Maintenance

Symptom Problem Solution
Won't do any operation 1.  No Air supply or Valves Turned off A.  Verify that air supply valves are open.
B.  Check compressor and/or plant air supply.
C.  Verify that air hoses are not kinked.
D.  Verify that air dryer is not plugged.
2.  Panic Buttons not set to proper position A.  Red Panic Button must be in the Out Position
3.  Air supply too low - CFM or PSI A.  Check pressure at compressor or plant supply lines
B.  Verify that air dryer is not plugged
C.  Verify that air hoses are not kinked and that valves are fully open.
D.  Water separator/lubricator not allowing enough air to pass.
4.  Air leaks on supply hoses or fittings A.  Check air hoses for leaks and fix if necessary.
B.  Check fittings for leaks and fix if necessary or reclamp if leaking through clamps.
C.  Check and replace if necessary any bad gaskets and/or fittings.
D.  Check for leaks in Armadillo fittings or 1/2" manifold tubes.
5.  Air leak on red 5/32" line feeding Control box A.  Check for air leaks on red 5/32" line, not enough air pressure for operation.  Reconnect or replace hose if necessary.
Assuming Good Air Supply & Red Panic Buttons are proper positioned - No Rotation 1.  Belt broken on rotation motor A.  Replace 900 cm belt.
2.  Bearing frozen in Head Assembly A.  Check bearings in Air Swivel.  Replace if necessary.
B.  Check bearing in rear saddle of Head Assembly. Replace if necessary.
C.  Check Water Swivel bearing.  Replace if necessary.
D.  Check bearing on shaft.  Replace if necessary.
3.Something jammed in rotating parts A.  Check all rotating parts for obstruction.
A.  Rotation motor broken or bad and/or slow start A.  Check rotation motor and/or slow start.  Replace if necessary.
5.  Slow start - flow regulator A. Properly adjust flow regulator valve.
6.  Not enough air pressure in yellow 5/32" line A. Check Yellow 5/32" line and/or Red 5/32" line for leaks.  Verify that they are connected properly.  Replace if necessary.
7.  Rotation Valve - Control Box A.  Check Rotation valve in Control Box.  Replace if necessary.
8.. Volume Control Valve A.  Check that screen in the bottom of Volume Control valve is not plugged with material.  
Symptom Problem Solution
No Water 1.  Pump not on or not engaged A.  Turn on and/or engage Pump.
2.  Cartridge in Dump Valve stuck or broken A. Check cartridge in dump valve and replace if necessary.  
3.  No Air Pressure on black 5/32" lines, red 5/32" lines, and/or yellow 5/32" lines A.  Check for air pressure and/or leaks on black 5/32" lines, red 5/32" lines and yellow 5/32" lines.  Reconnect or replace if necessary.
4.  Control Box pressure switch bad A.  Check pressure switch in control box that air is pressing through valve properly and replace if necessary.
5.  Dump Valve Air Actuator not moving properly A.  Check Air Actuator on Dump Valve and replace if necessary.
No Forward 1.  Not enough air pressure on blue 5/32" Lines A.  Check for leaks on 5/32" Lines and replace if necessary. 
2.  Broken Belts A.  Check belt - replace if needed
3.  Bad forward/reverse switch on Control Box A. Check for proper air flow from forward/reverse valve in Control Box.  Replace switch if necessary.
4.  Bad 5-Port 4-Way valve A.  Check 5-port 4-way valve that it is working properly.  Replace if necessary.
5.  Forward Flow regulator valve closed too tight. A.  Check the forward flow regulator.  Make sure that it is open enough.
6.  Air Leaks on 1/2" tubing or fittings A.  Check for possible air leak on one of the fittings that the 1/2" red tubing connects.  Reconnect or replace if necessary.
7.  Air leak under stationary Air Swivel A.  Check for leaks in Front Saddle of Air Swivel.  Replace gasket (O-ring) if necessary.
8.  Air Swivel seal leaking A.  Check Air Swivel for leaks between stationary & rotating parts. Replace seals if necessary.
9.  Lance stuck in drum. A.  Check lance to make sure it is free in the drum & not putting force on the Transfer Tube.
10.  Head Cartridges not adjusted A.  Adjust Head Cartridges properly
11.  Wheels on Head Cartridges worn out A.  Replace worn wheels
No Reverse 1.  Not enough air pressure on green 5/32" Line A.  Green 5/32" Line leaking 
2.  Broke Belts A.  Check belt - replace if needed
3.  Bad forward/reverse valve on Control Box A. Check for proper air flow from forward/reverse valve in Control Box
4.  Bad 5-Way 4-way valve A.  Check 5-port 4-way valve that it is working properly.  Replace if necessary.
5.  Reverse Flow regulator valve closed too tight. Check the reverse flow regulator.  Make sure that it is open enough. (If applicable)
6.  Air Leaks on 1/2" tubing or fittings A.  Possible air leak on a fitting that connects to the 1/2" red tubing.
7.  Air leak under stationary Air Swivel A.  Check for leaks in Front Saddle of Air Swivel.  Replace gasket (O-ring) if necessary.
