320XPC Mechanical Manual PDF

320XPC Mechanical Manual
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320XPC-UDC Mechanical Systems Manual Preface
Preface
This manual is provided as a guide to personnel involved with the operation, maintenance and repair of this rotary
blasthole drill. We recommend that such personnel review and become familiar with the general procedures and
information contained within this manual. In addition, we recommend that this manual be kept readily available for
reference when repairs or maintenance are necessary.
Due to the complexities of mining equipment and the environment in which it operates, situations may arise which
are not directly discussed in detail in this manual. When such a situation arises, past experience, availability of
equipment, and common sense play a large part in what steps are to be taken. In addition, a P&H MinePro Ser-
vices Representative is available to answer your questions and assist you upon request.
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Copyright
Copyright © 2012 P&H Mining Equipment, Inc. All rights reserved. All materials contained herein are protected by
United States copyright law and international treaties, and may not be reproduced, distributed, transmitted, dis-
played, published or broadcast without the prior written permission of P&H Mining Equipment. You may not alter
or remove any trademark, copyright or other notice from copies of the content. All rights in translations of these
materials shall remain exclusively with P&H Mining Equipment.
Copyright © 2012 P&H Mining Equipment, Inc. Peak Services

Preface.fm -i- Preface, Version 00 - 07/12
Preface 320XPC-UDC Mechanical Systems Manual
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Peak Services Copyright © 2012 P&H Mining Equipment, Inc.

Preface, Version 00 - 07/12 -ii- Preface.fm
BD320176 Mechanical Systems Manual
Section 0
Quick Table of Contents
Safety
(Section 1) Water Injection Hydraulic Bailing Air Electrical
System System System System
(Section 8) (Section 9) (Section 7) (Section 5)
Introduction
(Section 2)
t
Jib Crane
n
(Option)
e
Preventative Auxiliary Air
(Section 20)
Y
Maintenance
m
System
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(Section 3) (Option)
Pipe Handling & (Section 20)
Deck Tools
(Section 16)
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Leveling
A
System
I o p e (Section 11)
R ce O
BD1130c01
E
Auxiliary
t
AT nan en
Winch
(Section 18) Top Off Power Unit
Air Conditioning (Section 6)
System
M te m
(Section 19)
Mast (Section 20)
(Section 13)
E i n i p
C a q u Hydraulic Boarding Lubrication
Hoist /
E N M E
Ladders (Option) Systems
r
(Section 12)
r
(Section 20)
R
Pulldown
Machinery
(Section 14)
E E fo f o
E F S E House
S
Rotary
R U U
Pressurization
Machinery
(Section 17)
T T
(Section 15)
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Pipe Storage /
Handling
General Maintenance
(Appendix A)
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(Section 16) Cable Reel
(Section 4) General Hydraulic
System Maintenance
BD1129a01 (Appendix B)
Component Weights
Propel System (Appendix C)
(Section 10)
Model 320XPC Mechanical Systems Manual Visual Table of Contents

Sec00vtoc.fm -iii- Section 0, Version 00 - 02/12
BD320176 Mechanical Systems Manual
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Section 0, Version 00 - 02/12 -iv- Sec00vtoc.fm
320XPC-UDC Mechanical Systems Manual Table of Contents
Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Quick Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiii
SECTION 1, Blasthole Drill Safety

1.1 Operator Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.2 Operator Conduct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
n t 1.1
e
1.3 Functional Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Y
1.4 Operation Near Electrical Lines Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.5 Safety Decals and Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
O q t
1.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
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1.5.2 Hazard Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
A
1.5.3 Safety Hazard Decals and Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
I o p e
SECTION 2, Introduction
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E
R . .e. . . . . . .O. . . . . . . . . . . . . . . . 2.1
. . . . . . .c
2.1.1 Part Numbers . . . . . . . . . . . . . . . . . .T .......n . . . . . . .n. .t. . . . . . . . . . . . . . . . . . 2.1
A
2.1.2 Applicability . . . . . . . . . . . . . . . . . . . . . . . .n a
. . . . . . . .e
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2.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . t. e. . . . . . . .m
. . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.1 General . . . . . . . . . . . . . . .E . . . . . . . . i.p

. . . . . . .in
. . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.2 Drill Description . . . . . . .C . . . . . . .a. . . . . . . .u

. . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.3 Power Unit . . . . . . . . N . . . . . . .M. . . . . . . . . .q. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
E r r E
2.2.5 Rotary CarriageR . . . . . . .fo
. . . . . . .f.o
2.2.4 Lower Final Assembly (Undercarriage and Propel) . . . . . . . . . . . . . . . . . . . . . . . . 2.4
E
2.2.6 Mast, MastFLock Assy, E
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
E S S E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
and Back Braces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
R WinchU. .. .. .. .. .. U
2.2.7 Drill Pipe Storage and Handling
T
2.2.8 Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
O
2.2.9 Deck Wrenches
T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
N
2.2.10 Operator’s
2.2.11 Hydraulic N O
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
D O O
2.2.12 Water Injection System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.2.13
D
Automatic Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.2.14 Bailing (Main) Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.2.15 Towing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.2.16 Dust Curtains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.3 Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.4 Sign Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.5 Material Safety Data Sheets (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
SECTION 3, Preventive Maintenance

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

MG320176-00-ENTOC.fm -v- Table of Contents, Version 00 - 07/12
Table of Contents 320XPC-UDC Mechanical Systems Manual
Table of Contents (Continued)

3.2 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.3 Bolt Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.4 Bolts And Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.4.1 Special Bolt Tightening Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.5 Maintenance Schedule Check Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.5.2 Using The Maintenance Schedule Check Sheets . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.6 Maintenance Schedule Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
t
3.7 “A” Maintenance Checks (Daily or 8-10 Hours). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
n
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3.7.1 Note and Record Any Faults Displayed on GUI Fault Log . . . . . . . . . . . . . . . . . 3.13
Y
3.7.2 lnspect Operator Cab Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
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3.7.3 Check Hydraulic Tank Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3.7.4 Check Hydraulic Tank Breather Condition Indicator . . . . . . . . . . . . . . . . . . . . . . 3.16
O q t
3.7.5 Check Pump Drive Transmission Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
L f E ra
3.7.6 Check Main Air Compressor Oil Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . 3.18
A
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3.7.7 Fill Water Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
p
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3.7.8 lnspect Deck Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
E t
3.7.9 lnspect Auxiliary Winch and Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
AT nan en
3.7.10 lnspect Drill Pipe Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
3.7.11 Inspect Pipe Rack Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
M te m
3.7.12 Check Rotary Gearcase Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
E i n i p
3.7.13 Check Pulldown Gearcase Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
C a q u
3.7.14 Inspect Rotary Carriage Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
N M E
3.7.15 Inspect Machine For Damage And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
E
R o r r
3.7.16 Inspect Crawlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
o
E E f f
3.7.17 lnspect Jack Shoes And Retaining Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
F E
3.7.18 lnspect Jack Housing and Cylinder Mounting Hardware . . . . . . . . . . . . . . . . . . 3.25
E S S
3.7.19 Inspect Auxiliary Air Compressor Before Using. . . . . . . . . . . . . . . . . . . . . . . . . 3.25
R U U
3.8 “B” Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
T T
3.8.1 Perform “A” Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
O
N NO
3.8.2 lnspect Hydraulic System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
3.8.3 lnspect Breakout Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
O
3.8.4 Inspect Pipe Rack Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
D DO
3.8.5 lnspect Mast Racks and Pinions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
3.8.6 lnspect Rotary Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
3.8.7 Inspect Bailing Air System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
3.8.8 Check Main Compressor Oil Separator Filters . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
3.8.9 Check Main Compressor Air Intake Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
3.8.10 Check Hydraulic Charge Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
3.8.11 Check Main Compressor Oil Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
3.8.12 Check Hydraulic Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
3.8.13 Check Auto Lube Grease Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
3.8.14 Check Cable Reel Oil Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
3.8.15 lnspect Trail Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41

Table of Contents, Version 00 - 07/12 -vi- MG320176-00-ENTOC.fm

3.8.16 Check Crawler Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
3.9 “C” Maintenance Checks - Monthly or Every 160-250 Hours. . . . . . . . . . . . . . . . . . . . . 3.42
3.9.1 Perform “A” and “B” Maintenance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
3.9.2 lnspect Mast Back Braces And Slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
3.9.3 lnspect Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
3.9.4 lnspect Auxiliary Winch Rope and Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
3.9.5 Inspect Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
3.9.6 Inspect Crawler Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
n t
3.9.7 Check Propel Transmission Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
e
3.9.8 Inspect Cable Reel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
Y
3.9.9 Check Auxiliary Winch Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
m
NL uip ion
3.9.10 Clean/Flush Water Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
3.9.11 Clean Main Compressor and Hydraulic Oil Coolers . . . . . . . . . . . . . . . . . . . . . 3.49
O q t
3.9.12 Clean/inspect Machinery House Blowers And Filters . . . . . . . . . . . . . . . . . . . . 3.49
A L f E ra
3.9.13 Change Main Compressor Bearing Oil Filter (GD Compressor Only) . . . . . . . . 3.51
I o e
3.10 “D” Maintenance Checks (Quarterly or 500 Hours). . . . . . . . . . . . . . . . . . . . . . . . . . . .
p
3.51
ER ce O
3.10.1 Perform “A”, “B” and “C” Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
t
3.10.2 Check Bolts, Mounting And Attachment Torques . . . . . . . . . . . . . . . . . . . . . . . 3.52
AT nan en
3.11 “E” Maintenance Checks (Semi-annually or 1000 Hours) . . . . . . . . . . . . . . . . . . . . . . . 3.52
3.11.1 Perform “A”, “B”, “C” and “D” Maintenance Checks. . . . . . . . . . . . . . . . . . . . . . 3.52
M te m
3.11.2 Change Rotary Gearcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
E i n i p
3.11.3 Change Hoist/Pulldown Gear Reducer Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
C a q u
3.11.4 Replace Main Compressor Oil Separator Filters . . . . . . . . . . . . . . . . . . . . . . . . 3.55
N M E
3.11.5 Replace Oil Line Scavenger Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E
3.55
R o r r
3.11.6 Replace Suction Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
o
3.56
E E f f
3.11.7 Change Low Pressure Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58
F E
3.11.8 Change Main Return Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.60
E
R U U S S
3.11.9 Change Pump Drive Transmission Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11.10 Change Propel Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.63
3.65
T T
3.11.11 Lubricate Cable Reel Bearings, Trolly Wheels and Chains . . . . . . . . . . . . . . . 3.65
O
N NO
3.12 “F” Maintenance Checks - Annually or 2000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.12.1 Perform “A”, “B”, “C”, “D” and “E” Maintenance Checks . . . . . . . . . . . . . . . . . .
3.67
3.67
O
3.12.2 Change Hydraulic System Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.67
D DO
3.12.3 Change Auxiliary Winch Gearcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.67
3.12.4 Change Air Compressor Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.68
3.12.5 Change Cable Reel Gear Reducer Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.68
3.12.6 Change Cable Reel Hydraulic System Oil and Replace Filters. . . . . . . . . . . . . 3.70
SECTION 4, Cable Reel

4.1 Cable Reel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1.2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4.1.4 Cable Reel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

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4.2 Trail Cable Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.3 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
4.4 Cable Reel Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
4.4.1 Right Angle Bevel Gear Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
4.4.2 Lubricate Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
4.4.3 Cable Reel Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
4.4.4 Inspect Cable Reel Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
4.5 lnspect Trail Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
t
4.6 Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
n
e
4.6.1 Level Wind Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
Y
4.6.2 Hydraulic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
m
NL uip ion
4.7 Post Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
4.8 Cable Reel Hydraulic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
O q t
4.9 Component Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
L f E ra
4.9.1 Hydraulic Pump and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
A
I o e
4.9.2 Collector Ring Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
p
E R ce O
T an nt
SECTION 5, Electrical System
SECTION 6, Power Unit

6.1 General . . . . . . . . . . . . . . . . . . . . . . . .M
A
. . . . . . .e . .n
e
6.1.1 Power Unit Arrangement . .E . . . . . . . . . t. . . . . . .p
n m
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
CPower Unit i
a Components i
u . . . . . . . . . . . . . . . . . . . . . . . 6.2
. . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2 Power Unit Maintenance . . . N . . . . . . . . . . . . . . . . .q. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.1.2 Alignment Procedures for
6.2.1 Main Drive Motor E

M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
. . . . . . . r. . . . . . . . . E
6.2.2 Air CompressorR . . . . . . .f.o. . . . . . .o .r
E
F SE E f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
6.2.3 Hydraulic Pump Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
R E U S
SECTION 7, Main Air System
7.1 Major Component T
U
O T
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
N
7.1.1 Subsystems
7.1.2 Air Compressor N O
and Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Oil Circulation Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
D O Intake O
7.1.3 Scavenger Oil Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
7.1.4 Air
D Subsystem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
7.1.5 Air Compressor Discharge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
SECTION 8, Water Injection System

8.1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.2 Water Injection System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
8.2.1 1000 Gallon Water Tank R33238F3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.2.2 Submersible Water Pump 37U152D3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.2.3 Pressure Relief Valve R12410D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9

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8.3 Sensing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
8.4 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
SECTION 9, Hydraulic System

9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.2 Hydraulic System Shared Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.2.1 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.2.2 Hydraulic Tank Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
n
9.2.3 Hydraulic Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
t
e
9.2.4 Thermostatic Mixing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
Y m
9.2.5 Oil Replenishment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
NL uip ion
9.3 Propel System Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
O q t
9.3.1 Valve Bank 4 (VB4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
L f E ra
9.3.2 Main Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
A
9.3.3 Towing System (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.33
I o p e
9.3.4 Accumulator Pre-Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.40
R ce O
9.4 Auxiliary Hydraulic System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.41
E t
AT nan en
9.4.1 Auxiliary System Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.41
9.4.2 Auxiliary Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.43
M te m
9.4.3 Valve Banks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.46
E p
9.4.4 Auxiliary And Low Pressure Hydraulic Systems Data Sheet . . . . . . . . . . . . . . . . 9.76
C a q i n u i
9.4.5 Auxiliary And Low Pressure Hydraulic Systems Pressure Taps . . . . . . . . . . . . . 9.85
N
9.5 Low Pressure Hydraulic System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.93
E r M E
9.5.1 Low Pressure Hydraulic System Flow Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . 9.93
R f o o r
9.5.2 Low Pressure Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.95
E E f
9.5.3 Valve Bank 4 (VB4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.99
F
E S S E
. . . . . . . .U
SECTION 10, Propel System
10.1 General . . R . . . . . . .U
T
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
10.2.1 Propel O
10.2 Theory of Operation . . . .
T
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
N
10.2.2 Propel N O
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
D O O
10.2.3 Crawler Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
10.2.4
D
Crawler Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
10.3 Propel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
10.3.1 Propel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
10.3.2 Propel Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
10.3.3 Idler Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
10.3.4 Upper and Lower Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
10.3.5 Crawler Track Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
SECTION 11, Leveling System

11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1

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11.2 Rear Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
11.2.1 Rear Jack Hydraulic Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
11.2.2 Front Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
11.2.3 Leveling Jack Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12
11.3 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
SECTION 12, Lubrication

12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
n t
12.1.1 P&H Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
e
12.1.2 Operating in Cold Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Y m
12.1.3 Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
NL uip ion
12.2 Oil Bath Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
O q t
12.2.1 Pulldown Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
L f E ra
12.2.2 Hydraulic Pump Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4
A
12.2.3 Auxiliary Winch Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5
I o p e
12.2.4 Cable Reel Gear Reducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6
R ce O
12.2.5 Propel Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7
E t
AT nan en
12.3 Oil Pressure Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8
12.3.1 Rotary Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8
M te m
12.3.2 Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9
E p
12.4 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
C a q i n u i
12.5 Manual Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
N
12.5.1 Lube Points Without Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
E r M E
12.5.2 Lube Points with Grease Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
R fo o r
12.5.3 Mast Back Braces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
E E f
12.6 Lubrication Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14
F
E S S E
12.6.1 Reference Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14
R U U
12.6.2 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
12.7 Automatic Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
T T
12.7.1 Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.17
O
N NO
12.7.2 Grease System Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19
12.7.3 Automatic Lubrication System Components . . . . . . . . . . . . . . . . . . . . . . . . . . 12.25
O
D DO
12.7.4 Lubrication Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.31
SECTION 13, Mast

13.1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
13.2 Mast Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
13.2.1 Mast Weldment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
13.2.2 Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
13.2.3 Back Braces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
13.2.4 Mast Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
13.2.5 Mast Hoist Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4

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13.2.6 Auxiliary Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4
13.2.7 Back Braces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
13.2.8 Back Brace Locking Collar Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
13.2.9 Mast Locking Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.12
13.2.10 Mast Raise/Lower Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.16
13.2.11 Mast Lower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.21
SECTION 14, Hoist/Pulldown Machinery

n t
e
Y m
14.1.1 Hoist/Pulldown Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2
NL uip ion
14.2 Pulldown System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5
O q t
14.2.1 Pulldown Motor 83013-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5
L f E ra
14.2.2 Pulldown Motor Blower R37819D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.8
A
14.2.3 Pulldown Gearcase 914J434F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.10
I o p e
14.2.4 Pulldown Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.16
R ce O
14.2.5 Pulldown Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22
E t
AT nan en
14.2.6 Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.23
14.2.7 Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.23
M te m
14.2.8 Pulldown Pinions R5544D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.24
E p
14.2.9 Idler Pinions R7560D3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.24
C a q i n u i
14.2.10 Guide Rollers R54362F3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.25
N
E r M E
15.1 Theory of Operation .R
SECTION 15, Rotary Machinery
. . . . . . .f.o. . . . . .f.o
r
F ECase .E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
15.1.2 RotaryE Drill PipeS

15.1.1 Rotary Gear
E
CouplingS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
U. . . . . . . U
R Components.
T
15.2 Rotary Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3
15.2.2 RotaryO
15.2.1 Rotary Motor
T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3
N
15.2.3 Bit Air N O
Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10
D O
RemovalO
15.2.4 Oil Pump and Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
15.2.5
D And Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
15.2.6 Intermediate Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15
15.2.7 Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.18
15.2.8 Rotary Drill Pipe Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.23
15.2.9 Gearcase Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.25
SECTION 16, Pipe Handling Equipment

16.1.1 Pipe Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2

MG320176-00-ENTOC.fm -xi- Table of Contents, Version 00 - 07/12

16.1.2 Deck Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
16.1.3 Breakout Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3
16.2 Pipe Handling Equipment Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4
16.2.1 Removing the Deck Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4
16.2.2 Disassembling the Deck Wrench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5
16.2.3 Cleaning, Inspecting and Repaing the Deck Wrench . . . . . . . . . . . . . . . . . . . . 16.5
16.2.4 Assembling the Deck Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6
16.2.5 Installing the Deck Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6
16.2.6 Disassembling the Deck Wrench Cylinders 5010453 . . . . . . . . . . . . . . . . . . . . 16.7
n t
e
16.2.7 Cleaning, Inspecting and Repairing the Deck Wrench Cylinders . . . . . . . . . . . 16.8
Y
16.2.8 Assembling the Deck Wrench Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.8
m
NL uip ion
16.2.9 Aligning the Breakout Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9
16.2.10 Inspecting the Breakout Wrench Die Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . 16.11
O q t
16.2.11 Inspecting the Breakout Wrench Components . . . . . . . . . . . . . . . . . . . . . . . 16.11
L f E ra
16.2.12 Inspecting the Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.11
A
I o e
16.2.13 Lubricating the Breakout Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.11
p
R ce O
16.2.14 Inspecting and Adjusting the Breakout Wrench Hydraulic Circuits . . . . . . . . 16.12
E t
16.2.15 Pipe Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.12
AT nan en
16.2.16 Adjusting the Pipe Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.14
16.2.17 Replacing the Pipe Rack Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.15
M te m
16.2.18 Removing the Pipe Rack Upper Support Arm (Gate) . . . . . . . . . . . . . . . . . . 16.16
E i n i p
16.2.19 Cleaning, Inspecting and Repairing the Pipe Rack Upper Support Arm . . . . 16.17
C a q u
16.2.20 Installating the Pipe Rack Upper Support Arm . . . . . . . . . . . . . . . . . . . . . . . 16.17
N M E
16.2.21 Adjusting the Pipe Rack Upper Support Arm (Gate) . . . . . . . . . . . . . . . . . . 16.17
E
R o r r
16.2.22 Removing the Pipe Rack Upper Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.18
o
E E f f
16.2.23 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.24
F E
E S S
R U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
17.1 General . . . . . . . . . . . . . . . . . U
SECTION 17, House Pressurization
T T And Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2

O
17.3 Filter Housing RemovalO
17.2 Inspect Machinery House Blowers
N N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4
O O
17.4 Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6
D D Winch
SECTION 18, Auxiliary
18.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
18.2 Winch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2
18.3 Winch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3
18.4 Winch Motor Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5
18.4.1 Removal And Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5
18.4.2 Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6
18.4.3 Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6
18.5 Winch Brake Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7

Table of Contents, Version 00 - 07/12 -xii- MG320176-00-ENTOC.fm

18.5.1 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7
18.5.2 Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.9
18.5.3 Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.9
18.6 Winch Final Drive Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.11
18.6.1 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.11
18.7 Winch Primary Drive and Drum Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.13
18.7.1 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.13
n t
e
Y
m
NL uip ion
18.8 Auxiliary Winch Sheaves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.16
18.8.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.17
O q t
18.8.2 Cleaning, Inspection, and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.17
L f E ra
18.8.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.17
A
I o p e
19.1 Mine Air Climate Control System . . . . . . . . . . . .R
E . . . .. .. c.. ..e.. .. .. .. ..t.. ..O.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 19.2
SECTION 19, Cab Climate Control
19.1.1 Installation . . . . . . . . . . . . . . . . . . . .T .......n

