speed, do not force-shift the knob, or strike

it to push it in. Instead, turn the hand-adjustment knob on theback of the gearbox to help mesh the gears.

From time to time, the system may require adjustments. For help, consult the

troubleshooting table on page 42.

Stopping the Auto-Driller system

To disengage or stop the Auto-Driller, push the main air control valve knob in.

ON OFF

pull push


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4 Maintenance and Troubleshooting

Maintenance

The Auto-Driller has been tested and calibrated prior to shipping. To ensure

optimum operation, perform these maintenance tasks.

Daily maintenance

1. Check air filter for accumulated water and sediment. Blow clean asnecessary.

2. Check hydraulic fluid level in the lubricator. Add hydraulic fluid

(p/n A-11) when necessary.

3. Check that the system controller is properly calibrated. As shown in

Figure 18, make sure that the thumb screw is positioned at the top of the

slot, and that it is firmly hand-tight.

Figure 18. System controller calibration

Thumbscrew must

be positioned at the

top of the slot, and

firmly tightened.


38/94


Chapter 4. Maintenance and Troubleshooting

Maintenance Weekly maintenance

Weekly maintenance

1. Check the air motor/differential gear box for oil leaks. Check the oil levelin the sight glass. If you suspect that the gearbox is no longer level and

you cannot see oil in the sight glass, open the oil filler plug and inspect

the level visually. Replenish the reservoir with 10W motor oil and replace

the filler plug.

2. Inspect the systems air lines for abrasions or cuts. Ensure that fittings are

tight and do not leak. If your system includes a deadline diaphragm

assembly, check the constant air bleed connection and the air line to

ensure that there are no obstructions.

3. Check the drum rotation sensor to ensure that the air cylinder is working

properly. The rubber wheel should be making good contact with the drum

flange. The rubber wheel should be aligned at a right angle to the drums

rotational axis, and should roll freely as the drum turns. Add light grease

(chassis lube) to the rotation sensors sliding parts. Inspect the rubber

wheel for wear, and ensure that the air cylinder operates properly.

4. Check the flex-shaft, and ensure that it is not abraded. If necessary,

tighten the set screws that secure it to the differential gear and to the drum

rotational sensor.

5. Keep the controller and instrument case clean and free of dust and dirt.

Ensure that the interior of the instrument is clean and that the cover closessecurely against the gasket.


39/94



Weekly maintenance Maintenance

6. Deposits from the airflow through the microflow valve can accumulate on

the valves interior surfaces. If this occurs, follow these instructions to

clean the valve:

a. Disassemble the microflow valve.

b. Clean the valve thoroughly with solvent.

c. Reassemble the microflow valve: Lubricate the o-ring and the

dampener chamber within the cap with a very heavy lubricant such

as gun grease or petroleum jelly. Be sure to install the pressure

plate toward the bonnet, and position the plate spacer as shown in

Figure 19.

Figure 19. Cleaning the microflow valve

O-ring

cap

bonnet

pressure

plate

plate

spacer


40/94



Maintenance Cleaning the Auto-Driller orifice

Cleaning the Auto-Driller orifice

Checking to see if the orifice needs cleaning

Periodically, or if the drill line will not stop feeding, check to see if the

instrument orifice requires cleaning:

1. Push the main air control valve in to stop the Auto-Driller system.

2. Disconnect the lift line from the brake lever.

3. Pull the main air control valve out to start the Auto-Driller system.

4. Rotate the Bit Weight Control knob until the flapper is clear of the orifice.

5. If the Air Output gauge registers 3-5 psi with 20 psi registering on the

supply gauge, the Auto-Driller orifice needs cleaning.

6. Push the main air control valve in.

7. Clean the orifice according to the directions on page 41.

8. Pull the main air control valve out. The Air Output gauge should indicatea ZERO reading.

9. Push the main air control valve in.

10. Attach the lift line to the brake lever and resume drilling.

Auto-Driller

Air Supply gauge

Speed Regulatorgauge

Bit Weight

Control knob

Air Output gauge

Air Motor gaugeSpeed Penetration

Control knob


41/94



Cleaning the Auto-Driller orifice Maintenance

Cleaning the orifice

Follow these instructions to clean the Auto-Driller orifice:

1. Remove the three screws from the flappers coverplate.

2. Use wire, string, or tape to hold the flapper open.

3. Be careful not to disturb the spring attached to the bottom of the flapper.

Use a 3/8-inch wrench to remove the instrument orifice.

Flapper

coverplate.

wire, string, or

tape

spring

orifice


42/94



Maintenance Troubleshooting

4. Clean the orifice with solvent and blow dry. Do not apply oil.

5. Replace the orifice.

6. Release the flapper.

7. Replace the flappers coverplate and three screws.

Troubleshooting

Table 1. Troubleshooting the Auto-Driller

Problem Probable Cause Corrective Action

Drawworks continues to

feed off drill line after bit

weight has been

achieved.

Instrument orifice is dirty. Clean the instrument orifice

(see page 40).