Symptom Problem Solution
No Reverse (cont.) 8.  Air Swivel seal leaking A.  Check Air Swivel for leaks between stationary & rotating parts. Replace seals if necessary.
9.  Too much lance in drum A.  Drum is full of lance & won't allow anymore to load on drum.
10.  Head Cartridges not adjusted A.  Adjust Head Cartridges properly
11.  Wheels on Head Cartridges worn out A.  Replace worn wheels
Poor Operation (Intermittent Operation) 1.  Water in Air System A.  Check for water in Air System.  
B.  Clean Air System - Blow out all water (debris)
2.  Water in pilot Control System A.  Check pilot control lines & valves for water.  Clean if necessary - Blow out all debris.
3.  Air leaks A.  Check for air leaks.  Could have air leaks only while in operation mode & not be able to hear the leaks.
Slow Rotation 1.  Rotation Motor Icing A.  Check rotation motor for icing (freezing) conditions.  Thaw if necessary.
2.  Rotation Motor going bad. A.  Rotation Motor air vanes could be wearing. 
B.  Rotation Motor mechanical gears are dry & wearing - Needs to be greased.
3.  Air leak on yellow 5/32" Line A.  Check yellow 5/32" line for proper air pressure.
4.  Air leak on red 5/32" line A.  Check the red 5/32" line for air leaks
5.  Flow Regulator adjusted incorrectly A.  Check flow regulator - May be closed to tight - adjust as needed.
6.  Bearings going bad in Head Assembly A.  Check the bearings in the Air Swivel & the Middle saddle 
7.  Guide hose filling up with debris A.  Check guide hose that it is free from debris.  May need to flush clean or change guide hose.
8.  Tubes have too much material left inside A.  May be going too fast through tubes - worm holing the product you are cleaning, which could be binding the lances rotation.
9.  Bent tubes creating excess drag A.  Bent tubes could be binding the lances rotation.
10.  Volume Control Valve screen plugged A.  Check & clean the screen on the inlet of the Volume Control Valve.
11.  1/2" tubing leaking A.  Check for air leaks on the supply lines.
B.  Check the 1/2" red tubing & elsewhere.
Slow Forward 1.  Broken Belt A.  Check belt - replace if needed
2.  Head Cartridge not adjusted properly A.  Too much space between the 2 cartridges - adjust properly.
3.  Wheels on Head Cartridges worn out A.  Deep grooves in wheels - no friction left - Replace worn wheels.
4.  Air leak on 1/2" tubing from 5-port 4-way air motors A.  1/2" red tubing leaking - repair or replace the section of 1/2" red tubing
5.  Air leak on pilot control lines A.  Check all of the 5/32" lines for leaks.  Leaks on the red, yellow, black or blue could affect the forward speed.
Symptom Problem Solution
Slow Forward (cont.) 6.  Air Swivel seals leaking A.  Check Air Swivel seals for leaks - replace if necessary.
7.  Flow regulator adjusted incorrectly A. Check setting of forward Flow Regulator - replace if necessary.
8.  Air leak under stationary port of Air Swivel A.  Check for leaks under Air Swivel - replace gasket (O-ring) if necessary.
9.  Guide Hose plugging with debris A.  Check guide hose for debris - flush if necessary
10.  Bent tubes excess drag or worm holing. Excess drag could be coming from bent tubes or worm holing tubes.
Slow Reverse 1.  Broken Belt A.  Check belt - replace if needed
2.  Head Cartridge not adjusted properly A.  Too much space between the 2 cartridges - adjust properly.
3.  Wheels on Head Cartridges worn out A.  Deep grooves in wheels - no friction left - Replace worn wheels.
4.  Air leak on 1/2" tubing  A.  1/2" red tubing leaking - repair or replace the section of 1/2" red tubing
5.  Air leak on pilot control lines A.  Check all of the 5/32" lines for leaks.  Leaks on the red, yellow, black or green could affect the forward speed.
6.  Air Swivel seals leaking A.  Check Air Swivel seals for leaks - replace if necessary.
7.  Flow regulator adjusted incorrectly A.  Check setting of reverse Flow Regulator - replace if necessary. (If applicable)
8.  Air leak under stationary port of Air Swivel A.  Check for leaks under Air Swivel - replace gasket (O-ring) if necessary.
9.  Guide Hose plugging with debris A.  Check guide hose for debris - flush if necessary
10.  Bent tubes excess drag or worm holing. A.  Excess drag could be coming from bent tubes or worm holing tubes.
Lance goes so far then stops 1.  Lance to short A.  If lance keeps going a long way into the tube then stops - chances are the lances is too short.