19.1
19.1.2 Function. . . . . . . . . . . . . . . . . . . .A . . . . . . . .a . . . . . . . .n
19.1.3 Controls . . . . . . . . . . . . . . . . .M . . . . . . .e n e . . . . . . . . . . . . . . . . . . . 19.2
19.1.4 NORMAL OPERATION . .E . . . . . . . . . t. . . . . . .p

m
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.5
n . . i. . . . . . . . . . . . . . . . . . . . . . . . . . 19.6
19.1.5 REFRIGERATION . . . .C . . . . . . . . .i. . . . . . u
. . . . . . . . . . . . . . . . . . . . . . . . . 19.5
a
. . . . . . . . . . . . . . . . .q. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.6
19.2 Maintenance . . . . . . . . . . . N
19.2.1 General . . . . . . . E
M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.6
. . . . . . . r. . . . . . . . . E
R f o Filters .o .r
E
19.2.2 lnspect Operator Cab Air
f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.8
19.2.4 CheckingF FastenersEand Fittings E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.10

19.2.3 Cleaning Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.9
E S S
R U . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 19.13
19.1 Troubleshooting. . . . . . . . . . . U
19.2.5 Preventive Maintenance 19.11
T T. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.13
O
19.1.1 General Information.
N O
N
O O
SECTION 20, Optional Equipment
D
20.1 Auxiliary
D
Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
20.2 Boarding Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.3
20.2.1 Boarding Ladder Hydraulic Control (VB6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.4
20.2.2 Boarding Ladder Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5
20.2.3 Boarding Ladder Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.6
20.3 Lubricant Replenishment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.7
20.3.1 Top Off Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.7
20.3.2 Wiggins Quick Fill System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.13
20.4 Jib Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.14

MG320176-00-ENTOC.fm -xiii- Table of Contents, Version 00 - 07/12

SECTION A, General Maintenance
A.1 Removal – General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1
A.2 Disassembly – General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1
A.3 Inspection, Cleaning And Repair – General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1
A.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2
A.5 Maintenance Of Specific Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3
A.5.1 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3
A.5.2 Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3
n t
A.5.3 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.5
e
A.5.4 Coupling Alignment - Straightedge-Feeler Gauge Method . . . . . . . . . . . . . . . . . . A.6
Y
A.5.5 Coupling Alignment - Dial Indicator Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6
m
NL uip ion
A.5.6 Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.7
O q t
A.5.7 Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.7
L f E ra
A.6 Gear Tooth Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8
A
A.6.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8
I o p e
A.6.2 Gear Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8
R ce O
A.6.3 Surface Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.9
E
T an nt
A.6.4 Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10
A
M ten me
SECTION B, General Hydraulic
B.1 General . . . . . . . . . . . . . . . . . . . . .E . . . . . . . . i.p

System Maintenance
. . . . . . .in
B.2 General Maintenance Rules . . .C . . . . . . .a u . . . . . . . . . . . . . . . . . . . . . . . . . . B.1
q . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3
B.2.1 Correct Tightening ofN M
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1
Hydraulic Connections
E
E o. r. . . . . . . r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4
B.2.2 Pipe Thread Connections
E R
B.2.3 SAE Flare Connections .f. . . . . . .f.o
F ThreadE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4
E
B.2.4 SAE Straight
S .S
E
Connection (O-ring Seal) . . . . . . . . . . . . . . . . . . . . . . . . . . B.4
R O-ringUHydraulic U
B.2.5 Split Flange Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6
T
B.2.6 Flat Face Seal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.8
O
B.2.7 Troubleshooting
T Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9
N Trouble
B.2.8 Developing
B.2.9 Recognizing
O
N Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10
Systematic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10
SECTIOND
O O Weight Tables
D
C, Component

Table of Contents, Version 00 - 07/12 -xiv- MG320176-00-ENTOC.fm
320XPC-UDC Mechanical Systems Manual List of Figures
List of Figures
Section 0 Model 320XPC Mechanical Systems Manual Visual Table of Contents . . . . . . . . . 0.iii
Figure 2-1: Model 320XPC Rotary Blasthole Drill (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Figure 2-2: Model 320XPC Deck Plan (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

n t 3.13
Y e 3.14
Figure 3-1: GUI Current Drill Activities Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
L m
Figure 3-2: Operator Cab Filters (MineAir - Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
p
N i n 3.16
Figure 3-3: Hydraulic Tank Sight Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.15
O qu tio 3.18
Figure 3-4: Hydraulic Tank Breather Condition Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . .
L f E ra
Figure 3-5: Pump Drive Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.17
I A e
Figure 3-6: T-Tank Oil Level Sight Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
o p
R
Figure 3-7: Rotary Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.21
E nc t e O
Figure 3-8: Pulldown Gearcase Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.23
T
A na en
Figure 3-9: Carriage Roller Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.24
Figure 3-10: Compressor Air Inlet Filters / Condition Indicator . . . . . . . . . . . . . . . . . . . . . . .
3.30
M te m
Figure 3-11: Main Compressor Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.31
E in ui p
Figure 3-12: Air Filter Condition Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.32
N C a
Figure 3-13: Charge Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
q
3.33
M
Figure 3-14: Main Air Compressor Oil Filter Indicator - GD . . . . . . . . . . . . . . . . . . . . . . . . .
3.34
E r or E
Figure 3-15: Replacing Main Compressor Oil Filter - GD . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.37
E R fo f
Figure 3-16: Hydraulic Return Line Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.38
F E
Figure 3-17: Cable Reel Components - Right Front View . . . . . . . . . . . . . . . . . . . . . . . . . .
3.39
E
RE US US
Figure 3-18: Cable Reel Hydraulic Cabinet Components - Door Open. . . . . . . . . . . . . . . . .
3.41
Figure 3-19: Check Crawler Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.42
T T
Figure 3-20: Propel Transmission Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.47
O
Figure 3-21: House Pressurization Filter Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.50
N N O
Figure 3-22: Rotary Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.53
Figure 3-23: Pulldown Gearcase Oil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.55
O
D D O
Figure 3-24: Suction Strainer (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.57
Figure 3-25: Low Pressure Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.58
Figure 3-26: Main Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.61
Figure 3-27: Pump Drive Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.64
Figure 3-28: Cable Reel Components (Top View - shown with chain guards removed). . . . 3.66
Figure 3-29: Auxiliary Winch Gear Reducer Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.68
Figure 3-30: Cable Reel Right Angle Drive Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . 3.69
Figure 3-31: Cable Reel Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.70

Figure 4-1: P&H Mining Equipment Cable Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

MG320176-00-ENLOF.fm -xv- List of Figures, Version 00 - 07/12
List of Figures 320XPC-UDC Mechanical Systems Manual
List of Figures (Continued)

Figure 4-2: Cable to Cable Reel Maximum Approach Angle. . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Figure 4-3: Cable Reel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Figure 4-4: Cable Reel Components - Right Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Figure 4-5: Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Figure 4-6: Component Locations (Top View - shown with chain guards removed) . . . . . . . 4.15
Figure 4-7: Brush Holder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
Figure 4-8: Control Valve and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
Figure 4-9: Adjusting System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
Figure 4-10: Cable Reel Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
n t
e
Figure 4-11: Cable Reel Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
Y
Figure 4-12: Hydraulic Cabinet Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
L ip n m
Figure 4-13: Collector Ring Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26
N
O qu tio
A L f E ra
Figure 6-1: Power Unit (Typical - Gardner Denver). . . . . I. . . . . . . .o. . . . . . p . .e
Figure 6-2: Main Drive Motor. . . . . . . . . . . . . . . . . . . .R . . . . . . .e . . . . . . .O

. . . . . . . . . . . . 6.1
T E. . . . . n. . c. . . . . . .t. . . . . . . . . . . . . . . . . . 6.4
. . . . . . . . . . . . . . . . 6.3
A . .a. . . . . . . .n
Figure 6-3: Power Unit (Typical - Gardner Denver).
Figure 6-5: Pump Drive Flexible Coupling.M

Figure 6-4: Pump Drive Transmission (PDT) (Typical)
. . . . . . .e n e . . . . . . . . . . . . . . . . . . . . 6.6
Figure 6-6: Coupling Hub Removal . . .E . . . . . . . . . t. . . . . . .p

m
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
n . . i. . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
C . . . . . . .i . . . . . . u
. . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
Figure 6-7: Bolt Tightening Sequence.
N a q
E or r M E
R f o (Power Unit - Typical). . . . . . . . . . . . . . . . . 7.1
SECTION 7, Main Air System
F E E
Figure 7-1: Main Air System Major Components f
E
Figure 7-2: Main Air System
S
Major
S E (Left Platform - Bottom Typical) . . . . . . . . . 7.3
Components (Left Platform - Topside Typical) . . . . . . . . 7.2
Figure 7-4: MainR UFlow Diagram. U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

Figure 7-3: Main Air System Major Components
Figure 7-5: T-tank andT

Air System
O T
Oil Separators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
N
Figure 7-6: Underside
Figure 7-7: Circulation N O
of T-tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
Pump Plumbing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
D O O
Figure 7-8: Pump and Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
Figure 7-9: Pump
D
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
Figure 7-10: Cold Weather Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
Figure 7-11: Return to Tank Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
Figure 7-12: Main Compressor Air Cleaner - Gardner Denver . . . . . . . . . . . . . . . . . . . . . . . 7.21
Figure 7-13: Compressor Right Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
Figure 7-14: Compressor Left Side Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
SECTION 8, Water Injection System

Figure 8-1: Water Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Figure 8-2: Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4

List of Figures, Version 00 - 07/12 -xvi- MG320176-00-ENLOF.fm

Figure 8-3: Water Level Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Figure 8-4: Lower Left Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Figure 8-5: Water Tank and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
Figure 8-6: Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
Figure 8-7: Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11

Figure 9-1: Block Diagram - Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
n t
Figure 9-2: Hydraulic System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
e
Figure 9-3: Hydraulic Tank Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Y m
Figure 9-4: Hydraulic Tank Temperature Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
NL uip ion
Figure 9-5: Hydraulic Tank Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
O q t
Figure 9-6: Hydraulic Oil Level Sight Glass and Temperature Gauge . . . . . . . . . . . . . . . . . 9.10
L f E ra
Figure 9-7: Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
A
Figure 9-8: Thermostatic Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
I o p e
Figure 9-9: Propel System Hydraulic Components Block Diagram. . . . . . . . . . . . . . . . . . . . 9.14
R ce O
Figure 9-10: Propel Control Valves (Stations 1-3 on VB4) . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
E t
AT nan en
Figure 9-11: Valve Bank 4 Propel Control Schematic (Shown with optional Tow Kit). . . . . . 9.17
Figure 9-12: Main Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
M te m
Figure 9-13: Main Hydraulic Pump / Motor Schematic (LH Shown; RH Similar). . . . . . . . . . 9.19
E p
Figure 9-14: Pump Start-up and Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
C a q i n u i
Figure 9-15: Propel Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
N
Figure 9-16: Pump NULL Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30
E r M E
Figure 9-17: Tow Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.34
R fo o r
Figure 9-18: Emergency Brake Valve with Trip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.34
E E f
Figure 9-19: Towing Tether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.35
F
E S S E
Figure 9-20: Transmission Disconnect for Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.36
R U U
Figure 9-21: Brake Manual Release Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.37
Figure 9-22: Crawler Frame Manual Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.39
T T
Figure 9-23: Auxiliary Hydraulic System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.42
O
N NO
Figure 9-24: Auxiliary Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.43
Figure 9-25: Valve Bank Locations (Inside Machinery House) . . . . . . . . . . . . . . . . . . . . . . . 9.46
O
D DO
Figure 9-26: Valve Bank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.47
Figure 9-27: Relief/Unload Oil Diverter Valve Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.48
Figure 9-28: VB1 and VB2 Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.50
Figure 9-29: Auxiliary Winch Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.51
Figure 9-30: Mast Hoist Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.53
Figure 9-31: Optional Hydraulic Dust Curtain Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . 9.55
Figure 9-32: Pipe Rack Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.58
Figure 9-34: Breakout Wrench Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.61
Figure 9-35: Deck Wrench Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.64
Figure 9-36: Back Brace Lock Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.66
Figure 9-37: Mast Anchor Pins Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.67

MG320176-00-ENLOF.fm -xvii- List of Figures, Version 00 - 07/12

Figure 9-39: Unloader Relief Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.70
Figure 9-40: Front Jacks Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.71
Figure 9-41: Rear Jacks Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.74
Figure 9-42: Low Pressure Hydraulic System Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . 9.94
Figure 9-43: Low Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.95
Figure 9-44: Low Pressure Pump and Motor Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.97
Figure 9-45: Pump Compensator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.98
t
Figure 9-46: Valve Bank 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.100
n
e
Figure 9-47: Pipe Rack Upper Gate Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.101
Y
Figure 9-48: Deck Hatch Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.103
m
NL uip ion
Figure 9-49: GD Compressor Inlet Valve Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 9.105
Figure 9-50: Pipe Rack Holdback Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.107
O q t
Figure 9-51: Head Brake Enable Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.109
A L f E ra
Figure 10-1: Propel Drive Components. . . . . . . . . . . . . . I. . . . . . . .o. . . . . . p . .e
Figure 10-2: Propel Motor . . . . . . . . . . . . . . . . . . . . . .R . . . . . . .e. . . . . . .O

. . . . . . . . . . . 10.1
Figure 10-3: Propel Transmission . . . . . . . . . . . .T

E . . c. . . . . . .t. . . . . . . . . . . . . . . . . 10.3
.......n
. . . . . . . . . . . . . . . 10.2
Figure 10-4: Crawler Final Assembly . . . . . . .A . . . . . . . .a . . . . . . . .n

Figure 10-5: Crawler Frame . . . . . . . . . . .M . . . . . . .e n e . . . . . . . . . . . . . . . . . . . 10.4
Figure 10-6: Upper Roller . . . . . . . . . .E . . . . . . . . . t. . . . . . .p

m
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
n . . i. . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
Figure 10-7: Idler Roller. . . . . . . . . .C . . . . . . . . .i . . . . . . u
. . . . . . . . . . . . . . . . . . . . . . . . . 10.5
N a. . . . . . .q. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
E
Figure 10-8: Propel Motor and Transmission
r M (RH E
Figure 10-10: Propel MotorR
Figure 10-9: Propel Motor Hose
f o
Connections
. . . .o r Shown) . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
E Adjustments.
F SE Assembly. f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
E S E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
Figure 10-11: Motor Displacement Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
R U 10-12
Figure 10-12: Propel Transmission
Figure 10-14: Spring Cage Fixture U

Figure 10-13: Legend for Figure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
T T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
O
Figure 10-16: Crawler FrameO
Figure 10-15: Brake Disk Arrangement.
N N Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
O CrawlerO
Figure 10-17: Upper and Lower Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
D DHammer Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30

Figure 10-18: Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
Figure 10-19: Slide
Figure 10-20: Drive Rod Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
Figure 10-21: Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
Figure 10-22: Track Tension Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34

Figure 11-1: Rear Jack Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
Figure 11-2: Rear Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Figure 11-3: Rear Jack Plumbing Covers (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4

List of Figures, Version 00 - 07/12 -xviii- MG320176-00-ENLOF.fm

Figure 11-4: Rear Jack Cylinder Regeneration Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
Figure 11-5: Rear Jack Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
Figure 11-6: Hydraulic Cylinder Serviceable Components . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
Figure 11-7: Front Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
Figure 11-8: Jack shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12

Figure 12-1: Pulldown Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
Figure 12-2: Hydraulic Pump Drive Transmission Lubrication . . . . . . . . . . . . . . . . . . . . . . . 12.4
n t
e
Figure 12-3: Auxiliary Winch Gear Reducer Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5
Y m
Figure 12-4: Cable Reel Gear Reducer Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6
NL uip ion
Figure 12-5: Propel Transmission Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7
O q t
Figure 12-6: Rotary Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8
L f E ra
Figure 12-7: Air Compressor T-Tank Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9
A
Figure 12-8: Main Air System Oil Filter Locations (Sullair) . . . . . . . . . . . . . . . . . . . . . . . . . 12.10
I o p e
Figure 12-9: Hydraulic Tank Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
R ce O
Figure 12-10: Hydraulic Tank Level Sight Gauge and Temperature Gauge . . . . . . . . . . . 12.12
E t
AT nan en
Figure 12-11: Mast Back Brace Manual Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . 12.13
Figure 12-12: Manual Lubricant Point Reference Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 12.14
M te m
Figure 12-13: Automatic Lubrication System Schematic (Typical) . . . . . . . . . . . . . . . . . . . 12.17
E p
Figure 12-14: Grease Tank Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.18
C a q i n u i
Figure 12-15: Grease Control Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.20
N
Figure 12-16: Automatic Lubrication System Injector Schematic (Typical) . . . . . . . . . . . . . 12.21
E r M E
Figure 12-17: Grease Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.25
R f o o r
Figure 12-18: Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.29
E E f
Figure 12-19: SL-V Injector Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.32
F
E S S E
Figure 12-20: Injector Volume Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.33
R U U
Figure 12-21: SL-V Injector Removal/Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . 12.34
Figure 12-22: Injector Components (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.35
T T
Figure 12-23: Bleeding Air at Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.37
O
N NO
Figure 12-24: Bleeding Air at Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.37
Figure 12-25: Bleeding Air from Feeder Lines (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.39
D O Mast O
D Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
SECTION 13,
Figure 13-1: 320XPC
Figure 13-2: Saf-T-Climb Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
Figure 13-3: Back Brace (exploded view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
Figure 13-4: Back Brace Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.9
Figure 13-5: Back Brace Locking Collar Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
Figure 13-6: Mast Lock Pin Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.12
Figure 13-7: Mast Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.15
Figure 13-8: Mast Raise/Lower Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.17
Figure 13-9: Mast Raise/Lower Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.19

MG320176-00-ENLOF.fm -xix- List of Figures, Version 00 - 07/12

Figure 13-10: Lower Mast Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.22
Figure 13-11: Dust Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.23
Figure 13-12: Mast Pivot Pin and Bushing Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . 13.24
Figure 13-13: Mast Bailing Air Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.25
SECTION 14, Hoist/Pulldown Machinery

Figure 14-1: Rotary Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
Figure 14-2: Pulldown Resolver Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4
Figure 14-3: Pulldown Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5
n t
e
Figure 14-4: Pulldown Motor Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7
Y
Figure 14-5: Pulldown Motor Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.8
m
NL uip ion
Figure 14-6: Pulldown Gearcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.10
O q t
Figure 14-7: Legend for Figure 14-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.11
L f E ra
Figure 14-8: Rotary Carriage Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.12
A
Figure 14-9: Legend for Figure 14-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.13
I o p
Figure 14-10: Pulldown Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.16
e
R ce O
Figure 14-11: Pulldown Brake Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17
E t
AT nan en
Figure 14-12: Pulldown Brake Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.19
Figure 14-13: Pulldown Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22
M te m
Figure 14-14: Guide Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.26
E in uip
Figure 14-15: Roller Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.28
SECTION 15, Rotary Machinery C

Figure 15-1: Carriage Assembly N . . . . . . .M
a
. . . . . . . . . .q. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
Figure 15-2: Rotary Coupling E r ...r
E
E RPinion.fo. . . . . . .f.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
F S.E.. .. .. .. .. .. ..E.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 15.8

Figure 15-3: Installing Motor
Figure 15-5: RotaryE S

Figure 15-4: Pinion Dimensions 15.5
R U 15-5U
Gearcase.
T
Figure 15-6: Legend for Figure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.9
Figure 15-8: SwivelO

Figure 15-7: Bit Air Components
T. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10
Figure 15-9: Oil N N O

Housing and Air Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11
Pump Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
D O O
Figure 15-10: Intermediate Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.16
Figure 15-11:
D
Checking Main Drive Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.21
Figure 15-12: Rotary Drill Pipe Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.23

Figure 16-1: Pipe Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
Figure 16-2: Deck Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
Figure 16-3: Breakout Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3
Figure 16-4: Deck Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4
Figure 16-5: Deck Wrench Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7
Figure 16-6: Breakout Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9

List of Figures, Version 00 - 07/12 -xx- MG320176-00-ENLOF.fm

Figure 16-7: Breakout Wrench (Typical), . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.10
Figure 16-8: Breakout Wrench Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.11
Figure 16-9: Pipe Rack with Mechanically Operated Upper Gate (Typical) . . . . . . . . . . . . 16.12
Figure 16-10: Legend for Figure 16-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.13
Figure 16-11: Pipe Wrenches and Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.14
Figure 16-12: Pipe Wrenches and Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.15
Figure 16-13: Pipe Rack Swing Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.21
Figure 16-14: Pipe Holder Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.24
n t
Figure 17-1: House Pressurization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e
Figure 17-2: House Pressurization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Y . . . . . . .m

. . . . . 17.1
Figure 17-3: House Pressurization System. . . . . . . . . . . . . . . . . . . N

L
. . . . . . . . .i.p. . . . . .n
. . . . . . . . 17.3
Figure 17-4: House Pressurizer . . . . . . . . . . . . . . . . . . . . . . . . .O

q u
. . . . . . . . . . . . . . . .io
t
. . . 17.4
Figure 17-5: Filter Packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E

. . . . . 17.5
Figure 17-6: Blade Pack . . . . . . . . . . . . . . . . . . . . . . . . . .A