Brake lever spring is not

keeping the brake

engaged.

Increase the spring tension.

Drum sensor wheel is not

turning.

See erratic drill line feed-

off malfunction (below).

Microvalve leaks. Tighten the fittings or

replace the valve if

necessary.

Sluggish or no response

to changes in deadline

tension.

Internal instrument knob

not set at minimum.

Adjust the internal

instrument knob.

Air in hydraulic system. See page 30.

Air hose plugged. Clean dirt or mud out of the

air hoses or replace air

hoses.

Faulty gear box and

motor.

Clean and fill the lubricator.

Repair or replace the air

motor.

Broken flex-shaft core. Replace the flex-shaft core.


43/94



Troubleshooting Maintenance

Erratic dril l l ine feed. Drum sensor wheel not

contacting drum flange

properly.

Adjust the air cylinder rod

end.

Drum wheel slipping due

to grease on drum

flange.

Clean the drum flange.

Drum sensor tire worn

down to wheel flanges.

Replace the rubber wheel.

Set screws loose on flex-

shaft coupling.

Tighten the set screws.

Gear box line pull is not

strong enough to lift brake

lever.

Flex-shaft set screws are

loose.

Tighten the set screws.

Rubber wheel is worn. Replace the rubber wheel.

Spring tension is too

strong.

Adjust (loosen) the spring

tension.

Broken flex-shaft core. Replace the flex-shaft core.

Flex-shaft moves back

and forth at gearbox.

Faulty bearing in the flex-

shaft coupling at the

gearbox.

Replace the bearing.

Table 1. Troubleshooting the Auto-Driller (continued)

Problem Probable Cause Corrective Action


44/94



45/94


46/94


Appendix A. Illustrated Parts

Auto-Driller controllers


There are two AOI Auto-Driller controller types:

Wall-mount controllers, model number series SA101-x-xxx

Console-mount controllers, model number series SA102-x-xxx

Figure 20. SA101 Wall-mount Auto-Driller controllers.

Auto-Driller

SA101-x-100 series for use with

deadline diaphragm.


tension sensator load cell models

50, 75, and 100.


tension sensator load cell model 40.


47/94




Figure 21. SA102 Console-mount Auto-Driller controllers

SPEEDREGULATOR

0 - 100 PSI 0 - 100 PSI

CONTROLKNOB

PULL- ON


SPEEDPENETRATION

Auto-Driller


deadline diaphragm.


tension sensator load cell models

50, 75, and 100.


tension sensator load cell model 40.


48/94




Auto-Driller system controller models

SA101 wall-mount and SA102 console-mount models are configured for usewith specific weight sensors and flex shaft lengths.

Table 2. SA101 Wall-mount controller model part numbers

Figure No.-Item No. Part Number Description

QuantityRequired

20 SA101-x-100 Wall-mount controller for use with

deadline diaphragm

1

SA101-4-100 Deadline diaphragm with 40-inch flex shaft




SA101-x-1000 Wall-mount controller for use with

sensator models 50, 75, and 100

1

SA101-4-1000 Sensator with 40-inch flex shaft, 1000 psi





sensator model 40

1





Auto-Driller


49/94




Table 3. SA102 Console-mount controller model part numbers

Figure No.-

Item No. Part Number DescriptionQuantityRequired

21 SA102-x-100 Wall-mount controller for use with

deadline diaphragm

1






sensator models 50, 75, and 100

1






sensator model 40

1





SPEEDREGULATOR

0 - 100 PSI 0 - 100 PSI

CONTROLKNOB

PULL- ON


SPEEDPENETRATION

Auto-Driller


50/94



Wall-mount system major components

Wall-mount system major components

Figure 22. SA101 Wall-mount Auto-Driller system components

1

2

4

5

6

7

8

9

10

12

9

9

weightsignalsourceoptions

3

Auto-Driller

11

9

Table 4. SA101 Wall-mount Auto-Driller system part numbers

Figure No.-Item No. Part Number Description

QuantityRequired

22 - 1 SA101-XXX SA101 INSTRUMENT 1

DS-212-100 SA101-100 Instrument, wall-mounted,

0-100


0-1000


0-1500


51/94


52/94



Console-mount system major components

Console-mount system major components

Figure 23. SA102 Console-mount Auto-Driller system

Auto-Driller

SPEEDREGU LATOR

0 - 100 PSI 0 - 100 PSI

CONTROLKNOB

PULL- ON

P US H- OF F C AU TI ON CONTROLKNOB

SPEEDPENETRATION

0

1

2

3

4

5

6

6

6

7

8

10

Driller's Console

weightsignalsourceoptions

9

Table 5. SA102 Console-mount Auto-Driller system part numbers

Figure No.-

Item No. Part Number Description Quantity

23 - 1 INSTRUMENT, console-mounted 1

DS-213-100 SA102-100 Instrument, console-mounted,

0-100


0-1000


0-1500


53/94


54/94



Instrument controller


Figure 24. DS-2311 Instrument controller

SATELLITE II

THISTEXTSAYS SOMETHINGINTHE DRAWINGTHATI S

THISTEXTSAYSS OMETHINGINTHE DRAWINGTHATIS

THIST

THISTEXTSAYSSOMETHINGINTHE DRAWINGTHATISTOOSMALLTOREADSOTHISISJUSTGREEKING

ADDEDTOMAKEITLOOKLIKETHEGREEKEDLINESOFTEXTTHATAREINTHEORIGINALDRAWINGTH

ATDIDN'TPRINTVERYWELL.