2.  Lance is flipped in the drum A.  If the lance goes in a short or long distance into the tube and stops and this action continues - chances are the lance is flipped in the drum.  The lance will have to be rewound onto the drum. 
3.  Excess material built up on lance. A.  Excess material could be sticking to the lance not allowing it to be propelled forward.  Clean off excess material.
No Brake 1.  Brake Tower Timer A.  Brake Tower Timer could have water or debris inside.  Change or clean as necessary.
2.  Air leak - 5/32" line A.  Check 5/32" line from Brake Timer Tower to brake Caliper for leaks.
B.  Check white 5/32" line for air leaks.
3.  Brake Caliper leaking A.  Check for leak on the Brake Caliper.  There is an O-ring between the two halves of the  Brake Caliper.  Replace if necessary
Symptom Problem Solution
Brake Won't Release 1.  Brake Tower Timer A.  Check the adjustment of the Brake Tower Timer
2.  Caliper not floating freely A.  Check that the caliper moves freely on the mounting bolts.
Low Water Pressure 1.  Possible pump problem A.  Check pump - packing, valves & by-pass valve
2.  Water leak somewhere A.  Check for water leaks, fittings, stinger, lance, etc.
3.  5/32" lines leaking (not enough air  pressure on black line.) A.  Check for proper air pressure on black 5/32" line
B.  Leaks on red, yellow, blue, green or black 5/32" lines could effect the proper pressure for the black 5/32" line.
4.  Tip blown out A.  Check tip - replace if necessary.
5.  Air Actuator on Dump Valve not moving far enough - Dirty or vent plugged. A.  Check the travel of the air actuator on the Dump Valve - May be dirty inside stopping full travel.
B.  Check the vent on the back side of  the piston - may be plugged causing an air bound situation behind the piston not allowing full travel.  Repair or replace as needed.
Forward Won't Stop 1.  5-port 4-way Valve stuck - Forward/Reverse valve bad A.  The 5-port 4-way valve could stick causing the lance to travel forward or reverse after the forward/reverse valve has been released to the neutral position. The Red Panic Buttons will not stop this situation.  The Red Panic Buttons will stop the rotation taking the danger away.  The air has to be shut off at the 1" Ball Valve on the back of the Armadillo or the Air Dryer or at the air source.  Change the  5-port 4-way Valve.
2.  The blue 5/32" line won't bleed off A.  The blue 5/32" line may not be releasing it's air pressure.  Check the Forward/Reverse Valve that it bleeds off.  Change if necessary.
Reverse Won't Stop 1.  5-port 4-way Valve stuck - Forward/Reverse valve bad (Bleed off) A.  The 5-port 4-way valve could stick causing the lance to travel forward or reverse after the forward/reverse valve has been released to the neutral position.  The Red Panic Buttons will not stop this situation.  The Red Panic Buttons will stop the rotation taking the danger away.  The air has to be shut off at the 1" Ball Valve on the back of the Armadillo or the Air Dryer or at the air source.  Change the  5-port 4-way Valve.
2.   The green 5/32" line won't bleed off A.  The green 5/32" line may not be releasing it's air pressure.  Check the Forward/Reverse Valve that it bleeds off.  Change if necessary.
Rotation Won't Stop 1.  Volume Control Valve bad A. Volume Control Valve won't shut off -  Change valve
2.  Yellow 5/32" line won't bleed off - Rotation Valve bad (Control Box) A.  Check that the yellow 5/32" line is bleeding off when the Rotation Valve is in the off position - Change valve is necessary.
Water Pressure Won't Release 1.  Water Valve Bad (Control Box) A.  Check that the water valve in the Control Box is bleeding off the black 5/32" line.  Change valve is necessary.
2.  Air Actuator stuck A.  Check that Air Actuator on the Dump Valve is moving fully.  Repair or replace as needed.
Symptom Problem Solution
Water Pressure Won't Release(cont.) 3.  Dump Cartridge bad A.  Check the Dump Cartridge - could be stuck.  Replace if necessary.
Too Much Water Pressure 1.  Tip plugged A.  Check tip for debris in holes.  Clean or replace flush system before replacing tip.
2. Something in lance A.  Something could have gotten into the water system somehow causing a restriction greater than the restriction in the tip.  Have to break down the system to find the restriction.  Repair
3.  Put the wrong tip on the stinger A.  The tip could have been replaced with the wrong sized tip.  Replace with proper tip.
4.  Pump adjusted incorrectly. A.  Check the pump adjustment.  It could be set wrong by mistake.  Also by running a worn tip & increasing the pump to compensate, then replacing the tip.  Every time a tip is changed the pump adjustment must be reset.
Rotation Won't Slow Down 1.  Flow regulator bad A.  Check the Flow Regulator Valve.  May not be working properly.  Change if necessary.