L a
. . . . . . . . f. . . . . . . . .r. . . . . . . . . 17.7
. . . . . . . . . . . . . . . . 17.7
I o p e
E R ce O
Figure 18-1: Auxiliary Winch . . . . . . . . . . . . . . .T .......n . .t. . . . . . . . . . . . . . . . . 18.1
SECTION 18, Auxiliary Winch
. . . . . . .n
Figure 18-2: Auxiliary Winch Hose Connections . . . . .n A a
. . . . . . . .e
M
Figure 18-3: Wire Rope Installation. . . . . . . . . . . . t. e . . . . . . . .m
. . . . . . . . . . . . . . . . . . . . . 18.2
Figure 18-4: Auxiliary Winch Motor . . .E . . . . . . . . i.p

. . . . . . .in
. . . . . . . . . . . . . . . . . . . . . . . 18.4
Figure 18-5: Auxiliary Winch Brake C a . . . . .u

. . . . . . . . . . . . . . . . . . . . . . . . . 18.5
N inM Piston. . . .q. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.10

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7
E
Figure 18-6: Brake Spring Arrangement
r r E . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.11
RPrimaryfoDrive and
Figure 18-7: Auxiliary Winch Final
E
Drive
f oDrum Components . . . . . . . . . . . . . . . . . 18.14
Components
Figure 18-9: AuxiliaryF E

Figure 18-8: Auxiliary Winch
E S
Winch Sheaves
S E
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.16
R ClimateUControlU
T Control
SECTION 19, Cab
O T. . . . . .Unit
O
Figure 19-1: Mine Air Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
N . . .N. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.5
Figure 19-2: Mine Air Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.3
Figure 19-4:O O
Figure 19-3: Controls.
D CleaningD Coils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.9

Filter Locations (MineAir - Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.8
Figure 19-5:
Figure 19-6: Mine Air Systems Troubleshooting - No Cooling . . . . . . . . . . . . . . . . . . . . . . 19.14
Figure 19-7: Mine Air Systems Troubleshooting - No Heating - C1 De-energized . . . . . . . 19.15
Figure 19-8: Mine Air Systems Troubleshooting - No Heating - C1 Energized . . . . . . . . . . 19.15

Figure 20-1: Auxiliary Air Compressor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Figure 20-2: Typical Boarding Ladder (Right Rear Shown) . . . . . . . . . . . . . . . . . . . . . . . . . 20.3
Figure 20-3: Ladder Hydraulic Control (VB6) Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.4
Figure 20-4: Boarding Ladder Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5

MG320176-00-ENLOF.fm -xxi- List of Figures, Version 00 - 07/12

Figure 20-5: Ladder Remote Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.6
Figure 20-6: Filter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.7
Figure 20-7: Dual Top Off Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.8
Figure 20-8: Dual Top Off Tank Pumping System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.9
Figure 20-9: Filling Compressor Oil Dual Top Off Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.11
Figure 20-10: Dispensing Oil to Compressor T-Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.12
Figure 20-11: Wiggins Quick Fill Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.13
Figure 20-12: Jib Crane (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.14
n t
e
SECTION B, General Hydraulic Y

L ip n m
System Maintenance
Figure B-1: Tightening SAE Flare Connections . . . . . . . . . . . . .O
N
. . . . . . . . .u . . . . . . .io
Figure B-2: Incorrect O Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . E
L q a t . . . . . . B.3
Figure B-3: Correct O Ring Installation . . . . . . . . . . . . . . .A . . . . . . . . f. . . . . . . . .r. . . . . . . . . . B.6

. . . . . . . . . . . . . . . . . B.5
Figure B-4: Split Flange Tightening Sequence . . . . . . . . I. . . . . . . .o. . . . . . p . .e

Figure B-5: Flat-face O Ring Seal Connection . . . . . .R . . . . . . .e . . . . . . .O
. . . . . . . . . . . . B.6
T E nc t . . . . . . . . . . . . . . . . B.9
SECTION C, Component Weight Tables A

n a en
Figure C-1: 320XPC Component Weights M (Sheet 1te of 3) . . . .m
E i n i p . . . . . . . . . . . . . . . . . . . . . . . . C.2
Figure C-2: 320XPC Component Weights
C (Sheet (Sheet 2 of 3)
u
a 3 ofq3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . C.3
N
Figure C-3: 320XPC Component Weights
E M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

List of Figures, Version 00 - 07/12 -xxii- MG320176-00-ENLOF.fm
320XPC-UDC Mechanical Systems Manual List of Tables
List of Tables
Table 2-1: Auxiliary Winch Lifting Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

Table 3-1: Recommended Torque Values for American Standard Threads (Sheet 1 of 2) . . . . . 3.2
t
Table 3-1: Recommended Torque Values for American Standard Threads (Sheet 2 of 2) . . . . . 3.3
Table 3-2: Recommended Torque Values for Metric Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
e n
Y
Table 3-3: English to Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
m
NL uip ion
Table 3-4: “A” Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Table 3-5: “B” Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
O q t
Table 3-6: “C” Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
L f E ra
Table 3-7: “D” Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
I A e
Table 3-8: “E” Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
o p
R ce O
Table 3-9: “F” Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
E
Table 3-10: Cable Reel Gear Reducer Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
A T an nt
Table 4-1: Cable Reel Controls . . . . . . . . . . . . . . . . . .n. . . . . . . .e
M t e m . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
E
Table 4-2: Cable Reel Level Wind Sprocket Selection
i n i pChecks. . . . . . . . . . . . . . . . . . . . . . 4.9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
C Reducer u
a . . .q. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Table 4-3: P&H Mining Equipment Cable Reel Maintenance
E N
. . . . . . .M
Table 4-4: Lubrication, Cable Reel Gear
.......E
R fo fo
Table 4-5: Motor Specifications.
r r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
E
F SE E
R E U S
T T U
Table 6-1: Power Unit Arrangement and Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
N O O
SECTION 7, Main
N
Air System
D O
Table 7-1: Main
O
Air Subsystems - Gardner Denver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
SECTION 8, Water DInjection System

Table 8-1: Schematic References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Table 8-2: Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12

Table 9-1: Hydraulic Groups and Subsystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Table 9-2: Hydraulic System Shared Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
Table 9-3: Propel (Main) Hydraulic System Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20

MG320176-00-ENLOT.fm -xxiii- List of Tables, Version 00 - 07/12
List of Tables 320XPC-UDC Mechanical Systems Manual
List of Tables (Continued)

Table 9-4: Propel (Main) Hydraulic System Pressure Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
Table 9-5: Auxiliary Hydraulic System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.41
Table 9-6: Winch Lifting Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.52
Table 9-7: Auxiliary and Low Pressure Hydraulic Systems Data Sheet . . . . . . . . . . . . . . . . . . . 9.76
Table 9-8: Auxiliary and Low Pressure Hydraulic Systems Pressure Taps . . . . . . . . . . . . . . . . 9.85
Table 9-9: Low Pressure Hydraulic System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.93
n t
Table 11-1: Jack Shoe Styles and Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e
Table 11-2: Auxiliary Hydraulic System Troubleshooting . . . . . . . . . . . . .Y ......m

. . . . . . . 11.12
N L ip n . . . . . . . . . . 11.13
O q u tio
. . . . . . . .E
Table 12-1: Pulldown Gearcase Recommended Lubricants . L . . . . . . . .a
I A o f e r . . . . . . . . . . . 12.3
R. . . . .. ..e.. .. .. .. .. .. ..O.. .. p.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 12.5

Table 12-2: Hydraulic Pump Drive Transmission Recommended Lubricants . . . . . . . . . . . . . . . 12.4
Table 12-4: Cable Reel Recommended Lubricants E . . . . . . .c

Table 12-3: Auxiliary Winch Recommended Lubricants
T
Table 12-5: Propel Transmission Recommended Lubricants . . . . . n
a n t 12.6
Table 12-6: Rotary Gearcase Recommended A n e

. . . . . . . . . . . . . . . . . . . . . . 12.7
M te Lubricants
Lubricants . . .
m . . . . . . . . . . . . . . . . . . . . . . 12.13
. . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8
Table 12-8: Lubrication Schedule . . . .E . . . . . . . . i.p

. . . . . . .in
Table 12-7: Miscellaneous Pins, Levers and Linkages
C a Points u
. . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
N . . .M. . . . . . . . . .q. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40

Table 12-9: Automatic Lubrication System Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.22
E
Table 12-10: Troubleshooting Guide.
r r E
E R fo fo
F SE . . . . .E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.26
SECTION 13, Mast
E
Table 13-1: Mast Troubleshooting.
R U Machinery S
U
T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.29
Table 14-1: Troubleshooting . . T
SECTION 14, Hoist/Pulldown
N O O
N
O O
SECTION 15, Rotary Machinery
D
Table 15-1:
D
Pinion Mounting Data (refer also to Figure 15-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5
Table 15-2: Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.27

Table 16-1: Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.25
SECTION 18, Auxiliary Winch

List of Tables, Version 00 - 07/12 -xxiv- MG320176-00-ENLOT.fm
320XPC-UDC Mechanical Systems Manual List of Tables

Table 18-1: Auxiliary Winch Lifting Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
SECTION 19, Cab Climate Control

Table 19-1: Preventive Maintenance - Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.11
Table 19-2: Preventive Maintenance - Every 250 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.11
Table 19-3: Preventive Maintenance - Every 500 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.12
Table 19-4: Preventive Maintenance - Seasonal Pre-Cooling . . . . . . . . . . . . . . . . . . . . . . . . . 19.12
Table 19-5: Preventive Maintenance - Seasonal Pre-Heating . . . . . . . . . . . . . . . . . . . . . . . . . 19.12
n t
. . . . . . . . . .e
Table 20-1: Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Y
m
NL uip ion
. . . . . . . . 20.1
O q at
L
A of per E
I
SECTION B, General Hydraulic
Table B-1: Pipe Thread Leaks. . . . . . . . . . . . . . . . . . .R

System Maintenance
. . . . . . .e
Table B-2: Flare Connection Leakage. . . . . . . . . . . . . . . . . . . . . . . . .t. .O
E c . . . . . . . . . . . . . . . . . . . . . . . . . . B.4
Table B-3: Split Flange Leakage . . . . . . . . . . .A

T . n. . . . . . .n. . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..B.5
. . . . . . . .a
Table B-4: Split Flange Torque Values . . . . . . . . . . . .n . . . . . . . .e
B.7
M . . . . . . . .m. . . . . . . . . . . . . . . . . . . . . . . . . .B.10
Table B-5: Flat-face Seal Torque Values . . . . . . . t. e
. . . . . . . . . . . . . . . . . . . . . . . . . B.8
E i n i p
C a q u
E N
SECTION C, Component Weight Tables
M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
D DOO

MG320176-00-ENLOT.fm -xxv- List of Tables, Version 00 - 07/12
List of Tables 320XPC-UDC Mechanical Systems Manual
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

List of Tables, Version 00 - 07/12 -xxvi- MG320176-00-ENLOT.fm
320XPC-UDC Mechanical Systems Manual Blasthole Drill Safety
Section 1
Blasthole Drill Safety
1.1 Operator Qualifications
t
1. Pass a written examination which accurately measures practical knowledge of the drill, and an evaluated dem-
n
onstration of the proper methods and techniques to be used in operating the drill.
e
Y m
NL uip ion
2. Have vision of at least 20/30 Snellen in one eye and 20/50 Snellen in the other, with or without corrective
lenses.
3. Have good depth perception.

O q t
A L f E ra
I o e
4. Be able to distinguish colors, regardless of the position of the color.
R ce O p
E
5. Have adequate hearing, with or without hearing aid.
t
AT nan en
6. Have sufficient strength, endurance, agility, coordination, and speed of reaction to meet the demands of drill
operation.
M te m
E i n i p
7. Have no physical defects or emotional instability that could render a hazard to the operator or others, or which
C a q u
could interfere with the operator’s performance.
E N M E
r
8. Not be subject to seizures or loss of physical control.
R fo o r
E E f
9. Not be under the influence of alcohol or drugs.
E F S E
S
10. Provide written assurance from the prescriber of any prescribed medication that the medicine will not affect the
R U U
operator's ability to operate the drill in a safe manner.
T T
11. Maintain a good attitude towards safety at all times.
N O O
N
O
D DO
1.2 Operator Conduct
Safety must always be the operator's primary concern. An operator must refuse to operate the
drill when a known unsafe condition exists. Consult your supervisor when safety is in doubt.
1. Read and understand the Operator's Manual and be familiar with all instructions and signs on the drill.
2. Inspect and ensure the drill is in proper order before operating.
3. Do not operate the drill when physically or otherwise unfit.

Sec01Safety.fm -1.1- Section 1, Version 00 - 07/12
Blasthole Drill Safety 320XPC-UDC Mechanical Systems Manual
4. Do not engage in any practice that will divert attention while actually engaged in operating the drill.
5. Ensure that people, other mining equipment, and material are kept out of the work area.
6. Give a warning signal prior to starting, operating, or moving the drill.
7. Test all controls before beginning a new shift. If any control does not operate properly, have the controls
repaired before operating the drill.
8. Promptly report defects to the maintenance department. Notify the next operator of any remaining uncorrected
defects upon changing shifts.
n t
1.3 Functional Checks
Y e
m
NL uip ion
• Confirm there are no warning tags or lockout tags on the starting controls.
O q t
L f E ra
• Confirm that all required maintenance and inspections have been performed and all necessary repairs
I A e
made.
R ce O o p
E
• Confirm that all equipment guards are in place and all inspection and cover plates are closed and locked.
t
AT nan en
• Look inside, outside and underneath the drill to make sure everything is clear before starting the drill.
M te m
• After starting the drill, check all gauges and indicators for proper readings and operation.
E i n i p
C a q u
• Test all controls for proper operation and controllability before drill operation or travel, including a thorough
N
check of the brakes.
E M E
R o r o r
f
• Check audible warning devices and alarms used for travel warning for proper operation.
F E E f
E
• During operation, be alert for unusual noises or vibrations; look and smell for unusual smoke or fumes.
E S S
R U ULines Precautions
1.4 Operation NearTElectrical
T
O
N N O
O
D DO
! DANGER
Keep clear of power lines when machine is in operation. Death or injury could result
should any part of the machine comes within minimum distance of an energized power
line specified by local, state and federal regulations.
Working in the vicinity of electrical power lines presents a very serious hazard and special precautions must be
taken. Safe operating practices require that you maintain the maximum possible distance from the lines and never
violate the minimum clearances.
Before working in the vicinity of power lines, the following precautions should be observed:
• Contact the owners of the power lines or the nearest electric utility before beginning work.

Section 1, Version 00 - 07/12 -1.2- Sec01Safety.fm
320XPC-UDC Mechanical Systems Manual Blasthole Drill Safety
• Machine operator and electrical utility representative must jointly determine what specific precautions are
taken.
• Machine operator and electrical utility representative must confirm that all precautions are taken and fol-
lowed.
• Even when power lines are known to be locked out and tagged out, consider them to be energized.
• Inform all ground personnel to stand clear of the machine at all times.
Use a signal person to guide the machine into close quarters. The sole responsibility of the signal person is to
t
observe the approach of the machine to the power line. The signal person must be in direct communication with
n
the operator and the operator must pay close attention to the signals
Y e
m
1.5 Safety Decals and Signs
NL uip ion
O q t
1.5.1 General
A L f E ra
I o p e
R ce O
Hazard Indicators and Safety Hazard Decals and Signs identify potential safety hazards and prevent accidents by
E
displaying standard symbols, headers and pictographs or custom graphics. Headers, graphics, and layouts of indi-
T an nt
cators, decals, and signs conform to current ANSI guidelines, and are consistent with the industry standards for
A
M ten me
such devices commonly used for high voltage, personal protection, confined space, and bilingual applications.
E n p
1.5.2 Hazard Indicators
C a q i u i
N
DANGERS, WARNINGS, CAUTIONS, NOTICES, and SAFETY FIRSTS are used on signs and decals, and
E M E
throughout our manuals to emphasize important and critical instructions. In written documentation, DANGERS,
r
R o r
WARNINGS, CAUTIONS, and SAFETY FIRSTS will precede the paragraph or item to which they apply. NOTICES
E E f f o
will follow the paragraph or item to which they apply. DANGERS, WARNINGS, CAUTIONS, NOTICES and
F
SAFETY FIRSTS are identified and defined as follows:
E S S E
R U U ! DANGER
T T
O
N NO
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury. This signal word is limited to the most extreme situations.
O
D DO ! WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
major injury.

Sec01Safety.fm -1.3- Section 1, Version 00 - 07/12
Blasthole Drill Safety 320XPC-UDC Mechanical Systems Manual
A Caution without a Safety Alert Symbol (Triangle and Exclamation Point) is used to
warn of hazards that result only in property damage.
Used to indicate a statement of company policy directly or indirectly related to the safety of per-
sonnel or protection of property. This signal word is not associated directly with a hazard or haz-
t
ardous situation and is not used in place of DANGER, WARNING, or CAUTION.
e n
Y m
NL uip ion
Used to indicate general instructions relative to safe working practices, remind of proper safety
O q t
procedures, and indicate the location of safety equipment.
A L f E ra
I o e
1.5.3 Safety Hazard Decals and Signs
R ce O p
E
Safety Hazard Decals and Signs use hazard indicators discussed in the preceding paragraphs, and also display
t
AT nan en
pictographs to show, both graphically and verbally, where potential safety hazards exist around the rotary blasthole
drill. These decals and signs do not represent every possible hazard. They are not intended to be a substitute for
M te m
safe working practices and good judgement.
E i n i p
Do not remove, cover, paint over, or deface these Safety Hazard Decals or Signs. If they become damaged or
C a q u
obscured, request replacement decals and signs from your local MinePro Services office. For locations and main-
N M E
tenance information for the Safety Hazard Decals and Signs, refer to the Centurion Drill Electrical Maintenance
E r r
Manual or the LinkOne Parts Manual for your machine.
R
E E fo f o
E F S E
R U U S
T T
O
N NO
O
D DO

Section 1, Version 00 - 07/12 -1.4- Sec01Safety.fm
320XPC-UDC Mechanical Systems Manual Introduction
Section 2
Introduction
2.1 General
t
This manual provides the information required to repair and maintain the P&H Mining Equipment Model 320XPC
Rotary Blasthole Drill.
e n
Y m
NL uip ion
2.1.1 Part Numbers
O q t
Repair parts information is provided in the LinkOne electronic parts manual that is prepared for your drill. The drill
L f E ra
serial number is located inside the operator's cab.
I A o e
Part numbers may be shown in this manual to identify specific assemblies and the information and procedures that
p
R ce O
apply to that specific assembly. Since this book is not updated on a continuous basis, do not use these part num-
E
bers to order repair parts.
t
AT nan en
NOTICE
M te m
E i n i p
Always obtain the part numbers from the up-to-date LinkOne electronic parts manual.
C a q u
2.1.2 Applicability
E N M E
R o r o r
f f
All information in this manual, including descriptions, specifications, and illustrations is for P&H model 320XPC
FE E
Rotary Blasthole Drill, at the time of publication. Product improvements, owner modifications, or other changes
E S E
introduced after this manual was published are not covered.
S
R U U
Questions concerning the drill or this manual should be referred to your P&H MinePro Services representative.
T T
2.2 DescriptionN NOO
O
D DO
2.2.1 General
The rotary blasthole drill is designed to drill blast holes. These holes are then filled with explosives, which fracture
the material for most efficient removal. The drill can be equipped for single-pass drilling or multiple-pass drilling by
coupling additional lengths of drill pipe to form a drill string. This drill only drills vertical holes.
All drill motions use electric motors with the exception of the propel motion, which uses hydraulic power. Power for
the drill is provided by a double-shafted electric motor, coupled on one end to the air compressor and on the other
end to the hydraulic pump drive transmission (PDT).