THISTEXTSAYSSOMETHINGINTHE DRAWINGTHATISTOOSMALLTOREADSOTHISISJUSTGREEKING

ADDEDTOMAKEITLOOKLIKETHEGREEKEDLINESOFTEXTTHATAREINTHEORIGINALDFAFGHF

ATDIDN'TPRINTVERYWELL.ANDTHISBOTTOMLINEEXTENDSALLAWAYOVERTOTHEEND

BACK

FRONT

6

16 17

12

3 4 57

8

9 1211

14

15

10

27

13

22

21

23

26

24

25

18

1920

29 3028

31

Auto-Driller


55/94




Table 6. DS-2311 Instrument controller part numbers

Figure No.-Item No. Part Number Description Quantity

24 - 1 DS-2311-12 INSTRUMENT ASSEMBLY, complete -

100 psi

1

- 1 DS-2311-13 INSTRUMENT ASSEMBLY, complete -

1000 psi

1

- 1 DS-2311-14 INSTRUMENT ASSEMBLY, complete -

1500 psi

1

- 2 DS-2316 . INSTRUMENT COVER ASSEMBLY 1

- 3 DS-2317 . FLANGE BEARING 2

- 4 DS-2318 . SUPPLY GAUGE 0 - 30 1

- 5 DS-2319 . OUTPUT GAUGE 0 - 30 1

- 6 DS-2310 . CONTROL PRESSURE BLOCK 1

- 7 DS-2322 . HINGE PIN 2

- 8 DS-2328 . LATCH SPRING 1

- 9

12DS-2329 . SUPPLY TUBING with nut andsleeve 1

- 10

12

DS-2320 . OUTPUT TUBING with nut andsleeve 1

- 11

12

13

DS-2331 . CONTROL TUBING with nut andsleeve

1

- 14 DS-2333 . MACHINE SCREW 2



- 17 DS-2336 . GASKET 1

not shown DS-2337 . CONTROLLER BRACKET (to case) 1

not shown DS-2338 . CONNECTOR, 1/16-inch NPT 1

not shown DS-2339 . CONNECTOR, 1/8-inch NPT 1


56/94




24 - 18 TG-684 . TAG, identification 1

- 19 DS-888321-967 . V-DRIVE 7

- 20 DS-2359 . NAMEPLATE,

AOI Instrumentation Auto-Driller

1

- 21 DS-725-503C . SCREW, set 6-32 x 1/4 1

- 22 DS-2575 . LABEL, knob 1

- 23 DS-2323 . KNOB, weight control 1

- 24 DS-2327 . BUSHING PANEL 1

- 25 DS-2326 . SPRING, knob - weight on bit control 1

- 26 DS-2325 . STEM, knob - weight on bit control 1

- 27 DS-2367 . COVER GASKET 1

- 28 DS-2332 . SCREW 7

- 29 DS-291A-12553 . WASHER, flat #6 crescent 1

- 30 DS-2321 . INSTRUCTION PLATE 1

- 31 DS-2363 . KNOB 1

not shown DS-2362 . . SET SCREWS for part number

DS-2363

2

Table 6. DS-2311 Instrument controller part numbers (continued)

Figure No.-



57/94



This page intentionally blank.


58/94



Instrument controller Controller subassembly

Controller subassembly

Figure 25. Controller subassembly

17

18

1

9

12

11

14

13

10 8

3

7

2

16

19

4

6

15

5

Controller subassembly

Table 7. Controller subassembly part numbers


25 - 1 DS-2330 FLAPPER 1

- 2 DS-2350 HEX NUT 2

- 3 DS-2349 MOUNTING BRACKET 1

- 4 DS-2354 FLAPPER PIVOT POINT 2

- 5 DS-2364 MACHINE SCREW 3


59/94



Controller subassembly Instrument controller

25 - 6 DS-2357 MACHINE SCREW 2

- 7 DS-2340 FULCRUM BEAM CASE 1

- 8 DS-2348 ORIFICE ASSEMBLY 1


- 10 DS-2347 ORIFICE BLOCK 1

- 11 DS-2343 FLAPPER SPRING 1

- 12 DS-2342 SPRING SUPPORT 1

- 13 DS-2365 PROPORTIONAL BAND PLATE 1

not shown DS-2366 PROPORTIONAL BAND PLATE

not adjustable

1

- 14 DS-2344 BOURDON TUBE, 100-pound 1

DS-2345 BOURDON TUBE, 1000-pound 1

DS-2346 BOURDON TUBE, 1500-pound 1


not shown DS-2359 NAMEPLATE,

AOI Instrumentation Auto-Driller

1

- 16 DS-2361 PRESSURE ADJUSTMENT ASSEMBLY 1

- 17 DS-2351 KNOB 1

- 18 DS-2352 SLIDING BLOCK ASSEMBLY 1

- 19 DS-2355 PIVOT BLOCK 1

Table 7. Controller subassembly part numbers

Figure No.-



60/94



Instrument controller SA101 Controller assembly

SA101 Controller assembly

Figure 26. SA101 Controller assembly rear view

123

3

1116

2

4

5

5

5

7

7

8

9

12

12

11

14

15

16

18

11

11

6

6

6

10

10 135 512 1616

18

20

19

5

21

22

24

17 11

6


61/94



SA101 Controller assembly Instrument controller

Table 8. SA101 Controller part numbers

Figure No.-


26 - 1 A11485A-01 INSTRUMENT ASSEMBLY MODULE 1

- 2 DS-2421 VALVE, micro-flow 1

- 3 DS-2386 REGULATOR, instrument 1

- 4 98-5436 ELBOW, 1/4 x 1/4 male 2

- 5 98-799 BUSHING, 1/4 x 1/8 BRS 10

- 6 98-692 PLUG, hex head, 1/4 NPT 3

- 7 98-685 CONNECTOR, male, 5/16-inch tubing 4

- 8 98-71 PLUG, square head, 1/8 NPT 2

- 9 98-474 FITTING, Pipe street TEE 1

- 10 98-69-4 ELBOW w/o nut 3/16-inch 4

- 11 98-821-3 NUT, 0.187-inch dbl comp, BRS 10

- 12 98-821-5 NUT, 0.312-inch dbl comp, BRS 4

- 13 98-991 NIPPLE, hex, 1/4 NPT, SST 1

- 14 98-843-22 COUPLING, pipe, 1/4 NPT 1

- 15 98-809Y1 NIPPLE, 1/4 NPT close 1

- 17 98-821-32 CONNECTOR, male, dbl comp body 7

- 17 98-362-5 NIPPLE, hex, 1/8 NPT 1

- 18 98-843-21 COUPLING, pipe, 1/8 NPT 1

- 19 210-516A TUBE, 5/16-inch 1

- 20 210-516B TUBE, 5/16-inch 1

- 21 210-316B TUBE, 3/16-inch 1

- 22 210-316C TUBE, 3/16-inch 1

- 23 210-316D TUBE, 3/16-inch 1

- 24 210-316E TUBE, 3/16-inch 1


62/94



Instrument controller SA101 Controller assembly

Figure 27. SA101 Controller front and bottom views

2

3

4

65

1

7

Auto-Driller



27 - 1 A11485A-01 INSTRUMENT ASSEMBLY MODULE 1

- 2 SA1267 CASE, instrument 1

- 3 SA1265 INST. PLATE, hose 1

- 4 999241-015 SCREW, DR-type U, #4 x 0.25 3

- 5 DS-2379 SPEED REGULATOR GAUGE 1

- 6 DS-2370 AIR MOTOR GAUGE 1

- 7 DS-2301 SPEED PENETRATION CONTROL

REGULATOR

1


63/94



SA101 Controller assembly Instrument controller

Figure 28. SA101 Controller rear view of interior

2

35 6 4 1117

8

9 10

interior view


Figure No.-


28 - 1 J826-1QC PLUG, square head, 1/8 NPT 2

- 2 DS-2379 GAUGE, speed regulator 1

- 3 DS-2370 GAUGE, air motor 1

- 4 J10399A-2 FITTING, bulkhead adaptor 5

- 5 DS-2301 REGULATOR, speed control 1

- 6 DS-2377 CASE CLIP 2

- 7 J811-8KQ SCREW, 1/4-20 x 1, sch, gr 4

- 8 85-4NP LOCKNUT, 1/4-20 4

- 9 999397-640 NUT, 1/4 - 20 x 0.226, machine 4

- 10 999321-320 WASHER, lock, hex, 1/4, 0.2 4

- 11 DS-2555 LABEL, Speed Penetration 1


64/94



Instrument controller SA102 Controller modules (console-mounted)

SA102 Controller modules (console-mounted)

The SA102 is console-mounted in two main parts. (The main air control valve

for the system is mounted in the controller module not as a separate item.)