Sec02Intro.fm -2.1- Section 2, Version 00 - 07/12
Introduction 320XPC-UDC Mechanical Systems Manual
2.2.2 Drill Description
The 320XPC rotary blasthole drill (hereafter, the drill) produces pulldown bit load up to 150,000 lbs and has been
optimized to drill single-pass or multi-pass holes up to 22" (55.88 cm) in diameter (see Figure 2-1). The total
machine weight is approximately 365,000 lbs (165,564 kg). The pipe rack provides storage for one 65-foot (19.8-
meter) long pipe with 2-inch (50 mm) pipe wall thickness and up to 10.75 inches (273 mm) in diameter. Refer to
Figure 2-2 for the drill deck plan.
LEGEND
01. Mast
02. Back Brace (2)
t
03. Vent
n
04. Cable Reel
e
05. Rear Boarding Ladder
Y m
06. Machinery House
NL uip ion
01 07. Right Boarding Ladder
08. Crawler Assembly (2)
O q t
09. Air Conditioner
L f E ra
10. Operator’s Cab
11. Dust Curtain
I A o p e
12. Drilling Deck
R ce O
13. Left Rear Levelling Jack
E
14. Rotary Carriage
t
AT nan en
M te m
E i n i p
C a q u
14
E N M E
R o r o r
02 03 04
E E f f
E F S E
R U U S
T T
13 O
N NO
O
D DO
12
11
10 09 08 07 06 05 BD1129a01
Figure 2-1: Model 320XPC Rotary Blasthole Drill (Typical)

Section 2, Version 00 - 07/12 -2.2- Sec02Intro.fm
01 02 03 04 05 06 07 08 09 10
11
12
31
13
30
n t
Y e 14
m
29
NL uip ion 15
O q t
A L f E ra
I o e
16
R ce O p 13A
E t
BD1130c01
AT nan en
M te m
28 27 26 25 24 23 22 21 20 19 18 17
E i n i p
LEGEND
C a q u 13. Auxiliary Air Compressor 22. Top-Off Filter Panel
N M E
01. Drill Deck (Option) 23. Grease Reservoir
E r
02. Water Tank 13A.Auxiliary Air Compressor 24. Pump Drive Transmission
03. Valve Bank 3
R fo o r (Alternate Location) (PDT)
E E f
04. Valve Bank 4 14. Main Transformer 25. Valve Bank 1
F E
05. Hydraulic Tank 15. Machinery House Heater 26. Mast Cylinder (2)
E S
06. T-Tank (Option) 27. Air Conditioner
R U U
08. Oil Cooler S
07. Startup Oil Circulation Pump 16. DC Drives Cabinet
17. Right Front Leveling Jack
28. Operator’s Cab
29. Auxiliary Winch
T T
09. High Voltage Cabinet (Reference) 30. Valve Bank 2
O
N NO
10. HV Disconnect Switch Cabinet 18. Main Air Compressor 31. Jib Crane (Option)
11. Soft Start Transformer 19. Main Control Cabinet
(Option) 20. Main Motor
O
D DO
12. Soft Start Cabinet (Option) 21. Top-Off Tank
Figure 2-2: Model 320XPC Deck Plan (Typical)
2.2.3 Power Unit
The power unit provides a single source of torque to drive the main air compressor and the three pumps for the
auxiliary and propel hydraulic systems. Major components of the power unit include an electric motor, main air
compressor and a pump drive transmission which are all mounted on a rigid base. The structural section of the
base is sized to retain alignment of these components, regardless of the skid mounting support.
Refer to Section 6 for descriptive and repair information of the power unit components.

2.2.4 Lower Final Assembly (Undercarriage and Propel)
The two crawler frames are attached to the underside of the main frame by a fixed rear axle and an oscillating front
axle. This arrangement increases stability and isolates the main frame from excessive loading when propelling
over rough terrain.
The crawler shoes are of excavator design. There are 58 cleated and uncleated crawler shoes per crawler. The two
crawlers are independently driven by drive tumblers with planetary transmissions directly bolted to the crawler
frame. An individual “plug-in” hydrostatic motor powers each planetary transmission. The transmissions are nested
within the drive tumbler for protection from travel damage in rough areas.
t
Each planetary transmission has an integral spring-set, hydraulically released wet-type multiple disc parking brake.
n
The propel motor can be manually disengaged from the transmissions to allow towing the drill with the optional
e
towing package installed.
Y m
NL uip ion
Only to be used on occasion, the crawlers can be counter-rotated to provide maximum maneuverability for tight
turns and rapid travel from point to point.
O q t
L f E ra
Refer to Section 10 for repair information of the propel system components.
2.2.5 Rotary Carriage

I A o p e
ER ce O
t
AT nan en
Two electric DC motors drive the rotary driveshaft through the rotary gearcase. The rotary drive shaft protrudes
from the bottom of the rotary gearcase for connection to the drill string.
M te m
Each rotary motor output shaft fits into the rotary gearcase first reduction pinion shaft, which is supported by bear-
E i n i p
ings on both the top and the bottom. An oil pump on the bottom of the first reduction shaft provides lubrication for
C a q u
the upper bearings in the gearcase.
E N M E
r
A rotary air swivel ensures sealed air flow through the rotary drive shaft. The rotary air seal also prevents water
R o r
from entering the rotary gearcase oil when the drill is configured with water injection for dust suppression.
f o
F E E f
E
Pulldown is accomplished by means of a rack and pinion drive. The rack is mounted vertically on the mast and the
E S S
drive pinion on the rotary carriage shipper shaft. The rotary carriage guide rollers are provided with an eccentric
R U U
arrangement for adjustment of rack/pinion gear backlash and alignment with the mast. An electric DC motor drives
T T
the hoist/pulldown pinions through the pulldown transmission.
O
N NO
Refer to Section 15 for repair information of the rotary carriage components or to Section 14 for repair information
of the hoist/pulldown components.
2.2.6 Mast, O
D DO
Mast Lock Assy, and Back Braces
The mast safety sling ensures retention of a falling drill pipe without structural damage to the mast.
The mast weldment is raised and lowered by two hydraulic cylinders and is locked in the vertical position by two
hydraulically actuated mast lock pins located on the drilling deck. The position of these pins is monitored by the
Programmable Logic Controller (AC800 control system).
The back braces fold and unfold automatically when the mast is raised and lowered. Two back brace locking col-
lars slide over the folding knee joints between the upper and lower back braces to keep the back braces rigid, lock-
ing the mast in the vertical drilling position.
Refer to Section 13 for repair information of the mast components.

2.2.7 Drill Pipe Storage and Handling
Drill pipe can be stored in the pipe rack(s). Each pipe rack is hydraulically controlled to move inward or outward. A
mechanical mechanism is used to lock the drill pipe into place while stored.
Refer to Section 16 for repair information of the pipe storage and handling system components.
2.2.8 Auxiliary Winch
A hydraulic motor driven winch is mounted on the mast support assembly to handle tools and lift loads on the drill-
ing platform. It features a one-way clutch, so that the winch will hold a load, yet will automatically release when the
t
load is hoisted. Winch wire rope feeds through guide sheaves mounted on a support bar on the mast crown. A
n
remote pendant control is located on the water tank outside of the operator’s cab.
e
Y m
NL uip ion
Winch lifting capacity is based on an operating pressure of 2,000 psi (138 bar) and the number of wraps on the
drum (refer to Table 2-1, below).
O q t
A L f E ra
I o e
No. of Wire Rope Lifting Capacity
R ce O p
Wraps on Drum lbs. (kg)
E 0
t
16,360 (7436)
AT nan en
1 15,640 (7110)
M te m 2 13,820 (6282)
E i n i p
3 12,360 (5620)
C a q u
N M E
Table 2-1: Auxiliary Winch Lifting Capacity
RE o r r
o
Refer to Section 18 for repair information of the winch components.
2.2.9 Deck Wrenches E f f

E F SE E
R U US
The drill is equipped with opposing hydraulic ram type deck wrenches which are used to hold the drill string and
T T
prevent counter-rotation while adding or removing items from the drill string.
O
N NO
Refer to Section 16 for repair information of the deck tools.
O
D DO

2.2.10 Operator’s Controls
The controls are arranged on left and right hand consoles attached directly to the operator seat. Two Graphical
User Interfaces (GUIs) provides continuous information for the operator. Refer to the Operator’s Manual for details.
2.2.11 Hydraulic Systems
The hydraulic system is comprised of two major subsystems:
• Propel (also referred to as Main) Hydraulic System
t
• Auxiliary and Low Pressure Hydraulic System
e n
Y
2.2.11.1 Propel (Main) Hydraulic System
m
NL uip ion
Two identical axial piston pumps with crossover-center variable displacement provide speed and direction control
O q t
for the hydraulic motors that drive the propel motors. The two hydraulic pump circuits are closed-loop.
L f E ra
Port H on the left main pump is connected to Port P1 on valve bank 4 to supply hydraulic power to operate the pro-
A
I
pel brake release and propel speed control functions.
o p e
ER ce O
Refer to Section 9 for additional information and repair information of the propel hydraulic system. Also, refer to
t
AT nan en
Section 10 for repair information of the propel system components.
M te m
2.2.11.2 Auxiliary and Low Pressure Hydraulic System
E i n i p
u
A double vane auxiliary pump supplies hydraulic power through valve banks 1 through 3 for operating the pipe rack
C a q
cylinders, mast raise, auxiliary winch, mast locks, back brace locks, deck wrench, breakout wrench and leveling
N M E
jacks. It also provides hydraulic power for operating the and mast carriage head brake.
R E o r r
f f o
A pressure compensated, axial piston pump supplies low pressure hydraulic power through Port P2 on valve bank
E E
4 to operate the mast carriage head brake, the pipe rack gate and deck hatch cylinders, the pipe rack holdback cir-
F
E S S E
cuit, and the main compressor inlet valve circuit (drills with the Gardner Denver compressor, only).
R U U
Refer to Section 9 for detailed information of the auxiliary hydraulic system.
TSystemT
O
N NO
2.2.12 Water Injection
O
The water injection system suppresses rock chips and drilling dust. It also helps keep the drill bit cool.
D DO
Refer to Section 8 for detailed information of the water injection system.
2.2.13 Automatic Lubrication System
The automatic lubrication system is powered by an electrically driven pump which is controlled by the AC800 con-
trol system. The system delivers lubricant from an on-board tank to injectors, which measure and deliver lubricant
to selected points around the drill at regular intervals. The operator can manually initiate a lubrication cycle from
the GUI when required.
Refer to Section 12 for detailed information of the automatic lubrication system.

2.2.14 Bailing (Main) Air System
The purpose of the bailing air system is to blow drill cuttings out of the drill hole and to cool the rock bit bearings.
The compressor output is adjustable to allow for optimum bailing air velocity.
A compressor inlet valve controls the air draw into the rotary screws. The valve is hydraulically closed during start-
up. During operation, the inlet valves modulate air intake by means of pneumatic controls.
Refer to Section 7 for detailed information of the main air system.
2.2.15 Towing System
n t
CAUTION
Y e
m
NL uip ion
Towing the drill requires an optional towing package to be installed. Do not attempt to
tow a drill that does not have the towing package installed.
O q t
L f E ra
If towing becomes necessary and the towing package is not already on your drill, contact your local MinePro Ser-
A
I o e
vices representative or P&H Mining Equipment for assistance.
R ce O p
E
2.2.16 Dust Curtains
t
AT nan en
Dust curtains surround the area beneath the drilling platform to contain the dust and chips created by drilling.
M te m
2.3 Serial Number Location E i n i p
C a q u
E N M E
R o r o r
The drill serial number is located inside the operator’s cab.
E E f f
E F S E
2.4 Sign Maintenance
R U U S
T T
Signs of various types are located wherever required on the drill to warn personnel of potential hazards, identify
O
N NO
controls and components, and to provide useful information.
O
Because these signs aid in the safe and efficient operation of the drill, inspection of all signs must be a part of the
D DO
inspection program.
If signs are dirty, missing, or illegible, clean or replace them. Refer to Subsection 1.5 for a list and description of
each decal and where it is located on the drill.

2.5 Material Safety Data Sheets (MSDS)

In order to transfer MSDS information from our suppliers to our customers, P&H Mining Equipment will provide this
service upon customer request. All customer requests must be specific because of the volume and complexity of
the MSDS system.
To identify the appropriate MSDS, one of the following must be included: P&H part number, vendor trade name, or
vendor name.
Address inquiries concerning MSDS to your P&H MinePro Services representative.
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

320XPC-UDC Mechanical Systems Manual Preventive Maintenance
Section 3
Preventive Maintenance
3.1 General
t
This section outlines the maintenance procedures that should be performed on the drill at regular intervals to
e n
ensure optimum performance. Each maintenance item is listed in one of the maintenance check sheets provided in
this section. Specific descriptions of each maintenance or lubrication item are provided. Use these descriptions in
Y m
NL uip ion
conjunction with the maintenance check sheets to ensure that each item is performed at the prescribed time inter-
val.
O q t
A L f E ra
I e
3.2 Lubrication
R ce O o p
E
Preventive Maintenance means performing inspections and services that are necessary to keep the drill operating
t
AT nan en
at peak performance. Lubrication is an essential component of Preventive Maintenance. The breakdown of lubrica-
tion services that must be performed are covered in greater detail in Section 12, and there are lubrication service
M te m
checklists starting at Topic 12.6. Those procedures are incorporated into this section.
E i n i p
C a q u
3.3 Bolt Lubrication
E N M E
R o r o r
f f
Unless otherwise specified, all capscrews, bolts, and nuts used to secure or attach major components and assem-
E E
blies should be lubricated with an anti-seize thread lubricant when repairs or replacements are made. Lubricant
F
E S E
should be applied to the threads of fasteners and to the friction-bearing surface of bolt heads, nuts, and washers.
S
Additionally, the threaded connections of all drill pipe joints, rotary head coupling- to-pipe, and drill bit-to-stabilizer
R U U
connections must be lubricated with a silicone thread lubricant.
T T
3.4 Bolts AndN
O O
N
Bolt Torques
O
D DO
Recommended American Standard screw and bolt torque values are listed in Table 3-1 and metric screws and bolt
torque values are shown in Table 3-2.Unless otherwise specified, these torque values apply to all component
mounting bolts that attach structural members of all machinery. At least bi-annually, all mounting and attachment
bolts and capscrews should be checked using a torque wrench to ensure compliance with these tables. Heavy duty
mounting hardware as described in this manual, is equivalent to SAE grade 5 hardware or equal.
English to metric conversion factors are presented in Table 3-3.
Torque values are based on using plated hardware. If lubricants are used, torque values will vary.

Sec03PM.fm -3.1- Section 3, Version 01 - 07/12
Preventive Maintenance 320XPC-UDC Mechanical Systems Manual
Screw,Stud
or Bolt Studs
Diameter UNC Only
(inches) Threads
Coarse per Inch
Grade 2 Grade 4 Grade 5 Grade 7 Grade 8
Threads
UNC & 8UN Ft-Lbs N· m Ft-Lbs N· m Ft-Lbs N· m Ft-Lbs N· m Ft-Lbs N· m
t
1/4 20 6 8.13 10 13.6 9 12.2 11 14.9 12 16.3
5/16 18 11 14.9 20
e n
27.1 17 23.0 21 28.5 25 33.9
3/8 16 27.1
Y m
48.8 42.0 51.5 59.7
NL uip ion
20 36 31 38 44
7/16 14 32 43.4 58 78.6 50 67.8 61 82.7 70 94.9
1/2 13 49 66.4
O q t
90 122 75 102 93 126 106 144
9/16 12 70
A L f E ra
94.9 130 176 109 148 135 183 154 209
5/8 11 97
I132
o p
180
e 244 150 203 185 251 212 287
3/4 10
E
172
R ce O
233 315 427 266 361 330 447 380 515
7/8 9
A T an nt
170 230 505 685 430 583 530 719 610 827
n me
1 8 250 339 760 1030 650 881 800 1085 910 1234
1-1/8 7
M 355
e
t ip
481 1075 1457 800 1085 1130 1532 1290 1749
1-1/4 7
C E n
i u
500 678 1520 2016 1120 1518 1590 2156 1820 2468
N a q 895 2834 3240
M
1-3/8 6 660 1990 2698 1470 1993 2090 2390
1-1/2 6
E or r E
870 1180 2640 3579 1950 2644 2770 3756 3160 4287
1-3/4
4 E
5 R f fo 1370 1857 4160 5640 3080 4176 4370 5925 4990 6765
2
E F SE E 2060 2793 6250 8474 4630 6277 6570 9152 7500 10169
R 4.5 U US
2-1/4 4.5 3020 4095 9140 12392 6770 9179 9600 13016 10970 14873
4T
2-1/2 4130 5599 12500 16948 9250 12541 13130 17802 15000 20337
O T
O
2-3/4 5590 7579 16950 22981 12540 17002 17800 24133 20400 27658
3
N 4 N
4 7390 10019 22390 30356 16570 22465 23500 31861 26900 36471
3-1/2O O
3-1/4 9520 12907 28850 39115 21350 28946 30290 41067 34600 46911
D
3-3/4 D44 12030 16310 36450 49419 26970 36566 38300 51927 43800 59384
14940 20255 45300 61418 33500 45419 47600 64536 54400 73756
4 4 18280 24784 55400 75111 41000 55588 58200 78908 66500 90161
GN0123a01
Table 3-1: Recommended Torque Values for American Standard Threads (Sheet 1 of 2)

Section 3, Version 01 - 07/12 -3.2- Sec03PM.fm
Screw,Stud
or Bolt Studs
Diameter UNF Only
(inches) Threads
Fine per Inch
Grade 2 Grade 4 Grade 5 Grade 7 Grade 8
Threads
UNF & 12UN Ft-Lbs N· m Ft-Lbs N· m Ft-Lbs N· m Ft-Lbs N· m Ft-Lbs N· m
t
1/4 28 6 8.13 11 14.9 9 12.2 11 14.9 13 17.6
5/16 24 12 16.3 22
e n
29.8 18 24.4 23 38.2 26 35.3
3/8 24
Y
39
m
52.9 44.7 55.6 63.7
NL uip ion
22 29.8 33 41 47
7/16 20 34 46.1 62 84.1 52 70.5 65 88.1 74 100
1/2 20 53 71.9
O q t
95 129 81 110 100 136 114 155
9/16 18 75
A L f E ra
102 136 184 115 156 142 193 163 221
5/8 18 105
I 142
o
190
p e 258 162 220 200 271 228 309

3/4 16 183
ER ce O
248 332 450 282 382 350 475 400 542
t
AT nan en
7/8 14 180 244 530 719 450 610 560 760 635 861
1 12 260 353 790 1071 670 908 830 1125 945 1281
1-1/8 12
M te m
380 515 1150 1559 850 1152 1200 1627 1380 1871
E i n i p
u
2278 2590
C a q
1-1/4 12 525 712 1600 2169 1180 1600 1680 1910
N
3064 3498
M E
1-3/8 12 710 962 2150 2915 1590 2156 2260 2580
1-1/2
RE 12
o r r
930 1261 2820 3823 2090 2834 2960 4013 3380 4583
1-3/4
E E f
12
f o 1500 2034 4540 6155 3360 4555 4770 6467 5450 7389
2
E F S
12
E
2270 3078 6860 9300 5080 6887 7210 9775 8240 11171
2-1/4
R U U
12
S 3260 4420 9860 13368 7300 9897 10360 14046 11830 16039
T T
2-1/2 12 4500 6101 13630 18480 10100 13694 14310 19401 16360 22181
O
24760 13500 18303 19170 25991 21910 29706
N NO
2-3/4 12 6030 8175 18260
3 12 7860 10657 23800 32268 17600 23862 25010 33909 28600 38776
O
D DO
3-1/4
3-1/2
12
12
10040 13612 30400
12600 17083 38200
41216 22500 30506 32000 43386 36500 49487
51792 28200 38234 40100 45366 45800 62096
3-3/4 12 15500 21015 47100 63858 34800 47182 49400 66977 56500 76603
4 12 18900 25625 57300 77687 42400 57486 60100 81484 68700 93143
GN0124a01
Table 3-1: Recommended Torque Values for American Standard Threads (Sheet 2 of 2)

Nominal Shank
Diameter (mm)
and 5.8 8.8 10.9
Thread Pitch
(mm per thread)
N·m Ft-lbs N·m Ft-lbs N·m Ft-lbs

M6-1 7 5
n t 11 8 15 11
M8-1.25 17
Y
12
e 26 19 36 27
M10-1.5 33
L ip n
24
m 52 38 72 53
N
O qu tio
M12-1.75 58 43 91 67 126 93
L f E ra
M14-2 92 68 145 107 201 148
M16-2
I
143
A o p e
105 226 166 312 230
M20-2.5
E R ce O
279 206 441 325 610 450
T an nt
M22-2.5 380 281 601 443 831 613
M24-3
A n me
482 356 761 562 1053 777
M27-3
M e
t ip
707 521 1116 823 1544 1139
M30-3.5
C E n
i u 959 707 1514 1116 2094 1544
N a q
M
M36-4 1676 1236 2646 1952 3661 2700
M42-4.5
E or r E 2683 1979 4237 3125 5861 4323
R f fo
M56-5.5 E
M48-5 4031 2973 6364 4694 8804 6493
E F SE E 6480 4779 10231 7546 14153 10439
R U US
M64-6 9762 7200 15414 11368 21322 15726
M80-6 T T
M72-6 14199 10472 22419 16536 31013 22874
N N
M90-6
O O 19809
28681
14610
21154
31277
45286
23069
33401
43267
62645
31912
46205
O
D DO
M100-6 39870 29406 62952 46431 87083 64229
GN0125a01
Table 3-2: Recommended Torque Values for Metric Threads
3.4.1 Special Bolt Tightening Requirements
Any special bolt tightening requirements that differ from standard torque values are identified within the appropriate
assembly and installation instructions of this manual.