Figure 29. SA102 Controller module

Table 11. SA102 Controller module parts


29 - 1 A11485A-01 CONTROLLER 1

- 2 see page 54 BIT WEIGHT CONTROL

(#21 - 26, Figure 24)

1

- 3 DS-2318 GAUGE, air supply 1

- 4 DS-2319 GAUGE, output 1

- 5 DS-2379 GAUGE, speed regulator 1

- 6 DS-2370 GAUGE, air motor 1

- 7 DS-2112 CONTROL VALVE 1

- 8 DS-2301 REGULATOR, speed control 1

SPEED REGULATOR

0 - 100 PSI 0 - 100 PSI

CONTROL KNOB

PULL - ON

PUSH - OFF CAUTION CONTROL KNOB

SPEED PENETRATION

1 2

3 4

5 6

87

Auto-Driller


65/94


66/94



Hose assemblies SA102 Controller modules (console-mounted)

Hose assemblies

Figure 30. Hose assemblies

1

13

1

2

18 6

10

14

11

15

3

4

5

7

8

9

12

16

17

19


67/94



SA102 Controller modules (console-mounted) Hose assemblies

Table 12. Hose Assembly part numbers

Figure No.-


30 - 1 DS-2371 HYDRAULIC COUPLER, female 2

- 2 DS-2372 HYDRAULIC COUPLER, male 1

- 3 DS-2438 CONNECTION #6 1

- 4 DS-2479 CONNECTION #6, 1/4-inch NPT 1

- 5 DS-2430 CONNECTION #8 1

- 6 DS-2481 CONNECTION #8, 1/4-inch NPT 1

- 7 DS-2437 #6 AIR MOTOR HOSE ASSEMBLY 40 feet

- 8 DS-2439 #8 RIG AIR SUPPLY HOSE ASSEMBLY 50 feet

- 9 DS-2376 INSTRUCTION PLATE HOSE HOOKUP 1

- 10 DS-2377 CASE CLIP 2

- 11 DS-2533 BOLTS 2

not shown DS-2539 LOCK ANCHOR 2

not shown DS-2541 NUTS 2

- 12 DS-2378 MAIN INSTRUMENT CASE 1

- 13 DSW-2379 GAUGE, Speed Regulator 1

- 14 DS-2370 GAUGE, Air Motor 1

- 15 DS-2301 REGULATOR, Speed Penetration Control

(complete)

- 16 DS-2381 BULKHEAD ASSEMBLY 5

- 17 98-692 BRASS PLUG, 1/4-inch NPT 2

- 18 857190-002 BRASS NIPPLE, 1/4-inch NPT 1

- 19 109547-150 HOSE ASSEMBLY, Hydraulic, 50 feet 1


68/94


69/94



SA102 Controller modules (console-mounted) Speed of penetration contro

31 - 3 DS-2305 . BONNET 1

- 4 DS-2306 . BONNET SCREW 6

- 5 DS-2307 . PIVOT WASHER 1

- 6 DS-2308 . SPRING 1

- 7 DS-2309 . DIAPHRAGM 1

- 8 DS-2300 . REGULATOR BODY 1

- 9 DS-2411 . VALVE SEAT 1

- 10 DS-2412 . CAP 1

not shown DS-2413 . WASHER, brass 2

- 11 . O-RING (in repair kit DS-2414) 2

- 12 . VALVE (in repair kit DS-2414) 1

- 13 . VALVE SPRING (in repair kit DS-2414) 1

- 14 . CAP O-RING (in repair kit DS-2414) 1

DS-2414 REPAIR KIT, speed penetration control

regulator (includes items 11, 12, 13, 14)1

Table 13. DS-2301 Speed of penetration control regulator part numbers

Figure No.-



70/94



Air Filter SA102 Controller modules (console-mounted)

Air Filter

Figure 32. DS-2291 Air filter assembly

1

2

Table 14. DS-2291 Air filter assembly part numbers

Figure No.-


32 DS-2291 AIR FILTER, complete assembly 1

- 1 DS-2297 . O-RING 1

- 2 DS-2298 . BAFFLE and FILTER ELEMENT 1


71/94



This page intentionally blank.


72/94


73/94



SA102 Controller modules (console-mounted) Air pressure regulator

33 - 4 DS-2380 . DIAPHRAGM 1

- 5 DS-2391 . SPRING, diaphragm 1

- 6 DS-2392 . SPACER 1

- 7 DS-2393 . SCREW, pressure regulating 1

- 8 DS-2394 . LOCKNUT, screw 1

- 9 DS-2395 . CAP 1

- 10 DS-2455 . NIPPLE, close pipe 1

- 11 DS-2462 . REDUCER, pipe 2

- 12 DS-2449 . ADAPTER, ELL, male to male copper

tube

1

DS-2396 AIR REGULATOR REPAIR KIT

(includes items 13, 14, 15, 16)

- 13 . GASKET, cap (in repair kit DS-2396) 1

- 14 . SPRING, valve (in repair kit DS-2396) 1

- 15 . PAD, spring (in repair kit DS-2396) 1

- 16 . VALVE (in repair kit DS-2396) 1

Table 15. DS-2386 Air pressure regulator assembly part numbers

Figure No.-



74/94


75/94



SA102 Controller modules (console-mounted) Microflow valve

35 - 3 DS-2425 . DIAPHRAGM BOLT, microflow valve 1

- 4 DS-2424 . DIAPHRAGM (set of 2) 1 set

- 5 DS-2426 . SEAT SCREW 1

- 6 DS-2427 . PRESSURE PLATE, upper 1

- 7 DS-2428 . PRESSURE PLATE, lower (indicate

ratio when ordering)

1

- 8 DS-2429 . PLATE SPACER (indicate ratio whenordering)

1

- 9 DS-2473 . 1/8-inch NPT plug 2

- 10 DS-2300 . MICROFLOW VALVE BODY 1

- 11 DS-2414 . MICROFLOW VALVE REPAIR KIT 1

. . VALVE with #14 o-ring 1

. . O-RING 2

. . SPRING 1

- 12 DS-2411 . SEAT 1

- 13 DS-2420 . SCREEN 1

- 14 DS-2412 . CAP 1

Table 16. DS-2421 Microflow valve assembly part numbers (continued)

Figure No.-



76/94



Lubricator SA102 Controller modules (console-mounted)

Lubricator

Figure 35. DS-2236 Lubricator assembly

Table 17. DS-2236 Lubricator part numbers


35 DS-2236 COMPLETE LUBRICATOR ASSEMBLY 1


77/94


78/94



Right-angle gear, wheel and hub SA102 Controller modules (console-mounted)

Right-angle gear, wheel and hub

Figure 36. DS-2141/DS-2142 Right-angle gear assembly

Figure 37. Wheel and hub on right angle gear

25

12

13

15

9*

1

4

5

6

7

8

9*

10

Key (18) slot

525

9*

12

14

16

9*9a

9a

11

11

20

19 21

17 (see Figure 32)

9a

9a

3

* #9 differs according to model # of the assembly.

21

19

20

22

23, 24

18

3


79/94



SA102 Controller modules (console-mounted) Right-angle gear, wheel and hub

Table 18. Right-angle gear part numbers

Figure No.-


36 DS-2141 RIGHT-ANGLE GEAR UNIT with tire

DS-2142 RIGHT-ANGLE GEAR UNIT without tire

- 1 DS-2144 . HOUSING 1

- 2 DS-2478 . PLUG 1

- 3 DS-2145 . GREASE ZERT 1

- 4 DS-2146 . WORM GEAR SHAFT 1

- 5 DS-2148 . BALL BEARING 2

- 6 DS-2149 . BEARING RETAINER (lower) 1

- 7 DS-2140 . SEAL 1

- 8 DS-2151 . BEARING RETAINER (lower) 1

- 9* DS-2152 . SCREW, fine

(check assembly model #)

16

- 9* DS-2153 . SCREW, coarse(check assembly model #)

16

- 9a DS-2154 . . LOCKWASHER 16

- 10 DS-2155 . WORM GEAR SHAFT (no gear) 1

- 11 DS-2150 . BEARING, roller 2

- 12 DS-2161 . GASKET 2

- 13 DS-2162 . OUTPUT BEARING RETAINER 1

- 14 DS-2163 . OUTPUT BEARING CAP 1

- 15 DS-2164 . OUTPUT SHAFT SEAL 1

- 16 DS-2156 . WORM GEAR (no shaft) 1

- 17 DS-2165 . WHEEL ASSEMBLY

(bolts, hub and tire)

1

- 18 DS-2526 . . KEY 1


80/94



Drum rotation sensor SA102 Controller modules (console-mounted)


Figure 38. DS-2126 Drum rotation sensor assembly

37 - 19 DS-2166 . . WHEEL RIMS ONLY 2

- 20 DS-2167 . . HUB 1

- 21 DS-2168 . . TIRE, replacement 1

- 22 DS-2528 . . SET SCREW 1

- 23 DS-1568 . HEX HEAD, 5/16 x 1 s/s 6

- 24 DS-1569 . LOCKNUTS, 5/16 s/s 6

- 25 DS-2157A . BEARING CUP 2

- 25 DS-2157B . BEARING CUP 2

Table 18. Right-angle gear part numbers (continued)

Figure No.-


12

3

4

5

6

7

8

9

10

11

12

13

1415

16

17

18

19

2021


81/94



SA102 Controller modules (console-mounted) Drum rotation sensor

Table 19. DS-2126 Drum rotation sensor mounting assembly part numbers


38 DS-2126 DRUM ROTATION SENSING UNIT

COMPLETE

1

- 1 DS-2127 . SLIDE BASE and ANCHOR 1

- 2 DS-2535 . BOLT ANCHOR 1

- 3 DS-2539 . LOCK ANCHOR 1

- 4 DS-2534 . NUT ANCHOR 1

- 5 DS-2129 . WHEEL MOUNT, base only 1

- 6 DS-2128 . WHEEL MOUNT, complete, with bolts 1

- 7 DS-2531 . BOLT 4

- 8 DS-2541 . NUT 4

- 9 DS-2120 . BOLT 1

- 10 DS-2131 . LOCK 1

- 11 DS-2132 . NUT 1

- 12 DS-2133 . CYLINDER SLIDE 1

- 13 DS-2134 . AIR CYLINDER 1

- 14 DS-2135 . O-RING 1

- 15 DS-2136 . CYLINDER SPRING 1

- 16 DS-2478 . No. 4 ELL CONNECTION 1

- 17 DS-2137 . CLEVIS 1

- 18 DS-2138 . NUT 1

- 19 DS-2537 . BOLT, clevis 1

- 20 DS-2530 . LOCK, clevis 1

- 21 DS-2543 . NUT, clevis 1


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Flexible shafts SA102 Controller modules (console-mounted)