Multiply by to get equivalent Multiply by to get equivalent

number of: number of:
LENGTH TORQUE
Inch 25.4 milimetres (mm) in-lbs 0.11298 newton-metres (N. m)
Foot 0.3048 metres (m) ft-lbs 1.3558 newton-metres
Yard 0.9144 metres ft-lbs 0.1383 kg-m (kgm)
t
Mile (Statute) 1.609 kilometres (km)
e n
Y
AREA
m
POWER
NL uip ion
Inch² 645.2 milimetres² (mm²) Horsepower 0.746 kilowatts (kW)
6.45 centimetres² (cm²)
O q t
Foot² 0.0929 metres² (m²)
L f E ra
Yard² 0.8361 metres²
I A o p e
R ce O
VOLUME PRESSURE OR STRESS
Inch³ 16 387
E mm³
t
Inches of:
AT nan en
16.387 cm³ mercury 3.377 kilopascals (kPa)
0.0164 litres (l) water 0.2491 kilopascals
M te m
Quart 0.9464 litres Pounds/sq.
Gallon 3.7854 litres in. (psi) 6.895 kilopascals
Yard³
E 0.7646
i n i p
metres³ (m³) in. (psi) 0.069 bars
C a q u
E N M E
r
MASS ENERGY OR WORK
Pound
R fo o
0.4536
r kilograms (kg) BTU 1 055. joules (J)
FE E
Ton (Short)
f
907.18 kilograms Foot-pound 1.3558 joules
E
Ton (Short) 0.907 tonne (t) Kilowatt-hour 3.6 x 10 6 joules
E S S
or
R U U
3600000
(J = one Watt-second)
T T
O
N NO
FORCE VELOCITY
Kilogram 9.807 newtons (N) Miles/hour 1.6093 kilometres/hr (km/h)
O
Ounce 0.278 newtons
D DO
Pound 4.448 newtons
TEMPERATURE CONVERSION CHART

°F °F
-40 32 59 140 212
0 40 50 80 120 160 200
°F = (9/5 °C) + 32
°C = 5/9 (°F - 32) -20 10 20 40 80

60 100
-40 0 15
°C °C
ES01756a01
Table 3-3: English to Metric Conversions

3.5 Maintenance Schedule Check Sheets
3.5.1 General
The actual operating environment of the drill governs the maintenance schedule. The check sheets on the follow-
ing pages indicate the areas of the drill to be checked and the suggested intervals at which they should be
checked. The order in which the items are listed is suggested only and does not constitute the order of perfor-
mance. Maintenance items may be performed in any order desired within a given time interval.
The following suggested schedule check sheets are based on average operating conditions. The type of work
being done, the type and hardness of the materials being drilled, and the ground and weather conditions are all
t
factors that must be considered when establishing a maintenance schedule for this drill. The suggested schedule is
n
e
given for hours of operation and calendar intervals.
Y m
NL uip ion
Any changes in the established schedule check sheets should be preceded by a complete re-evaluation of drill
operation. Carefully study previous maintenance check sheets and records before making changes in, or extend-
O q t
ing, the maintenance check intervals.
3.5.2 Using The Maintenance Schedule Check Sheets

A L f E ra
I o p e
R ce O
The maintenance schedule check sheets are designed as a preventive maintenance guide until adequate experi-
E t
ence is obtained to establish a schedule to meet a specific operating environment and machine. Detailed proce-
AT nan en
dures for each check sheet operation are provided following the check sheets. The check sheets can be
reproduced on any copy machine.
M te m
E n p
Maintenance personnel should indicate on the sheet that the required check has been completed, and that the drill
C a q i u i
will be ready for continued operation until the next scheduled check is due. Completed check sheets should be
retained as a permanent part of the drill maintenance records for future reference.
E N M E
R o r o r
The following topics describe the maintenance procedures to be performed on this blasthole drill. Each topic cov-
f f
ers a specific time period. Detailed maintenance instructions are provided for the individual lubrication and service
E E
points listed on the corresponding maintenance check sheets. The maintenance person may use the following pro-
F
E S S E
cedures in conjunction with the maintenance check sheets to ensure that all service and lubrication points are cor-
rectly serviced at the appropriate time interval. The lubrication charts and figures shown in the Lubrication Section
R U U
provide general locations of the individual service points and list the type of lubricant which should be used for each
T T
component. Refer to these charts for the location of lubrication points on this drill. The location of service points
O
N NO
other than lubrication points are described in the following paragraphs as applicable.
O
D DO

3.6 Maintenance Schedule Tables
P&H Model 320XPC Rotary Blasthole Drill

“A” Maintenance Checks (Daily / 8-12 Hours)
Maintenance Person:
Date Performed:
Machine Serial Number:
Machine Hours:
!
n
WARNING t
Y e
m
NL uip ion
Unexpected machine movement can cause severe personal injury or death. Shut
down the machine before performing inspections, service or maintenance. Establish a
procedure to guard against inadvertent equipment operation or movement while con-
ducting inspections.
O q t
L f E ra
Use lockout and tagout procedures prior to conducting maintenance or service.
A
√ I
ITEMS TO BE VERIFIED
o p e REF COMMENTS
ER ce O
t
Note and record any faults on the GUI Fault Log Subsection 3.7.1
AT nan en
Inspect operator’s cab air filter Subsection 3.7.2
M te m
Check hydraulic oil reservoir level Subsection 3.7.3
E i n i p
Check hydraulic oil reservoir breather Subsection 3.7.4
C a q u
N
Check pump drive transmission oil level Subsection 3.7.5
E r M E
r
Check main air compressor oil reservoir level Subsection 3.7.6
R
E E
Fill water tank
fo f o Subsection 3.7.7
E F S
Check deck wrenches
E Subsection 3.7.8
R U U S
Inspect auxiliary winch and rope Subsection 3.7.9
T T
Inspect drill pipe sling Subsection 3.7.10
O
N NO
Inspect pipe rack operation Subsection 3.7.11
O
Check rotary gearcase oil level Subsection 3.7.12
D DO
Check pulldown gearcase oil level
Inspect rotary carriage rollers

Subsection 3.7.13
Subsection 3.7.14
Inspect machine for damage and leaks Subsection 3.7.15
Inspect crawlers Subsection 3.7.16
Inspect jack shoes and retaining pins Subsection 3.7.17
Inspect jack housing mounting hardware Subsection 3.7.18
Table 3-4: “A” Maintenance Checks


“B” Maintenance Checks (Weekly / 40-100 Hours)
Maintenance Person:
Date Performed:
Machine Hours:
WARNING
t
!
e n
Y m
NL uip ion
O q t
A L f E ra
e
√ ITEMS TO BE VERIFIED
I
REF COMMENTS
Perform “A” maintenance checks

R ce O o p Subsection 3.8.1
E t
AT nan en
Inspect hydraulic system components Subsection 3.8.2
Inspect breakout wrench Subsection 3.8.3
M te m
p
Inspect pipe rack condition Subsection 3.8.4
E
C a q i
Inspect mast racks and pinionsn u i Subsection 3.8.5
N M E
Inspect rotary machinery
E
Subsection 3.8.6
R o r o r
Inspect bailing air system components Subsection 3.8.7
E E f f
F
Check main compressor oil separator filters Subsection 3.8.8
E S S E
Check main compressor air Intake filters Subsection 3.8.9
R U U
Check hydraulic charge filters Subsection 3.8.10
T T
O
N NO
Check main compressor oil filter Subsection 3.8.11
Check hydraulic return line filters Subsection 3.8.12
O
D DO
Check autolube grease reservoir level
Check cable reel hydraulic oil level

Subsection 3.8.13
Subsection 3.8.14
Inspect trail cable Subsection 3.8.15
Inspect crawler belt tension Subsection 3.8.16
Table 3-5: “B” Maintenance Checks


“C” Maintenance Checks (Monthly / 160-250 Hours)
Maintenance Person:
Date Performed:
Machine Hours:
! WARNING
n t
Y e
m
NL uip ion
O q t
L f E ra
A
√
I
o p e REF COMMENTS
ER ce O
Repeat “A” and “B” maintenance checks Subsection 3.9.1
t
AT nan en
Inspect mast back braces and slides Subsection 3.9.2
M te m
Inspect mast Subsection 3.9.3
E i n i p
Inspect auxiliary winch rope and sheaves Subsection 3.9.4
C a q
Inspect main frame
u Subsection 3.9.5
E N M E
r r
Inspect crawler frames Subsection 3.9.6
R
E E fo f o
Check propel transmission oil level Subsection 3.9.7
E F S E
Inspect cable reel components Subsection 3.9.8
R U U S
Check auxiliary winch oil level Subsection 3.9.9
T T
Clean/flush water tank Subsection 3.9.10
O
N NO
Clean main compressor and hydraulic oil cooler
Clean/inspect machinery house blowers and filters

Subsection 3.9.11
Subsection 3.9.12
O
D DO
Change main compressor bearing oil filter (only
required on drills equipped with a Gardner Denver
Subsection 3.9.13
compressor)
Table 3-6: “C” Maintenance Checks


“D” Maintenance Checks (Quarterly / 500 Hours)
Maintenance Person:
Date Performed:
Machine Hours:
! WARNING
n t
Y e
m
NL uip ion
O q t
L f E ra
A
√
I
o p e REF COMMENTS
ER ce O
Repeat “A”, “B” and “C” maintenance checks Subsection 3.10.1
t
AT nan en
Retorque hardware Subsection 3.10.2
M te m Table 3-7: “D” Maintenance Checks
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO


“E” Maintenance Checks (Semi-annually / 1000 Hours)
Maintenance Person:
Date Performed:
Machine Hours:
! WARNING
n t
Y e
m
NL uip ion
O q t
L f E ra
A
√
I
o p e REF COMMENTS
ER ce O
Repeat “A”, “B”, “C” and “D” maintenance checks Subsection 3.11.1
t
AT nan en
Change rotary gearcase oil Subsection 3.11.2
M te m
Change hoist/pulldown gear reducer oil Subsection 3.11.3
E i n i p
Replace main compressor oil separator filters Subsection 3.11.4
C a q u
Replace oil line scavenger filter element Subsection 3.11.5
E N M E
r r
Replace suction filter elements Subsection 3.11.6
R
E E fo f o
Replace low pressure return filter elements Subsection 3.11.7
E F S E
Replace main return filter elements Subsection 3.11.8
R U U S
Change pump drive transmission (PDT) oil Subsection 3.11.9
T T
Change propel transmission oil Subsection 3.11.10
O
N NO
Lubricate cable reel bearings, trolly wheels and chains Subsection 3.11.11
O
Table 3-8: “E” Maintenance Checks
D DO


“F” Maintenance Checks (Annually / 2000 Hours)
Maintenance Person:
Date Performed:
Machine Hours:
! WARNING
n t
Y e
m
NL uip ion
O q t
L f E ra
A
√
I
o p e REF COMMENTS
ER ce O
Repeat “A”, “B”, “C”, “D” and “E” maintenance checks Subsection 3.12.1
t
AT nan en
Change hydraulic system oil Subsection 3.12.2
M te m
Change auxiliary winch gearcase oil Subsection 3.12.3
E
Change air compressor oil
i n i p Subsection 3.12.4
C a q u
Change cable reel right angle gear reducer oil Subsection 3.12.5
E N M E
r r
Change cable reel hydraulic system oil and replace oil Subsection 3.12.6
R o o
filters
E E f f
F E
Table 3-9: “F” Maintenance Checks
E
R U U S S
T T
O
N NO
O
D DO

3.7 “A” Maintenance Checks (Daily or 8-10 Hours)

The “A” Maintenance Checks should be performed daily, or at the beginning of each work shift. Park the drill on
level ground or use the jacks to level the drill prior to the inspection. If an item is found to be incorrect, the problem
must be corrected prior to start-up to ensure satisfactory operation of the drill.
3.7.1 Note and Record Any Faults Displayed on GUI Fault Log
The Graphical User Interface (GUI) provides a fault log that indicates conditions that need attention. To access the
GUI fault log, proceed as follows:
t
Touch the “Fault History Screen” icon on the GUI Main Page (Figure 3-1).
n
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
Figure 3-1: GUI Current Drill Activities Screen
The fault list is similar in appearance to the one shown in Figure 3-1.

3.7.2 lnspect Operator Cab Air Filters
Refer to Figure 3-2. The operator cab is pressurized with filtered air for operator comfort. To ensure that air enter-
ing the operator cab is satisfactorily filtered, the filter elements must be visually inspected on a daily basis.
• Remove cover on right side of unit and visually inspect the two operator cab air filters (01) for dirt and con-
tamination. If necessary, clean or replace the filter elements.
• Visually inspect the pressurizer filter (02). Replace the filter element when it has accumulated a thin layer of
dust.
n t
Y e
m
NL uip ion
O q t
A L f E ra 02
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
N M E
F6748a
RE o r r
E E f f o
E F S E LEGEND
R U U S 01. Operator Cab Recirculation Air Filters

02. Pressurizer Filter
T T
O
N NO
O
D DO MAS 1500 Model
01
Figure 3-2: Operator Cab Filters (MineAir - Typical)
3.7.3 Check Hydraulic Tank Oil Level
Refer to Figure 3-3. The hydraulic tank is located in the house on the left side of the machine. With the drill on level
ground, check the oil level by reading the oil level sight glass, located on the front of the tank. The legend along
side of the sight glass indicates the correct minimum and maximum permissible oil levels for the various positions
of the mast and drill leveling jacks:

MAXIMUM MAST DOWN AND JACKS FULLY RETRACTED

WITH HOT OIL - 180° F (82° C)

WITH COLD OIL
MINIMUM MAST DOWN AND JACKS FULLY RETRACTED
n t MAXIMUM MAST UP AND JACKS FULLY RETRACTED
e
Y m
NL uip ion
MAXIMUM MAST UP AND JACKS FULLY RETRACTED
WITH COLD OIL
O q t
MINIMUM MAST UP AND JACKS FULLY RETRACTED
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f MINIMUM MAST UP AND JACKS FULLY EXTENDED
F E
3.2 GALLONS / INCH 4.8 LITERS / CENTIMETER
E S S
| | | | | |
| | | |
| |
|
| |
| |
R5644101
| | | | | | |
| | | | |
R U U
|
T T
O
N NO CAUTION
Figure 3-3: Hydraulic Tank Sight Tube
O
D DO
Adding unfiltered oil can introduce contaminants that can damage the hydraulic system
and its components. Always filter oil that is added to the hydraulic tank.
Fill the hydraulic oil tank as needed, using either the top off system (refer to Section 20) or by adding filtered oil
directly to the hydraulic tank.
NOTICE
P&H Mining Equipment recommends that a sample of oil be drawn from the hydraulic tank at
least annually. The sample should be about two quarts and should be taken when the oil is

warmed through normal operation. The sample should be analyzed by a qualified lubrication
specialist to determine whether it is suitable for continued use. The interval between oil
changes depends upon operating conditions, on the care used in the handling of oils, and
cleanliness during the handling process.
3.7.4 Check Hydraulic Tank Breather Condition Indicator
01
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
R57523D1d
Figure 3-4: Hydraulic Tank Breather Condition Indicator
3.7.4.1 General
M te m
E i n i p
C a q u
Refer to Figure 3-4. The hydraulic tank breather is threaded onto an adapter on the top of the hydraulic tank.
E N M E
r r
3.7.4.2 Service
R
E E fo f o
Replace the breather when the pop-up indicator (01) appears.
E F S E
3.7.4.3 Replacement
R U U S
T T
Turn the breather counterclockwise to remove it from the adapter. Coat the threads on the new breather with
O O
thread sealant and install it onto the adapter until tight.
N DriveNTransmission
3.7.5 Check Pump Oil Level
O
D DO
The pump drive transmission mounted on the front end of the main power unit, drives the two main hydraulic
pumps and one auxiliary hydraulic pump. Refer to Figure 3-5 and check the oil level in the pump drive transmission
using the following procedure:
1. Shut down operation of the main power unit.
! WARNING
Working on or near rotating machinery while in operation is hazardous and can result in
injury or death. Shut down operation of the drill, and use lockout/tagout procedures
prior to working on or near rotating machinery.

2. Shut down, lock out, and tag the electrical controls to the drill to prevent inadvertent start-up during service
activities.
3. Check the pump drive transmission oil level using the dipstick (01).
4. If the oil level is low, remove the vent and fill cap (02) and add oil to bring the level even with the full mark on
the dipstick. (See Section 12, Lubrication, for lubricant specifications.)
t
LEGEND
n
01. Oil Level Dipstick
Y e 02. Vent and Fill Cap
m
03. Oil Drain Valve and Piping (Drains
NL uip ion
out below deck)
O q t
A L f E ra
I o p e
R ce O
02
E t
AT nan en
01
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
03
R U U S
T T
O
N NO
R59401F1_02a
O
D DO
Figure 3-5: Pump Drive Transmission
CAUTION
Operating the pump drive transmission when it has been overfilled will cause overheat-
ing of the pump drive transmission components resulting in component damage. Never
operate the pump drive transmission when the oil level is either too full or too low.

3.7.6 Check Main Air Compressor Oil Reservoir Level
01
EXCESS
OIL
n t FULL
Y e
m
NL uip ion
02
O q t
ADD
L f E ra
OIL
I A e
GH300849
R ce O o p
E t
AT nan en
M te m
E p
t-tank02
C a q i n u i
N
LEGEND
M E
01. Filler Plug: Fill through this port or use top off 02. Oil Level Sight Gauge: Oil level should be in the
system.
RE o r r
FULL area of the sight tube
E E f f o
E F S E Figure 3-6: T-Tank Oil Level Sight Tube
S
R U U CAUTION
T T
O
N NO
Operating the air compressor with insufficient oil can cause severe damage to the com-
pressor lobes. Never operate the main air compressor when the oil level is below the
O
D DO
LOW mark. Add oil of the type specified in the Lubrication Section any time the oil level
is at the ADD mark on the sight gauge.
Refer to Figure 3-6. The main air compressor oil reservoir (T-Tank) contains the lubricant for the compressor com-
ponents, including the screws, bearings, and gears. The reservoir is located on a platform on the left side of the
drill, outside the machinery house. Check the oil level in the main air compressor oil reservoir as follows:
1. With the drill parked on level ground, check the reservoir oil level at the sight glass on the reservoir T-tank.

! CAUTION
Air compressor components get extremely hot during operation. Shut down the air com-
pressor and allow components to cool before servicing. Failure to heed may result in
burns to the hands.
2. Wait for the main air system pressure to completely vent through the muffler.
! WARNING
n t
Pressurized oil will spray with extreme force from the reservoir when opening the filler
e
plug and can cause severe injury or death. Shut down the air compressor and allow air
Y m
pressure vent before opening the filler plug. Wear appropriate face, ear, and body pro-
NL uip ion
tective devices while venting the main air system and/or opening the filler plug.
O q t
NOTICE
A L f E ra
I o p e
R ce O
Oil can also be added to the T-tank using the quick-fill system. Refer to.
E t
AT nan en
3. Add oil to the main compressor oil tank by opening the filler plug (01), located on top of the tank. Add oil to the
full mark on the sight gauge (02). Use the type specified in the Section 12, Lubrication.
M te m
4. Apply pipe thread sealant and install the filler plug. Tighten the plug securely to prevent leakage.
E i n i p
3.7.7 Fill Water Tank
C a q u
E N M E
r r
The water tank is located on a platform at the left, side of the drill. At the start of each work shift or after each 8
R fo o
hours of operation, fill the tank with water. The tank should be filled to within approximately 1 inch (25 cm) from the
top of the tank.
E f
3.7.8 lnspect Deck Wrenches E
F E
E
R U U S S
T T
1. Inspect the pawls, bodies, and housings for cracks, wear, corrosion, and distortion.
O
N NO
2. Check for broken or weak springs.
O
D DO
3. Check for worn, broken, or missing hardware items.
4. Check the hydraulic and lubrication hoses and fittings for wear and leaks.
5. Check for free rotation around the hinge pins.
6. Refer to the Pipe Handling Section for repair procedures.

3.7.9 lnspect Auxiliary Winch and Wire Rope
The winch is mounted on the lower mast assembly at the base of the mast. The winch is used for hoisting drill pipe,
drill bits, and other accessory tools and equipment. At the beginning of every shift, inspect the winch for loose
mounting hardware, frame cracks, loose or leaking hydraulic hoses and fittings, and incorrectly spooled cable. Also
confirm that the cable clamps attaching the hook to the cable are securely tightened.
Visually inspect the winch rope at the start of each shift. This inspection is general, for the purpose of discovering
gross damage, such as:
• Distortion
• Corrosion
n t
Y e
m
• Broken or cut strands.
• Excessive broken wires.

NL uip ion
O q t
L f E ra
Presence of these conditions will prompt further inspection or rope replacement.
A
I o p e
R ce O
3.7.10 lnspect Drill Pipe Slings
E t
AT nan en
The pipe slings are designed to catch a loose pipe section and keep it from falling free of the mast should it sepa-
rate from the rotary head coupling. Visually inspect the pipe sling components for damage, cracks, or missing hard-
M te m
ware. All mounting hardware should be properly torqued. Replace any damaged or missing sections, cables and/or
p
hardware.
3.7.11 Inspect Pipe Rack Operation E i n i

C a q u
E N M E
R o r o r
To ensure safe and satisfactory pipe rack operation, and correct positioning of the drill pipes, inspect the condition
f f
of each pipe rack:
F E E
E S E
1. Before shutting down the drill, move the pipe racks in and out to confirm correct operation.
S
R U U
2. Lower the mast and shut down operation of the drill.
T TOil Level
O
N NO
3.7.12 Check Rotary Gearcase
O
The rotary gearcase is mounted to the lower end of the rotary carriage. Refer to Figure 3-7 and use the following
D DO
procedure to check the rotary gearcase oil level:
1. With the mast in the vertical position, lower the rotary carriage to the bottom of the mast and shut down opera-
tion of the drill.
! WARNING
Inadvertent machine movement can cause injury or death. Do not perform maintenance
work on a machine without first disabling the operator controls. Lock out and tag the
operator controls to prevent inadvertent machine start-up during maintenance.