Flexible shafts

Figure 39. Flexible shafts

Table 20. Flexible shafts part numbers


39 DS-2292 FLEX SHAFT, complete, 22-inch 1

DS-2283 FLEX SHAFT, complete, 40-inch 1




3

1

2


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Flex shaft couplers Flexible shafts

Flex shaft couplers

Figure 40. SA5038 - Flex shaft couplers

39 DS-2287 FLEX SHAFT, complete, 80-inch 1


- 1 DS-2280-1 BEARING ASSEMBLY, female 1

- 2 DS-2280-3 BEARING ASSEMBLY, male 1

- 3 DS-2529 SCREW, coupler, square head 2

Table 21. SA5038 - Flex shaft couplers part numbers


40 - 1 DS-2280-5 FLEX SHAFT COUPLER, flexible rubber

sleeve type

1

- 2 DS-2280-6 FLEX SHAFT COUPLER, chain link type 1

- 3 DS-2529 SCREW, coupler, square head 4

Table 20. Flexible shafts part numbers (continued)

Figure No.-


1

2

top view

3

Standard coupler

supplied


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Control valve Flex shaft couplers

Control valve

Figure 41. DS-2111 Control valve assembly

Table 22. DS-2111 Control valve part numbers


41 DS-2111 CONTROL VALVE ASSEMBLY, complete 1

DS-2112 CONTROL VALVE ASSEMBLY, less panel (9) 1

- 1 DS-2114 . KNOB, stainless steel 1

- 2 DS-2115 . WASHER, star lock 2

- 3 DS-2116 . NUT, seal-retaining 1

1

2

3

4

56

7

3

8

6

6

6

7

7

9

AOIAu

to-Drille

r


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Flex shaft couplers Spring set

Spring set

Figure 42. DS-2222 Spring set

41 - 4 DS-2117 . SPACER, 1/4-inch (for 1/8-inch panel) 1

- 4 DS-2118 . SPACER, 1/8-inch (for 1/4-inch panel) 1

- 5 DS-2121 . CONTROL VALVE BODY 1

- 6 DS-2122 . O-RING SEALS 3

- 7 DS-2119 . CAGE 3

- 8 DS-2110 . VALVE STEM 1

- 9 DS-2113 . CONTROL VALVE PANEL A/R

not shown DS-2468 . CONNECTION TEE 1

not shown DS-2483 . CONNECTION SWIVEL 1

not shown DS-2482 . CONNECTION (#8) 2

Table 22. DS-2111 Control valve part numbers (continued)

Figure No.-


Table 23. DS-2222 Spring set part numbers

Figure No.-


42 - DS-2222 SPRING SET, complete

- 1 DS-2221 . BRAKE HANDLE SPRING 3

- 2 DS-2243 . PLATE, spring assembly 2

- 3 DS-2244 . CHAIN, spring assembly A/R

1 2

3


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Air motor/differential gearbox Flex shaft couplers


Figure 43. DS-2171 Air motor/differential gearbox

1

2

34

5

67

8

9

10

11

1239

16

17

19

20

15

22 37

24

25

31

30

35

36

9a

40

21

23

29

28

3221a

35

9b

9c

1a

1c

1b

1d

1e

11

16a

14

13

18

27

33

20

7a

34

24a

26

21b38

41


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Flex shaft couplers Air motor/differential gearbox

Table 24. DS-2171 Air motor/differential gearbox part numbers


43 DS-2171 2-SPEED GEAR UNIT, complete 1

DS-2172 2-SPEED GEAR UNIT, less air motor

DS-2173 . MOUNTING PLATE 1

DS-2533 . BOLT 4

DS-2530 . LOCK 4

DS-2542 . NUT 4

- 1 DS-2174 . SHIFT, MANUAL, complete 1

- 1a DS-2175 . . SHIFT BODY 1

- 1b DS-2176 . . SHIFT KNOB 1

- 1c DS-2177 . . SHIFT SHAFT 1

- 1d DS-2178 . . KNOB, SET SCREW 1

- 1e DS-2179 . . SHIFT LOCKING SCREW 1

- 2 DS-2170 . LOCKWASHER, 3/8 1

- 3 DS-2481 . SHIFT FORK 1

- 4 DS-2530 . NUT, 5/8 1

- 5 DS-2182 . PLANET GEAR CARRIER ASSEMBLY,

complete

1

- 6 DS-2183 . SUN MOTOR GEAR/gear, flange 1

- 7 DS-2184 . MOTOR FLANGE MOUNT GEAR 1

- 7a DS-2185 . GASKET 1

- 8 DS-2187 . SET SCREW, 1/4 1

- 9 DS-2188 . AIR MOTOR, 1HP 1

- 9a DS-2626 . . GASKET 1

- 9b DS-2180 . . MUFFLER 1

- 9c 857190-002 . . NIPPLE, hex, 1/4 NPT 1


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Air motor/differential gearbox Flex shaft couplers