2. Lock out and tag the operator controls to prevent inadvertent start-up of the machinery. Follow the lockout and
tagout procedures outlined at the front of this manual.
3. Ensure that the machine is level, or as near level as possible. Check the oil level by removing and inspecting
the dipstick (02), located on the top of the rotary gearcase.
CAUTION
Operating the rotary machinery when the rotary gearcase has been overfilled with oil will
cause overheating and will damage gearcase components. Never operate the rotary
t
gearcase when the oil level is below the “L” low level or above the “F” full level.
e n
4. The oil level must be maintained between the “L” (low) and “F” (full) marks on the dipstick. Add oil of the type
Y m
specified in the Section 12, Lubrication through the breather on the top of the gearcase.
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
01
M te m
E p
02
C a q i n u i
E N M E
R o r o r
E E f f
E F S E
R U U S
F
T T
O
N NO L
O
D DO
BD0556c01 03
LEGEND
01. Breather 03. Drain Valve
02. Dipstick
Figure 3-7: Rotary Gearcase Lubrication
5. Recheck the oil level after adding oil. If oil appears above the full mark, open the drain valve (03) and drain
enough oil from the gearcase to maintain the oil level between the full and low marks.
6. Securely reinstall the breather and dipstick.

3.7.13 Check Pulldown Gearcase Oil Level
The pulldown gearcase is mounted at the upper level of the rotary carriage assembly. Refer to Figure 3-8 and use
the following procedure to check the pulldown gearcase oil level:
1. Lower the rotary carriage to the bottom of the mast, and shut down operation of the drill.
! WARNING
Inadvertent machine movement can cause serious injury or death. Do not perform main-
t
tenance work on a machine without first disabling the operator controls. Lock out and
n
tag the operator controls to prevent inadvertent machine startup during maintenance.
Y e
m
NL uip ion
O q t
3. Ensure that the drill is level, or as nearly level as possible.
CAUTIONIAL f E era
R o p
E c e O
t
Operating the pulldown gearcase after it has been overfilled with oil will cause overheat-
AT nan en
ing and will damage gearcase components. Never operate the pulldown gearcase when
the oil level is either below the LOW level or above the FULL level on the sight gauge.
M te m
E i n i p
4. The oil level must be maintained near the center of the upper sight glass (02). If necessary, remove the
C a q u
breather and add oil of the type specified in the Section 12, Lubrication through the breather opening located
N M E
on the inspection cover. Use care to avoid over-filling of the gearcase.
RE o r r
5. Recheck the oil level after adding oil. If oil appears to fill the upper sight glass, drain enough oil from the
E E f f o
gearcase to maintain the oil level near the center of the upper sight glass.
E F S E
S
6. Apply pipe thread sealant to the male threads on the breather pipe and securely install the breather.
R U U
T T
O
N NO
O
D DO

LEGEND
01. Inspection Cover with Breather:
01
Remove breather to fill gearcase.
02. Oil Level Sight Gauge:
Oil should appear to fill the lower 02
glass; the upper glass should
appear half full.
n t
Y e
m
NL uip ion
O q t
BD0870b01
A L f E ra
I o p e
ER ce O BD0870b01
t
AT nan en
M te m
Figure 3-8: Pulldown Gearcase Oil Level
E
3.7.14 Inspect Rotary Carriage Rollers
i n i p
C a q u
N M E
Check the clearance of the carriage rollers daily. The carriage rollers are mounted on eccentric shafts to permit
E
R o r o r
adjustment of roller position, and to maintain proper pulldown pinion engagement due to roller wear. The 16 mount-
f f
ing holes in the shaft flanges permit adjustment in increments equivalent to the 22.5° difference in the location of
the mounting holes.
F E E
E S E
!S WARNING
R U U
T T
O
Inadvertent machine movement or operation can cause injury or death. When necessary
N NO
to operate the blasthole drill while making an adjustment or performing a check, obtain
the assistance of a second person who is thoroughly familiar with the machine. Have the
O
D DO
assistant at the control panel to be sure that nothing is actuated that may be hazardous
to you or the machine.

3.7.14.1 Carriage Roller Adjustment
n t
Y e
m
NL uip ion
O q t
L f E ra
01
I A o p e
ER ce O
t
AT nan en
A
M te m
E i n i p 02
C a q u
LEGEND
E N M E
r r
01. Mast Chord
02. Rollers
R
E E fo
03. Eccentric Bushing
f o 03
F E
BD0552a01
A. 0.125 in (3 mm)
E
R U U S S
T T
Figure 3-9: Carriage Roller Adjustment
O
N NO
Refer to Figure 3-9 and proceed as follows:
O
1. Lower the mast unto the mast supports.
D DO
2. Remove the four socket head capscrews from the eccentric bushing (03).
3. Using a spanner wrench, turn the eccentric bushing until a gap of 0.025 in. (3 mm) is obtained between all of
the rollers (02) and the back of the mast chord (01).
Repeat Steps 1 through 3 for the three remaining roller carriers.
3.7.15 Inspect Machine For Damage And Leaks
Make a complete and thorough visual inspection of the mast, jacks, lower frame, and underside of the drill, looking
for leaks, loose connections, or any other unsatisfactory conditions. Ensure that problems found during inspection
are corrected prior to continued drill operation. If repairs are necessary, refer to the applicable section of this man-

ual, for detailed instructions. Additional specific inspection procedures are outlined elsewhere in this manual for
various time intervals. This topic is intended to locate potentially hazardous conditions before they result in equip-
ment damage or personal injury.
3.7.15.1 lnspect Air Lines For Leaks
Visually inspect each air system hose and pipe for leaks, abrasion, damage, kinks, or other signs of wear or decay.
Report any problems. Damaged hoses and piping must be replaced prior to continued operation of the drill.
3.7.15.2 lnspect Hoses And Hydraulic Lines
t
Visually inspect each hydraulic and lubrication hose, and tubing for abrasion, damage, kinks, or other signs of wear
n
or decay. Report any problems which are found. Damaged hoses and piping must be replaced prior to continued
operation of the drill.
Y e
m
NL uip ion
3.7.15.3 lnspect Hydraulic Fittings For Leaks
O q t
Refer to Appendix B, General Hydraulic System Maintenance and inspect all hydraulic and lubrication connections
L f E ra
as described, and if necessary use the appropriate tightening sequence to secure the connection.
A
I o p e
R ce O
3.7.15.4 lnspect Dust Curtain
E t
AT nan en
Visually inspect the condition of the dust curtain for damage caused by flying rocks and debris. Operate the dust
curtain through a full cycle to ensure that it operates correctly. Repair or replace damaged dust curtains prior to
M te m
continued drill operation.
3.7.16 Inspect Crawlers

E i n i p
C a q u
N
1. Check for cracked or broken shoes
E M E
R o r o r
f f
2. Check for excessively worn upper or lower rollers
F E E
E S S E
3. Check both axles for wear, cracks, and loose or damaged mounting hardware
R U U
4. Check for smooth mesh between shoe and tumbler lugs
T AndTRetaining Pins
O
N NO
3.7.17 lnspect Jack Shoes
O
The leveling capability and stability of the drill depends on the integrity of the jack shoe assemblies. Inspect these
D DO
assemblies weekly for cracked gussets, loose or broken retainer pin, and missing retainer pin capscrew and lock-
washer.
3.7.18 lnspect Jack Housing and Cylinder Mounting Hardware
The leveling capability and stability of the drill depends on the integrity of the jack assemblies. Inspect the jack
housing mounting hardware for proper torque. Check that the cylinder mounting pins are secure.
3.7.19 Inspect Auxiliary Air Compressor Before Using
Prior to starting the auxiliary air compressor, check the fluid level in the sump. Add oil if necessary. Refer to the
manual provided with the optional air compressor for details.

3.8 “B” Maintenance Checks

The “B” Maintenance Checks should be performed every week, or after 100 hours of operation, whichever occurs
first. If an item is checked and found to be incorrect, the problem must be corrected prior to machine start-up to
ensure satisfactory operation of the drill.
3.8.1 Perform “A” Maintenance Checks
Refer to the maintenance check sheets starting with Table 3-4 and complete all “A” Maintenance Checks before
proceeding with the “B” Maintenance Checks.
3.8.2 lnspect Hydraulic System Components

n t
Y e
m
Visually inspect each hydraulic component for damage and leaks. Operate each control valve and solenoid and
NL uip ion
check for correct component operation. Repair or replace any damaged or malfunctioning hydraulic component.
Inspect, but do not limit the inspection to the following components:
O q t
L f E ra
• All hydraulic control valves and connections.
• All hydraulic hoses and fittings.

I A o p e
ER ce O
t
• Drive-to-pump couplings.
• Hydraulic pumps.
AT nan en
M te m
• Suction and return filters.
E i n i p
C a q u
N M E
• Cylinders, pins, and bushings.
RE o r r
o
• Hydraulic motors.
3.8.3 lnspect BreakoutE

f f
E F E E
Wrench
S
R U US
1. Inspect for cracked, broken, or distorted arm or hinge pins.
T T
O
N NO
2. Inspect for missing die teeth, die retainers, shims, and pins.
3. Confirm that the arms move freely on the hinge pins.
O O Condition
D PipeDRack
3.8.4 Inspect
Inspect the condition of the pipe rack weekly. Proceed as follows:
! WARNING
Inadvertent operation of the drill while working on or near the mast structure can result
in injury or death. Lower the rotary carriage to the bottom of the mast, shut down drill
operation, lock out and tag the operator controls prior to working on or near the mast
structure. Follow the lockout and tagout procedures outlined at the front of this manual.

2. Inspect for the following:
• Breakout dogs on each pipe location, for wear.
• Hydraulic cylinders for oil leaks, wear, or damage.
• Pipe rack structure for damage.
t
• Pipe rack for correct operation.
• Linkages for looseness, wear, or damage.

e n
Y m
NL uip ion
Repair or replace worn or damaged pipe rack components. Refer to the applicable topic in this manual for repair
instructions regarding the pipe rack.
O q t
3.8.5 lnspect Mast Racks and Pinions
A L f E ra
I o p e
R ce O
Inspect the condition of the mast racks and pinions once weekly. Proceed as follows:
E t
AT nan en
1. Lower the rotary carriage to the bottom of the mast, lower the mast to the stored position, and shut down oper-
ation of the drill.
M te m
E
! WARNING
i n i p
C a q u
N M E
Working on or near the mast structure while the drill is operating is hazardous and can
E r r
result in the injury or death of personnel. Lower the rotary carriage to the bottom of the
R fo o
mast, lower the mast to the stored position, shut down drill operation, lock out and tag
E E f
the operator controls prior to working on or near the mast structure. Follow the lockout
F E
and tagout procedures outlined at the front of this manual.
E S
R U U S
T T
O
N NO
3. Inspect the gear racks and pinions for excessive wear, fractured or missing gear teeth, and other signs of dam-
age which could effect the operation of the rotary carriage or pulldown system. Repair or replace any damaged
O O
rack segments or pinions. Refer to the applicable topic in this manual for repair instructions or procedures.
D Rotary
3.8.6 lnspect D Machinery
Visually inspect the condition of the rotary machinery. Check for cracks, wear, or damage. Repair or replace any
worn or damaged components.
1. Lower the rotary carriage to the bottom of the mast.

! WARNING
Inadvertent machine operation while working on or near the mast structure can result in
the injury or death. Lower the rotary carriage to the bottom of the mast, shut down drill
operation, lock out and tag the operator controls prior to working on or near the mast
structure. Follow the lockout and tagout procedures outlined at the front of this manual.
2. Lock out and tag the operator controls to prevent inadvertent movement during maintenance activities.
3. Inspect for the following:
• Pulldown motor bolts for correct torque.

n t
Y e
m
NL uip ion
• Pulldown motor coupling for correct torque.
• Pulldown gearcase for secure mounting.

O q t
• Pulldown gearcase for oil leaks.
A L f E ra
I o p e
R ce O
• Resolver for secure mounting.
E t
AT nan en
• Hoist brake for assembly for secure mounting.
M te m
• Main rotary gearcase shaft for end play.
• Swivel for leaks.

E i n i p
C a q u
N M E
• Rotary motor bolts for correct torque.
E
R o r o r
f f
• Rotary gearcase for oil leaks.
FE E
E S E
• Rotary head side frames for cracks.
S
R U U
• Motor blowers for operation and cleanliness.
T T
O
N NO
• Drill pipe coupling damper for correct clearances.
O
• Drill pipe coupling for thread wear or damage.
D DO
• Condition of hoses and cables.
Refer to the applicable sections of this manual for detailed instructions on inspection and adjustment of the rotary
machinery.
3.8.7 Inspect Bailing Air System Components
Visually inspect the condition of the bailing air system components. Check for cracks, wear, or damage. Repair or
replace any damaged components. Inspection should include but not be limited to the following bailing air system
components:

• Check the GUI to confirm functioning of the main air pressure transducer (MAPT), bit air pressure trans-
ducer (BAPT), the main air temperature transducer (CATT), and the compressor oil temperature transducer
(COTT).
• Check all oil hoses and connections for leaks, wear, cracks, or damage.
• Check the thermostatic mixing valve for leaks.
• Check the oil cooler for dirt and leaks.
• Check the cooling fan and motor for proper operation.
• Check the T-Tank for air/oil leaks.

n t
Y e
m
NL uip ion
• Check the scavenger line oil filter for leaks.
O q t
3.8.8 Check Main Compressor Oil Separator Filters
A L f E ra
The main compressor oil separator is equipped with inner and outer filter elements. The separator system includes
I o e
two test ports (refer to the main air schematic in the LinkOne parts manual) which can be used to test the pressure
p
R ce O
differential between the inlet and outlet ports of the oil separator. When the differential pressure exceeds 35 psi (2.4
E
bar), the oil separator elements need to be replaced. As an alternative to testing, the separator element should be
t
AT nan en
replaced every 2000 hours or semi-annually.
M te m
Refer to Section 7 in this manual to replace the filter elements inside the oil separator.
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

3.8.9 Check Main Compressor Air Intake Filters
01
n t
Y e
m
02
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
Compressor_GD_RtSideView
LEGEND
E
01. Compressor Air Cleaner (2)
i n i p02. Restriction Indicator
C a q u
(also see Figure 3-12)
E N M E
R o r o r
f
Figure 3-10: Compressor Air Inlet Filters / Condition Indicator
FE E f
E
The main compressor is equipped with two air cleaners (01, Figure 3-10), one at each intake. Each air cleaner has
E S S
two filters in series; a primary filter element (04, Figure 3-11) and a safety element (02, Figure 3-11). To ensure that
R U U
the compressor retains its maximum output capacity, the air intake filters must be periodically cleaned.
T T
Visually inspect the main air compressor air cleaners for dirt and contamination. The air cleaner housing is supplied
O
N NO
with an adapter (15, Figure 3-11) which is plumbed to a restriction indicator (02, Figure 3-10). Also see Figure 3-12.
Check the GUI fault log to determine the need for cleaning. The air cleaner housing also includes a dust collector
O
cup which should be emptied daily.
D DO
Refer to Figure 3-11 and the following procedure for air cleaner element inspection, removal and replacement:
NOTICE
The safety element is designed not to be cleaned. For maximum compressor protection, install
a new safety element every third primary element cleaning (or replacement). Replace the main
air compressor air cleaner elements as follows:

! WARNING
tenance work on a machine without first disabling the operator controls. Lockout and
LEGEND
t
01. Air Cleaner Housing
n
02. Safety Element
Y e 03. Wing Nut
m
04. Primary Element
NL uip ion
05. Wing Nut
06. Cover Assembly
O q t
07. Gasket
L f E ra
08. Washer
A
09. Cotter Pin
I o e
10. Clamp
R ce O p 11. O-Ring (2)
E
12. Inlet Body
t
AT nan en
13. Clamp
14. Dust Cup
15. Restriction Indicator
M te m Adapter
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E Figure 3-11: Main Compressor Air Cleaner Assembly
R U U S
1. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
T T
O
N NO
2. Loosen the band clamp which secures air cleaner cover, and remove the cover.
3. Remove the wing nut and washer, to remove the primary element from the air cleaner assembly.
O
D DO
4. If the filter body requires cleaning, loosen the band clamps which secure housing and cup to primary body, and
separate the air cleaner assembly.
5. Clean or replace the primary element, and replace the secondary element as required.
6. Refer to Figure 3-11 and assemble the air cleaner with clean or new elements.

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m R15628D1
E i n i p
C a q u
N
Figure 3-12: Air Filter Condition Indicator
E r M E
R fo o r
FE E f
E S S E
R U U
T T
O
N NO
O
D DO

3.8.10 Check Hydraulic Charge Filters
01 02
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
R55475D1
LEGEND
O
N NO
01. LH Charge Filter 02. RH Charge Filter
O
D DO
Figure 3-13: Charge Filters
Each main hydraulic system is equipped with a pressure filter (also referred to as a charge filter) which is inserted
between the output of the control pressure charging pump and the input to the system control valves. The charge
filters are located on a support bracket above the pump drive transmission. Check the filters as follows:
1. Inspect the filter unit for visible damage, leaking seals, or leaking fittings.
2. If the GUI filter indicator shows that the element has become fouled (or, alternatively, after 6 months or 1000
hours of operation has passed), the element should be replaced. Refer to Section 9 to replace the charge filter
elements.

3.8.11 Check Main Compressor Oil Filter Indicator
To ensure unrestricted flow of oil to the main compressor, the oil filter assemblies must be serviced at regular inter-
vals.
3.8.11.1 Gardner Denver Compressor Oil Filter Indicator and Filter Replacement1
01 02
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u R57827F3_06a
E N M E
R o r o r
E E f f
E F S E
04
R U U S
T T
O
03
N NO
R51070D1b
O
D DO LEGEND
01. Indicator Showing “Filter OK”
02. Indicator Showing “Change Filter”
03. Oil Filter
04. Compressor Oil Differential Pressure
Switch (COPS)
R57827F3_04a
Figure 3-14: Main Air Compressor Oil Filter Indicator - GD

Refer to Figure 3-14. The main compressor oil filter is flange mounted to the oil return port on the right of the air
compressor. Several indicators are provided to help determine when the filter needs to be changed:
• When the filter indicator is in the CHANGE FILTER area (02). The compressor must be running and the oil
at operating temperature for the indicator to display accurately. Check the indicator with a bright light to be
certain of the indicator position. Some lubricants will obscure the indicator.
• The compressor oil pressure differential switch (04) monitors the condition of the oil filter element. If the
pressure drops below 8 psi (0.6 bar), a signal is sent to the AC800 control system to alert the operator that
the filter requires changing. NOTE: The GUI will register a fault when the filter element needs to be
changed.
n t
The element should be changed when indicated by any of the above monitoring systems. To change the main com-
e
pressor oil filter element, refer to Figure 3-15 and proceed as follows:
Y m
NL uip ion
! WARNING
O q t
L f E ra
A
I o p e
operator controls to prevent inadvertent machine operation.
ER ce O
T an nt
1. Lock out and tag out the operators controls to prevent inadvertent drill operation.
A
M ten me
! CAUTION
E i n i p
C a q u
Pressurized oil will spray with extreme force from the compressor main oil filter when
N
being loosened, and can cause severe injury. Slowly release air pressure or vent the T-
E r M E
Tank before loosening the filter canister. Wear appropriate face, ear, and body protective
R o r
devices while opening the canister.
f o
FE E f
E
2. Close the shut-off valve at the bottom of the T-tank.
E
R U U S S
3. Vent any residual air from the T-tank.
T T
4. Slowly open the bleed valve (03) to make sure all pressure is released from the filter housing.
O
N NO
5. Remove the drain plug from the bottom of the filter housing and drain the oil into a pail.
O
D DO CAUTION
Do not remove the filter element from the housing until all the oil has drained to prevent
unfiltered oil from contaminating the filtered compressor oil
6. Remove the nut assembly (04) from the filter head.
7. Remove the filter head and o-ring (07) from the housing.
8. Remove the baffle (08) and cup seal (09).
9. Remove the bypass valve (11) and o-ring (10) from the filter element.