43 - 10 1418 . ELBOW, 1/4 NPT 1

- 11 DS-2528 . SCREW, steel cap 1/4-inch 3

- 12 DS-2535 . LOCKWASHER, 1/4 4

- 13 DS-2192 . BEARING, high speed 1

- 14 DS-2193 . WORM GEAR SHAFT ASSEMBLY 1

- 15 DS-2194 . BEARING, high speed 1

- 16 DS-2195 . OIL RETAINER PLATE 1

-16a DS-2196 . . GASKET 1

- 17 DS-2198 . HAND WHEEL 1

- 18 DS-2197 . OIL SEAL 1

- 19 DS-2199 . MAIN GEAR CASE HOUSING 1

- 20 DS-2190 . OIL LEVEL SIGHT GLASS 1

- 21 DS-2103 . SPACER 1

- 21a DS-2102 . . BEARING 3

- 21b DS-2104 . . BEARING 2

- 22 DS-2106 . COMBINATION GEAR ASSEMBLY 1

- 23 DS-2105 . WORM GEAR W/44 PINS 1

- 24 DS-2107 . PRECISION BEARING 1

- 25 DS-2108 . BEARING 1

- 26 DS-2101 . CROSS-PINION SHAFT 1

- 27 DS-2100 . SIDE PLATE 1

- 28 DS-2211 . REEL CABLE 1

- 29 DS-2212 . SCREWS, steel cap AH 4

- 30 DS-2213 . OVERRUNNING CLUTCH 1

- 31 DS-2214 . NUT 1


Figure No.-



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Flex shaft couplers Air motor/differential gearbox

43 - 32 DS-2215 . GEAR SHAFT W/GEAR 1

- 33 DS-2525 . CLUTCH KEY 1

- 34 DS-2216 . REEL CLUTCH COVER 1

- 35 DS-2217 . SEAL 1

- 36 DS-2476 . PLUG, 1/2-inch 1

not shown DS-2475 . PLUG, 1/4-inch 1

- 37 DS-2218 . PLANET W/NEEDLE BEARINGS 3

- 38 DS-2219 . NEEDLE BEARINGS 6

- 39 DS-2529 . HEX HEAD, 1/4 x 20 x 1 SS 3

- 40 DS-2535 . LOCK WASHER, 1/4 3

- 41 DS-2109 . GASKET 1

not shown DS-2191 MUFFLER PAD 1

not shown DS-2223 CABLE (wireline from reel to brake) 1

not shown DS-2224 PULLEY (optional per installation) 1

not shown DS-2225 CLAMP (for cable at reel end) 2

not shown DS-2210 QUART (US) oil (gearbox capacity:

1.5 quarts, US)

1.5

quarts


Figure No.-



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Flex shaft couplers Deadline Diaphragm

Table 25. 60-421 Deadline diaphragm part numbers


44 60-421 DEADLINE DIAPHRAGM, complete

- 1 421-112 . Top hook 1

- 2 85-535 . Screw, hexhead, 1/2-13 x 1-1/2 1

- 3 85-540 . Screw, hexhead, 1/2-13 x 1-/3/4 1

- 4 42-114 . Shims 2

not shown 421-125 . Safety nut 1

- 5 421-227 . Deflection plug 1

- 6 421-228 . Cover 1

- 7 421-229 . Deflection plate 2

- 8 21-421 . Diaphragm rubber 1

- 9 421-226 . Back 1

- 10 85-312 . Screw, hexhead, 5/16-24 x 2 6

- 11 85-317 . Screw, hexhead, 5/16-24 x 1-3/4 14

- 12 85-3FEN . Nut, elastic stop, 5/16-24 20

- 13 421-805 . Hose clamp 2

- 14 98-71 . Drain plug 1

- 15 98-64 . Elbow 1

- 16 421-23 . C-clamp, complete, including the

following parts:

1

421-20 . . Clamp 1

421-21 . . Screw, C-clamp 1

421-19 . . Chain 1


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Disconnect couplings Flex shaft couplers

Disconnect couplings

Figure 45. Snap-type disconnect couplings

Table 26. Snap-type disconnect couplings


45 - 1 AJ235 HOSE FITTING, Reusable 1

- 2 569510-004 QUICK DISCONNECT, Female, GK 1

- 3 869510-005 QUICK DISCONNECT, Male, GK 1

- 4 98-996 NIPPLE, 1/4-inch 1

2

1

3

4


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AOI Auto Driller

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