10. Remove the filter element (12) from the housing.
11. Remove the spring (13) from the bottom of the housing.
12. If damaged, remove the visual indicator (01) from the head by using a screwdriver between the indicator
assembly and the head and carefully prying it outward.
13. If removed, install a new indicator assembly (01) and new, lubricated seal kit (02) into the head.
14. Install the spring (13) in the bottom of the housing with the larger diameter of the spring up.
15. Place the new element (12) into housing being sure the large diameter of spring contacts the new element.
n t
e
16. Install the bypass valve (11) and a new, lubricated o-ring (10) on the filter element (12). The bypass valve
Y m
snaps into the top of the element end cup.
NL uip ion
17. Install the baffle (08) and a new, lubricated cup seal (09) into the filter housing.
O q t
L f E ra
18. Install a new, lubricated o-ring (07) and the head on the housing.
I A o e
19. Secure the head on the housing with the nut kit (04).
p
ER ce O
20. Install the drain plug into the bottom of the housing.
t
AT nan en
21. Start the compressor and check for leaks and proper indicator reading.
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

LEGEND
01. Visual Indicator
02. Seal Kit
03. Bleed Valve
04. Nut Kit
05. Nut Retainer Kit
06. Fill Plug and O-ring
07. Head O-ring
08. Baffle
n t 09. Cup Seal
e
10. Bypass Indicator O-ring
Y
11. Bypass Valve
m
NL uip ion
12. Filter Element
13. Bypass Spring
Drain Plug (not shown)
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
Figure 3-15: Replacing Main Compressor Oil Filter - GD

3.8.12 Check Hydraulic Return Filters
01 02 03
n t
Y e
m
NL uip ion
O q t
A L f E ra
I e
04
R ce O o p
E t
AT nan en
R57523D1_01b
M te m
E i n i p
C a q u
LEGEND
N
01. Low Pressure Return Filter - Main Pump Case 03. Main Return Filters (2)
Drain Circuit
E r M E 04. Main Return Filter Condition Indicator (Gauge)
r
02. Low Pressure Return Filter - Winch, Mast, Propel
R fo f o
Motor and Misc. Drain Circuits
E E
E F S E
S
Figure 3-16: Hydraulic Return Line Filters
R U U
T T
Refer to Figure 3-16. The hydraulic system is equipped with four return filters: two low pressure (01 and 02) and
two main (03). These filters are located on the top of the hydraulic tank:
O
N NO
1. Check the filters for visible damage, leaking seals, and leaking connections.
O
D DO
2. If the filter indicator (04) is in the red zone, or after six months or 1000 hours of operation the filter elements
must be replaced. Refer to Subtopic 3.11.7 for the low pressure return filters or to Subtopic 3.11.8 for the main
return filters to replace the filter elements.
3.8.13 Check Auto Lube Grease Reservoir Level
Weekly or every 40 hours of operation, check the level of the grease lubricant in the automatic lubrication system
grease reservoir. Remove the cover of the grease reservoir and visually check the lubricant level. Refill the reser-
voir as necessary to maintain adequate lubrication.
Continued drill use will provide a history of grease consumption, which may dictate varied grease reservoir level
checks. If unsure of the lubricant level, shut down operation of the drill and check the reservoir level.

3.8.14 Check Cable Reel Oil Levels
3.8.14.1 Right Angle Gearcase
! WARNING
Working on or near the cable reel while the drill is operating is hazardous and can result
in injury or death. Shut down operation of the drill, and lock out and tag the operator
t
controls prior to working on or near the cable reel.
e n
Y m
NL uip ion
2. Remove the oil level plug (01) from the right angle gear case, and check the oil level. The oil should be at the
lower edge of the plug opening.
O q t
L f E ra
3. If the oil is below the lower edge of the oil level plug opening, remove the vent plug (02) and add oil, of the type
A
I o e
specified in Table 3-10, through the vent plug opening.
R ce O p
E t
AT nan en
01 02 03
M te m
p
09
E
C a q i n u i
E N M E
R o r o r
E E f f
E F S E
04
S
08
R U U
T T
O
N NO
05
O
D DO 07 06
DSC02993a
LEGEND
01. Oil Level Plug 06. High Voltage Junction Box (2)
02. Vent Plug (Not Shown) 07. Right Angle Gear Reducer
03. Name Plate 08. Sprocket Selection Decal
04. Collector Ring Cover 09. Level Wind Drive Sprockets and Chains (Below
05. Left Hand Cable Reel Frame Covers)
Figure 3-17: Cable Reel Components - Right Front View

The cable reel gear reducer uses gear oil, Material Specification P&H 497. Viscosity is indicated by a letter, and
should be selected according the expected extreme ambient temperatures. Refer to Table 3-10.
P&H
Specification
Ambient Temperature Range Number ISO Grade AGMA Grade SAE Grade
-20 °F (-29 °C) or lower 497C 68 2EP 75W
-20 °F to 20 °F (-29 °C to -7 °C) 497D 100 3EP 80W
20 °F to 110 °F (-7 °C to 43 °C)
t
497E 150 4EP 85W
n
Above 110 °F (43 °C) 497F 220 5EP 90W
Y e
Table 3-10: Cable Reel Gear Reducer Lubrication
m
NL uip ion
3.8.14.2 Cable Reel Hydraulic Oil Level
O q t
L f E ra
! WARNING I A o p e
ER ce O
t
AT nan en
M te m
E i n i p
u
NC a q
M E
2. Open the hydraulic cabinet doors.
RE o r r
f f o
3. Check the oil level on the oil level gauge (09).
FE E
E S S E
4. If the oil level is low, remove the fill cap (10) from the top of the tank (03) and add hydraulic oil.
R U U
T T
O
N NO
O
D DO

01
10
02
t
02
e n
Y m
NL uip ion
03
09
O q t
A L f E ra 04
I o p e
R ce O
05
E t
AT nan en
08
M te m
E i n i p
C a q u
E N M E 06
07
R o r o r
E E f f DSC02992
E F S E
S
LEGEND
R U U
01. Junction Box 05. Drain Valve ((Shown Closed) 09. Oil Level Gauge
T T
02. Filter/Breather (3) 06. Pump 10. Oil Fill Cap
03. Hydraulic Tank 07. Electric Motor
O
N NO
04. Manual Valve (Shown Closed) 08. Control Valve Assembly
O O
Figure 3-18: Cable Reel Hydraulic Cabinet Components - Door Open
D TrailDCable
3.8.15 lnspect
Proceed as follows.
! WARNING
Hazardous voltage can cause injury or death. Disconnect electric power to the tail cable
at the power substation and use lockout and tagout procedures prior to visual inspec-
tion or handling of the tail cable. Use qualified inspection personnel equipped with
appropriate devices for testing, handling, and personal protection.

Power is fed to the blasthole drill through the trail cable. It is imperative that this cable not be damaged, or cut.
Visually inspect the tail cable to ensure that it is not damaged, crushed, or cut. Replace the trail cable if it is dam-
aged.
3.8.16 Check Crawler Belt Tension
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
Figure 3-19: Check Crawler Belt Tension
E N M E
r r
Refer to Figure 3-19 and check crawler belt tension as follows:
E ER fo f o
1. Raise the drill until the crawler belt is free of the ground.
E F S E
S
2. Measure the distance from the bottom of the side frame nearest the mid-point of the crawler to the top of the
R U U
crawler pad where the roller normally contacts the pad.
T T
O
3. Normally this distance will be from 12 to 14 inches (300 to 360 mm). If the distance exceeds 14 inches, adjust-
N NO
ment is required. (Refer to Subtopic 10.3.5.4 in Section 10, Propel System.)
3.9 “C”D
O O Checks - Monthly or Every 160-250 Hours
D
Maintenance
The “C” Maintenance Checks should be performed monthly, or every 160 -250 hours. If an item is found to be
incorrect, the problem must be corrected prior to start-up to ensure satisfactory operation of the drill.
3.9.1 Perform “A” and “B” Maintenance Checks
Refer to the maintenance check sheets starting with Table 3-4 and complete all “A” and “B” Maintenance Checks
before proceeding with the “C” Maintenance Checks.

3.9.2 lnspect Mast Back Braces And Slides
Proceed as follows:
! WARNING
Cracks in the back brace pivot anchors will result in the pivot anchors separating from
the drill frame, or from the mast chords, resulting in the collapse of the mast. Collapse of
the mast may result in injury or death. Visually inspect the pivot points of the back
braces, and make repairs immediately if cracks are found.
n t
The back braces restrain movement of the mast during drilling operations. These tubular braces absorb a large
e
amount of the vibration from the drilling operation and as a result are common points for the development of struc-
Y m
NL uip ion
tural cracks. Visually inspect the pivot points of the back braces for cracks.
O q t
SAFETY FIRST
A L f E ra
I e
Although cracks are most commonly found at the upper mast anchor point, each pivot should
R ce O o p
be carefully checked. If any doubt exists as to the presence of a crack, test the crack using
E
chemical or magnetic crack detection methods.
t
AT nan en
If cracks are found, refer to the Mast Section of this manual, and repair the back braces. Inspect the slide surfaces
M te m
of the back brace locking sleeves for wear or damage. If the slides are excessively worn or damaged, repair the
slides and/or sleeves as described in Mast Section of this manual.
E i n i p
3.9.3 lnspect Mast
C a q u
E N M E
r r
Visually inspect the structural condition of the mast. Check for cracks, wear, or damage. Repair or replace the com-
R fo o
ponents of the mast, mast bracing, or lacing as revealed through this inspection.
E E ! WARNINGf
E F S E
R U U S
T T
O
result in injury or death. Lower the rotary carriage to the bottom of the mast, shut down
N NO
drill operation, lock out and tag the operator controls prior to working on or near the
mast structure.
O
D DO
Follow the lockout and tagout procedures outlined at the front of this manual. Inspect for the following:
• Mast chords and lacings for cracks or kinks.
• Mast hoist cylinder pins and retainers for wear or looseness.
• Ladders, platforms, and handrails for looseness.
• Hoist cylinder rods, pins, and seals for damage or wear.
• Hydraulic connections and cylinders for leakage.

• Pivot pins, anchors, and retainers for wear and looseness.
Refer to the Mast Section of this manual for detailed instructions on inspection of the mast.
3.9.4 lnspect Auxiliary Winch Rope and Sheaves
3.9.4.1 Wire Rope Inspection
The auxiliary winch uses a steel wire rope. Care of this wire rope is critical to the safe operation of the winch. Visu-
ally inspect the wire rope using the following procedure:
t
A periodic detailed rope inspection will show damage over the entire rope. All individual outer wires in the strands
n
of the rope are inspected, and any deterioration resulting in significant loss of original strength will be a factor in
e
Y
determining whether further use of the rope would constitute a hazard.
m
NL uip ion
A full written report of rope condition should be made by the inspector. This report must be dated, signed, and kept
on file where it is readily available to designated personnel.
O q t
L f E ra
The monthly inspection should be aimed at determining the degree of deterioration at the worst lay, since this will
A
I o e
determine the suitability for continued service. By definition, a rope lay is the axial distance along the rope in which
R ce O p
one strand makes one complete turn around the rope. These visual observations should be concerned with discov-
E
ering damage, such as listed below:
t
AT nan en
1. Reduction of rope diameter below normal due to loss of core support, internal or external corrosion or wear of
M te m
outside wires.
E i n i p
2. A number of broken outside wires and the degree of distribution or concentration of such broken wires.
C a q u
N M E
3. Worn outside wires.
RE o r r
o
4. Corroded or broken wires at the end connections
E E f f
F E
5. Corroded, cracked, bent, worn, or improperly applied end connections.
E
R U U S S
6. Distortion of the rope, such as kinking, crushing, unstranding, birdcaging, main strand displacement, or core
T T
protrusion.
O
N NO
7. Evidence of improper lubrication. When such damage is discovered, the rope should be removed from service
and replaced.
O
D DO
3.9.4.2 lnspect Auxiliary Winch Sheaves
Proceed as follows.
! WARNING
result in injury or death. Lower the rotary carriage to the bottom of the mast, shut down
drill operation, lock out and tag the operator controls prior to working on or near the
mast structure. Follow the lockout and tagout procedures outlined at the front of this
manual.

As wire rope passes over sheaves, the sheaves become worn. Inspect the condition of the winch sheaves monthly
to ensure that the sheaves are not excessively worn. Measure the sheave groove wear pattern using a sheave
gauge. Replace the sheaves as revealed through this inspection. Refer to the Mast Section of this manual for
repair instructions regarding the winch sheaves. The mast must be lowered to facilitate inspection of the sheaves.
3.9.5 Inspect Main Frame
Visually inspect the structural condition of the drill framework. Check for cracks, wear, or damage. Repair or
replace the components of the frame as revealed through this inspection.
Inadvertent machine operation during maintenance activities can cause injury or death. Shut down the drill before
t
performing inspections, service, or maintenance. Establish a procedure to guard against inadvertent equipment
n
operation or movement while conducting inspections. Use lockout and tagout procedures prior to conducting main-
tenance or service.
Y e
m
NL uip ion
1. Lock out and tag the operator controls to prevent inadvertent movement of the machine during maintenance
activities.
O q t
L f E ra
2. Inspect the following:
• Entire structural frame.

I A o p e
ER ce O
t
AT nan en
• Jack flanges and flange bolts.
• Stairways, ladders, and platforms.

M te m
• Machinery house framing.
E i n i p
C a q u
N
• Jack assemblies/jack shoes.
E M E
R o r o r
f
• Machinery house panels.
F E E f
E
• Machinery house doors.
E
R U U S S
• Water tank (optional equipment).
T T
O O
• Dust collector chutes (optional equipment).
N Frames
3.9.6 Inspect Crawler N
O
D DO
Visually inspect the structural condition of each crawler side frame. Check for cracks, wear, or damage. Repair or
replace the components of the crawler frames as revealed through this inspection.
! WARNING
the injury or death of personnel. Shut down operation of the drill, and use lockout/tagout
procedures prior to working on or near rotating machinery.
Inspect the following components:

• Entire structural crawler side frame.
• Track shoes.
• Crawler links.
• Idler rollers.
• Top guide rollers.
• Bottom guide rollers
• Main axle mounting bolts.

n t
Y e
m
NL uip ion
• Equalizer axle mounting pins.
O q t
• Track pins and retainers.
• Take-up adjustment assemblies.

A L f E ra
I o p e
R ce O
• Drive tumblers.
E t
AT nan en
3.9.7 Check Propel Transmission Oil Level
M te m
CAUTION
E i n i p
C a q u
N
Operating the propel transmission when it has been overfilled will cause overheating of
E M E
the propel transmission components resulting in component damage. Never operate the
r
R o r
propel transmission when the oil level is either too full or too low.
f o
F E E f
E
The propel transmissions are mounted at the front of each crawler assembly. Each propel transmission is driven by
E S S
a hydraulic motor and together with the transmission. serves as the drive mechanism to propel the drill. Monthly,
R U U
check the oil level in the propel transmissions using the following procedure:
T T
1. Refer to Figure 3-20 for the oil level/fill plug and drain plug locations.
O
N NO
2. Shut down operation of the drill.
O
D DO ! WARNING
3. Shut down, lock out, and tag the electrical controls to the drill to prevent inadvertent start-up during service
activities.

LEGEND
01. Oil Level/Fill Plug
02. Oil Drain Plug
01
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
BD1152a01
E i
02
n i p
C a q u
E N M E
R o r o r
Figure 3-20: Propel Transmission Plugs
E E f f
4. Remove the propel transmission oil level/fill plug (01).
E F S E
S
5. Check that the oil level is up to the bottom of the oil level/fill plug hole.
R U U
T T
6. If the oil level is low, add oil through the oil level/fill plug hole to bring the oil to the proper level (refer to Section
O
N NO
12, Lubrication, Subtopic 12.2.5. for lubricant specifications).
7. Apply pipe thread sealant to the oil level/fill plug, and install the plug securely.
O
D CableDO
3.9.8 Inspect Reel Components
Visually inspect the condition of the optional cable reel components. Check for cracks, wear, or damage. Repair or
replace the components of the cable reel as revealed through this inspection.
! WARNING

activities.
2. Inspect the following:
• Hydraulic motor. for leaks
• Drive chain for wear and tension.
• Chain sprockets for wear.
t
• Right angle gear reducer for leaks.
• Cable reel structure, for cracks

e n
Y m
NL uip ion
Refer to the applicable section of this manual specific to this drill for detailed instructions on correct inspection of
and/or adjustment of the cable reel machinery.
O q t
3.9.9 Check Auxiliary Winch Oil Level
A L f E ra
I o p e
R ce O
Monthly, check the auxiliary winch gearcase oil level as follows:
1. Shut down operation of the drill. E

T an nt
A
M ten me
! WARNING
E i n i p
C a q u
Working on or near rotating machinery while in operation is hazardous and can result in the
N M E
injury or death of personnel. Shut down operation of the drill, and use lockout/tagout procedures
R E o r
r
E E f f o
2. Use lockout and tagout procedures to prevent inadvertent start-up during service activities.
E F S E
S
3. Remove the oil level plug from the end opposite the hydraulic motor, and check the winch gearcase oil level.
R U U
The oil should reach up to the lower edge of the level plug opening.
T T CAUTION
N NOO
O
D DO
Operating the winch when the gearcase has been overfilled will cause overheating of the
gearcase components resulting in component damage. Never operate the winch when
the oil level is below or above the lower edge of the level plug opening.
4. The oil level must be even with the lower edge of the level plug opening. If the oil is below the lower edge of the
level plug opening, add oil, of the type specified in the Lubrication Section through the gearcase breather open-
ing.
5. Clean and securely reinstall the breather.
6. Apply pipe thread sealant to the level plug, and install securely.

3.9.10 Clean/Flush Water Tank
Flush and clean the optional water tank periodically to remove dirt, sediment, and contaminants accumulated over
time. Monthly, drain, clean, and flush the water tank. Refill the tank with fresh water.
3.9.11 Clean Main Compressor and Hydraulic Oil Coolers
To ensure satisfactory cooling of the main compressor oil, the main compressor oil cooler must be periodically
cleaned. At least monthly, or every 160 hours of operation, clean the oil cooler radiators as follows:
1. Shut down operation of the main air compressor and cooler.
n t
WARNING
e
!
Y m
NL uip ion
O q t
A L f E ra
I o e
2. Lock out and tag the electrical controls to the main air compressor pressor and cooler to prevent inadvertent
start-up during service activities.
R ce O p
E
T an nt
3. Remove the machinery house access covers to access to the main compressor oil cooler radiator.
A
M ten me
! CAUTION
E i n i p
C a q u
Pressurized steam used for cleaning can cause injury. Exercise care and caution when
N M E
using pressurized steam to clean machinery components. Wear protective clothing,
E r r
gloves, and face shield when operating a pressurized steam cleaner.
R
E E fo f o
4. Use a pressurized steam cleaner to flush dirt and contaminants from the fins of the main compressor oil cooler
F E
radiator. Ensure thorough cleaning of the entire radiator.
E S
R U U S
5. After the radiator has been thoroughly cleaned, use compressed air to blow the remaining dirt, contaminants,
T T
and water from the oil cooler fins.
O
N NO
6. Clean any dirt, contaminants, and water from the floor of the machinery house.
O
D DOMachinery House Blowers And Filters
7. Reinstall any access covers which were removed to permit cleaning of the oil cooler.
3.9.12 Clean/inspect
The following paragraphs describe the inspection and maintenance procedures that should be followed when ser-
vicing the machinery house blowers and impingement filters that provide pressurized air to the machinery house.
An electric-motor-driven blower provides air under slight positive pressure to the machinery house. This causes air
to flow outward through any house openings which helps keep dirt out.
Outside air is drawn from atmosphere, forced through filter assemblies and out into the machinery house. This
ensures that the pressurized air within the house is clean and fresh. Air flows through the house and is exhausted
to atmosphere through openings in the house.

The blowers and motors are installed in-line within sheet metal housings that are attached to impingement type fil-
ters. These filters separate dust and entrained particles from the input air stream and allow the resulting clean air to
enter the machinery house while dropping the separated particulate out of the machine.
Inspect the ventilation system as follows:
1. Remove all debris from the air inlet passages.
2. Check blower motor mounting for security.
3. Check that the blower blades are tight and set at the same angle.
n t
4. Check the filters for accumulated dirt and debris. A light coating of dust on the cells is normal and will not
e
impair operation or efficiency of the filters. However, the cell blades may accumulate a thicker deposit of sur-
Y m
face dirt due to the sticky character of some types of dust, or the presence of oil mist or similar vapor in the out-
NL uip ion
side air. When the accumulated deposit reaches a thickness of 0.125 inch (3.2 mm), the cell blades should be
cleaned. In addition to the 160-hour inspection, a more detailed inspection should be made twice annually.
O q t
Check that the blower blades are clean and not damaged.
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
01 02 03
E i n i p LEGEND
C a q u 01. Access Cover
N M E
02. Filter Packs
E r
03. Filter Housing
R fo o r
FE E f
E S S E
R U U
T T
O
N NO
O
D DO
R57583F1_02b
Figure 3-21: House Pressurization Filter Location
Remove the inspection cover (01) on top of the filter housing (03). Check the filter packs (02) for accumulated dirt
and debris. A light coating of dust on the cells is normal and will not impair operation or efficiency of the filters.

However, the cell blades may accumulate a thicker deposit of surface dirt due to the sticky nature of some types of
dust, or the presence of oil mist or similar vapor in the outside air. When the accumulated deposit reaches a thick-
ness of 0.125 inch (3.2 mm), the cell blades should be cleaned. (Refer to subsection 17.4, Filter Cleaning for filter
removal and cleaning procedures.)
3.9.13 Change Main Compressor Bearing Oil Filter (GD Compressor Only)
A spin-on type oil filter (located on the motor-end face of the compressor) is used to filter the bearing oil as it
passes through the main air compressor. This filter removes dirt and abrasives from the circulated oil before it
reaches the bearings.
t
The filter is disposable, and is equipped with a relief valve that opens in the event the element becomes dirty
n
enough to block the flow of oil. Replace this filter each time the main oil filter element is replaced. Use only the
e
replacement filter shown in the parts list; others may not have sufficient burst pressure strength.
Y
L ip nm
Replace the main compressor bearing oil filter as follows:
N
! WARNING O qu tio
A L f E ra
I o p e
Working on the main air system while the compressor is in operation is hazardous and
R ce O
can result in injury or death. Shut down the main air compressor, and use lockout/tagout
E t
AT nan en
procedures prior to starting any service on the machinery.
1. Lock out and tag the high-voltage main circuit breaker switch to prevent operation of the main air compressor
M te m
drive motor during system service.
E i n i p
C a q WARNING u
N
!
E r M E
R o r
Pressurized oil will spray with extreme force from the compressor bearing oil filter when
f o
E E f
being loosened, and can cause severe injury. Slowly release air pressure or vent the T-
F E
tank before loosening the filter canister. Wear appropriate face, ear, and body protective
E S S
devices while removing the filter from the compressor housing.
R U U
T T
2. Vent any residual air pressure from the T-tank. The T-tank will vent through the main air system muffler when
O
the main air compressor is not running.
N NO
3. Spin off the old filter and discard. Apply a film of oil to the filter gasket, then spin on the new filter. Tighten the fil-
O
D DO
ter firmly by hand to prevent oil leaks. Be sure the filter sealing surfaces are clean before installing the new fil-
ter.
NOTICE
When changing this filter between oil changes, add one quart of compressor oil to the system to
replace that retained in the old filter (see the Lubrication Section for specifications of the com-
pressor oil to use).
3.10 “D” Maintenance Checks (Quarterly or 500 Hours)

The “D” Maintenance checks should be performed every 500 hours, or quarterly. If an item is checked and found to
be incorrect, the problem must be corrected prior to start-up to ensure satisfactory operation of the drill.
3.10.1 Perform “A”, “B” and “C” Maintenance Checks
Repeat “A”, “B” and “C” Maintenance Checks before proceeding with the “D” Maintenance Checks, refer to the
maintenance check sheets starting with Table 3-4 and complete all of the “A”, “B”, and “C” Maintenance Checks.
3.10.2 Check Bolts, Mounting And Attachment Torques
It is recommended that all mounting and attachment bolts and capscrews be checked periodically for correct torque
n t
to ensure that all components remain securely mounted. This mounting bolt check should be made quarterly at first
and adjusted as experience dictates. Refer to the bolt and capscrew torque values provided in Table 17- 1 for appli-
cable bolt and capscrew torques.
Y e
L ip nm
3.11 “E” Maintenance Checks (Semi-annually or 1000 Hours)uN
O q tio
A L f E ra
I o e
The “E” Maintenance checks should be performed every 1000 hours, or semi-annually. If an item is checked and
p
RChecksce O
found to be incorrect, the problem must be corrected prior to start-up to ensure satisfactory drill operation.
E t
AT nan en
3.11.1 Perform “A”, “B”, “C” and “D” Maintenance
M te m
Complete the “A”, “B”, “C” and “D” Maintenance Checks before proceeding with the “E” Maintenance Checks.
E n i p
Refer to the maintenance check sheets starting with Table 3-4.
C a q i u
N
3.11.2 Change Rotary Gearcase Oil
E r M E
R o o r
The rotary gearcase is mounted to the lower end of the rotary carriage. This double-reduction gear reducer drives
f
E E f
the rotary head coupling, the drill bit, and the pipe string. Refer to Figure 3-22 and change the rotary gearcase oil
F E
as follows:
E
R U U S S
1. Lower the rotary carriage to the bottom of the mast.
T T ! WARNING
O
N NO
O
D DO
injury or death. Lower the rotary carriage to the bottom of the mast; use lockout/tagout
procedures to shut down the drill before performing service procedures.
2. Use lockout/tagout procedures to prevent inadvertent start-up during service procedures.

01
t
02
e n
Y m
NL uip ion
O q t
L f E ra
F
I A o p e
ER ce O
t
AT nan en
L
M te m
E n i p
03
i
BD0556c01
C a q u
E N M E
LEGEND
R o r o r
01. Breather
E E f f
03. Drain Valve and Magnetic Plug
F
02. Dipstick
E S S E
R U U
T T
Figure 3-22: Rotary Gearcase Lubrication
O
N NO NOTICE
O
D DO
The gearcase holds approximately 40 gallons (151 liters) of oil.
3. Remove the magnetic drain plug (03) from the bottom of the gearcase. Place a suitable container below the
drain valve and open the drain valve to drain the oil from the gearcase.
4. When the old oil is completely drained, close the gearcase drain valve. Clean the drain plug, apply pipe thread
sealant, and install it in the drain valve.
5. Remove the breather (01) from the top of the gearcase.
6. Add oil, of the type and amount specified in Section 12, Lubrication, Subtopic 12.3.1, through the fill pipe until
oil reaches the F (full) mark on the dipstick (02).

7. Clean and install the vent cap.
CAUTION
Operating the rotary machinery when the rotary gearcase has been overfilled will cause
overheating of the gearcase components resulting in damage to the gearcase compo-
nents. Never operate the rotary machinery with the rotary gearcase oil level above the
FULL mark on the dipstick.
3.11.3 Change Hoist/Pulldown Gear Reducer Oil
n t
The hoist/pulldown gear reducer provides the torque required to power the rotary carriage assembly along the ver-
Y e
tical length of the mast. Refer to Figure 3-23 and use the following procedure to change the oil in the reducer:
m
NL uip ion
1. With the mast raised and locked in the vertical position, lower the rotary carriage to the bottom of the mast for
easier access to the pulldown gearcase.
O q t
! WARNING L
A f E ra
I o p e
ER ce O
t
AT nan en
tenance work on a machine without first disabling the operator controls. Lockout and
M te m
E i n i p
C a q NOTICE u
E N M E
R o r o r
The oil capacity of the pulldown gearcase is 70 gallons (265 liters).
E E f f
F E
3. Place a suitable container below the drain pipe (03) to catch the used oil. Remove the drain cap and open the
E S S
drain valve to drain all of the oil.
R U U
T T
4. Close the drain valve and install the drain cap.
O
N NO
5. Remove the inspection cover, gasket and breather (01). Discard the gasket.
O
6. Fill the gearcase to the correct level as indicated on the sight gauge (02), with the type of oil specified in Sec-
D DO
tion 12, Lubrication, Subtopic 12.2.1.
7. Install a new gasket and the inspection cover and breather assembly.

LEGEND
01. Inspection Cover, Gasket and 01
Breather: Remove the inspection
cover and gasket to fill the gearcase.
Oil should appear to fill the lower
glass; the upper glass should appear
half full.
03. Drain Valve, Cap and Piping 02
n t
Y e
m
NL uip ion
O q t
L f E ra
BD0870b01
I A o p e
R ce O
03
E t
AT nan en
M te m
E i n i p
C a q u
BD0870c01
E N M E
R o r o r
f
Figure 3-23: Pulldown Gearcase Oil Replacement
F f
E E Oil Separator Filters
S
3.11.4 Replace Main Compressor
E S E
R U U
T T
two test ports (T18 and T19) which can be used to test the pressure differential between the inlet and outlet ports of
O
N NO
the oil separator. When the differential pressure exceeds 8 psi (0.5 bar), the oil separator elements need to be
replaced. As an alternative to testing, the separator element should be replaced every 2000 hours or semi-annu-
ally.
O
D DO
Refer to Subtopic: Maintaining the Air / Oil Separators on page 7.8. in the main air section of this manual to replace
the filter elements inside the oil separator.
3.11.5 Replace Oil Line Scavenger Filter Element
The oil line scavenger filter is located on the main air control panel. This filter cleans oil scavenged from the two oil
separator elements. Replace the filter as follows:

! WARNING
operator controls to prevent inadvertent machine startup during maintenance.
! WARNING
n t
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Use
e
lockout and tagout procedures to guard against inadvertent hydraulic system or
Y m
machine start up during service or maintenance. Allow the hydraulic system to cool
NL uip ion
before maintenance or repair. Slowly release pressure or vent circuits before discon-
necting hydraulic lines. Wear appropriate face and body protective devices while care-
fully loosening any connection or fitting.
O q t
A L f E ra
I o e
2. Be sure that no air or hydraulic pressure exists in the main air system.
R ce O p
E
3. Loosen and remove the filter housing from the body.
t
AT nan en
CAUTION
M te m
E i n i p
Small amounts of contaminants in the air compressor recirculation system can cause
C a q u
significant equipment damage. Clean dirt from the filter assembly before loosening the
housing.
E N M E
R o r o r
f
4. Remove and discard the used filter element.
F E E f
E
5. Check the filter seal for nicks and cuts. Replace as necessary.
E
R U U S S
6. Install a new filter element in the housing.
T T
O
7. Lubricate the seal with hydraulic oil, and install the housing securely in the filter body.
N Filter
3.11.6 Replace Suction O
N Elements
O
D DO NOTICE
It is normally unnecessary to remove the suction strainer assembly from the pump suction line
to service the filter.

LEGEND
02 01. Limit Switch
02. Seals
03. Filter Element
03 04. Shutoff Valve
05. Pressure Tap
02 06. Indicator Switch
07. Handwheel
04
01
n t 02
Y e
m
05
NL uip ion
O q t
L f E ra
06
I A
07
o p e F6221a01
ER ce O
t
AT nan en
Figure 3-24: Suction Strainer (Typical)
To replace either suction filter element, refer to Figure 3-24 and proceed as follows:
M te m
E i
! WARNING
n i p
C a q u
E N M E
R o r r
o
E E f f
tag the operator controls to prevent inadvertent machine start-up during maintenance
F E
work.
Step 1: E
R U U S S
Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance.
Step 2:
T T
Rotate the handwheel (07) counterclockwise to close the suction line shutoff valve (04).
Step 3: O
N NO
Remove the six capscrews and lockwashers from the filter cover and remove the cover assembly from
O
the filter body.
Step 4:
D DO
Inspect the seal and O-ring (02) between the cover and the body. Replace as required.
Step 5: Remove and discard the filter element (03). Replace with a new element.
Step 6: Lightly lubricate the O-ring and seal and install them in the cover. Install the cover assembly on the filter
body. Confirm that the seals are properly seated.
Step 7: Install the six capscrews and lockwashers to secure the filter cover.
Step 8: Turn the handwheel clockwise to open the shutoff valve.
Step 9: Remove the locks and tags from the operator controls.

3.11.7 Change Low Pressure Return Filters
13 03
01 02
12 04
11
n t
e
05
10
Y m
09
NL uip ion
O q t
A L f E ra06
I o e
R57523D1b
R ce O p
E t
AT nan en
08
M te m
07
E i n i p
HF4RT filter
C a q u
E N M E
R o r o r
E E f f
LEGEND
F
01. Low Pressure Return Filter - Main Pump 07. Outlet Port
E S S E
Case Drain Circuit
02. Low Pressure Return Filter - Winch, Mast,
08.
09.
Element
Bypass Valve
R U U
Propel Motor and Misc. Drain Circuits 10. O-ring
T T
03. Capscrew (4) 11. Spring
O
04. Cover 12. Inlet Port
N NO
05. Gasket 13. O-ring
06. Bowl
O
D DO Figure 3-25: Low Pressure Return Filters
Refer to Figure 3-25. The two low pressure return filters (01 and 02) are flange-mounted on top of the hydraulic
tank. The two filters are identical, and can be serviced without removal from the tank.
Each filter contains two, 3-micron filter elements which are mounted in tandem. Return oil flows from the outside to
the inside of the element and then exits to the tank after passing through the check valve (11) at the bottom of the
bowl (09). The filter is equipped with a bypass valve that begins to bypass unfiltered oil at 25 psi (1.7 bar). A dirt
alarm gauge (05) is mounted to the body of the right filter head (03) to indicate the operating condition of both filter
elements. The gauge faces are marked with red and green areas. Red indicates the need to replace the filter ele-
ments. A bypass indicator switch (08) is mounted to the body of the left filter head (03) to inform the operator
through the GUI that the filters are in a bypass condition.

The check valve (11) makes it possible to service components upstream from the check valve without the loss of
reservoir oil. The spring setting is 0.75-1.00 psi (0.06-0.07 bar) cracking.
3.11.7.1 Filter Replacement
Replace the hydraulic low pressure return filter elements as follows:
DISASSEMBLY
Refer to Figure 3-25. Disassemble the two low pressure return filters for replacement of filter elements as follows:
! WARNING
n t
Y e
m
NL uip ion
tenance work on a machine without first disabling the operator controls. Follow lockout
and tagout procedures to prevent inadvertent machine startup during maintenance.
O q t
L f E ra
A
I o p e
R ce O
2. Clean all dirt from the filter housings and fittings.
E t
AT nan en
! WARNING
M te m
E i n i p
C a q u
N M E
E r r
R
E E fo o
f
F E
3. Be sure that no pressure exists in any of the hydraulic system circuits before opening the filter assembly.
E S S
R U U CAUTION
T T
O
N NO
The filter cover (04) is under slight pressure from the bypass valve spring (11). Turn each
capscrew (03) a little at a time until the cover is no longer under pressure.
O
D DO
4. Remove the four capscrews (03) from the filter cover (04).
5. Remove the cover and O-ring (13) from the filter body.
6. Remove the spring (11) and bypass valve (09) from the filter body.
7. Remove the filter element (08) from the bowl (06).
8. Inspect the filter element for signs of damage or heavy buildup of debris collected on the inside of the element.
Note the type of debris found; debris can be a clue to potential component failures.

NOTICE
Filter element damage can warn that there is or has been a high pressure spike, or a surge of
return oil. Spikes would indicate a potential problem with a pump or hydraulic motor.
9. Inspect the filter bowl. Note any damage as well as the presence and type of debris buildup.
10. Discard the filter element.
11. Cover the opening of the filter body to prevent dirt or other small items from inadvertently falling into the bowl or
t
tank.
CLEANING AND INSPECTION

e n
Y m
NL uip ion
Clean and inspect all of the return filter components in accordance with the general cleaning and inspection proce-
dures described in Appendix A, of this manual. Replace any worn or damaged components. See the LinkOne
electronic parts manual for component identification.
O q t
A L f E ra
I e
ASSEMBLY
R ce O o p
E
Assemble the filter as follows (refer to Figure 3-25):
t
AT nan en
1. Install the new filter element (08) in the filter bowl (06).
M te m
2. Install the bypass valve (09) and spring (11) in the filter body.
E i n i p
C a q u
3. Lightly oil the O-ring (13) and then position it with the cover on the filter body and spring. Be certain that the
N M E
spring is correctly positioned on the top of the bypass valve and that the O-ring is properly positioned under the
E r
filter cover to prevent leakage during operation.
R f o o r
E E f
4. Install and alternately tighten the four capscrews to draw the cover down evenly unto the filter body. Then,
F E
tighten the capscrews securely.
E ReturnS S
R U U
3.11.8 Change Main Filter Elements
T T
O
The two main return filters (04, Figure 3-16) are flange-mounted on top of the hydraulic tank. The two filters are
N NO
identical, and can be serviced without removal from the tank.
O
D DO
Refer to Figure 3-26. Each filter contains two, 3-micron filter elements which are mounted in tandem. Return oil
flows from the outside to the inside of the element and then exits to the tank after passing through the check valve
(11) at the bottom of the bowl (09). The filter is equipped with a bypass valve that begins to bypass unfiltered oil at
25 psi (1.7 bar). A dirt alarm gauge (05) is mounted to the body of the right filter head (03) to indicate the operating
condition of both filter elements. The gauge faces are marked with red and green areas. Red indicates the need to
replace the filter elements.A bypass indicator switch (08) is mounted to the body of the left filter head (03) to inform
the operator through the GUI that the filters are in a bypass condition.
The check valve (11) makes it possible to service components upstream from the check valve without the loss of
reservoir oil. The spring setting is designed for 0.75-1.00 psi (0.05-0.07 bar) cracking.

n t
Y e
m
NL uip ion
R57523D1f
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO R57523D1fa
LEGEND
01. Filter Cover 07. Filter Element (2)
02. O-ring 08. Filter Elements Connector
03. Head 09. Bowl
04. Square O-ring 10. Gasket
05. Dirt Alarm Gauge (on RH filter, only) 11. Check Valve
06. Bypass Indicator Switch (on LH filter, only)
Figure 3-26: Main Return Filters

3.11.8.1 Filter Replacement
Replace the main return filter elements as follows:
DISASSEMBLY
Refer to Figure 3-26. Disassemble the main return filters for replacement of filter elements as follows:
! WARNING
t
n
e
Y m
NL uip ion
O q t
2. Clean all dirt from the filter housings and fittings.
A L f E ra
! WARNING
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
r r
3. Be sure that no pressure exists in any of the hydraulic system circuits before opening the filter assembly.
R fo
E E CAUTION f o
E F S E
R U U S
The filter cover (01) is under slight pressure from the bypass valve spring. Turn each of
T T
the four cover capscrews a little at a time until the cover is no longer under pressure.
O
N NO
4. Remove the four capscrews from the filter cover (01).
O
D DO
5. Remove the cover and O-ring (02) from the filter head.
6. Remove the two filter elements (07) and element connector (08) from the bowl (06).
7. Inspect the filter element for signs of damage or heavy buildup of debris collected on the inside of the element.
Note the type of debris found; debris can be a clue to potential component failures.
NOTICE
Filter element damage can warn that there is or has been a high pressure spike, or a surge of
return oil. Spikes would indicate a potential problem with a pump or hydraulic motor.
8. Discard the filter elements.

9. Inspect the filter bowl. Note any damage as well as the presence and type of debris buildup. To remove the
bowl and check valve assembly, remove the four capscrews that attach the head and bowl to the tank. Remove
the head and square o-ring (04) and then lift the bowl (09) and check valve (11) as an assembly out of the tank.
Remove and discard gasket (10).
10. Cover the opening in the head or tank to prevent dirt or other small items from inadvertently falling into the bowl
or tank.
CLEANING AND INSPECTION
Clean and inspect all of the return filter components in accordance with the general cleaning and inspection proce-
t
dures described in Appendix A, of this manual. Replace any worn or damaged components. See the LinkOne
n
Y e
m
ASSEMBLY
Assemble the filter as follows (refer to Figure 3-26):

NL uip ion
O q t
L f E ra
1. If removed, install a new gasket (10) and the bowl (09) on the top of the tank.
I A o p e
2. Install a new square o-ring (04) in the groove in the bottom of the head (03).
ER ce O
t
AT nan en
3. Install the head (03) on the tank in the same orientation as removed. Secure with four capscrews.
4. Install two new filter elements (07) and the element connector (08) in the filter bowl (09).
M te m
E n i p
5. Lightly oil the o-ring (12) and then position it with the cover on the top filter element and the head. Be certain
C a q i u
that the spring is correctly positioned on the top of the bypass valve and that the o-ring is properly positioned
N
under the filter cover to prevent leakage during operation.
E r M E
R o r
6. Install and alternately tighten the four cover capscrews to draw the cover down evenly unto the filter head.
f o
E E f
Then, tighten the capscrews securely.
3.11.9 Change PumpF

E
RE US US
Drive Transmission Oil
T T
Change the pump drive transmission oil as follows (see Figure 3-27):
O
N NO ! WARNING
O
D DO
injury or death. Lower the rotary carriage to the bottom of the mast; use lockout/tagout
procedures to shut down the drill before performing service procedures.
1. Use lockout/tagout procedures to prevent inadvertent start-up during service procedures.
NOTICE
The outlet for the pump drive transmission drain is located below the machinery deck.
2. Place a suitable container below the drain pipe (03). Open the drain valve and drain the oil from the gearcase.
The gearcase capacity is 2 gallons (7.6 liters)

LEGEND
01. Oil Level Dipstick
02. Vent and Fill Cap
03. Oil Drain Valve and Piping (Drains out
below deck)
n t
e
01
Y
02
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
03
E i n i p
C a q u
E N M E
r r
R59401F1_02a
R
E E fo f o
E F S E
S
Figure 3-27: Pump Drive Transmission
R U U
T T
3. After the old oil is completely drained, close the drain valve (03).
O
N NO
4. Remove the vent cap (02).
O
D DO
5. Add oil, of the type and amount specified in Section 12, Lubrication, Subtopic 12.2.2, until oil reaches the full
mark on the dip stick.
6. Clean and install the vent plug.
CAUTION
Operating the pump drive transmission when the transmission has been overfilled will
cause transmission components to overheat, resulting in damage to the transmission.
Never operate the pump drive transmission with the oil level above the full mark on the
dipstick (01).

3.11.10 Change Propel Transmission Oil
Refer to Figure 3-20 and use the following procedure to change the oil in the propel transmission:
! WARNING
Unexpected movement of the propel system could result in injury or death. Use lockout
tagout procedure to shut down the drill before starting propel transmission oil change
procedures.
t
1. Shut down the drilling operations. Use lockout/tagout procedures to prevent inadvertent drill movement.
2. Remove the oil fill/level plug (01).

e n
Y m
NOTICE
NL uip ion
O q t
L f E ra
The oil capacity of each propel transmission gearcase is 9.5 gallons (36 liters).
I A o p e
3. Place a suitable container below the drain plug (02) to catch the used oil. Remove the drain plug and drain all
of the oil.
ER ce O
t
AT nan en
4. Clean the oil drain plug. Apply a coating of pipe thread sealant, and install the drain plug.
M te m
5. Add oil through the oil level/fill plug hole to bring the oil level up to the bottom of the oil level/fill plug hole (refer
E n i p
to Section 12, Lubrication, Subtopic 12.2.5. for lubricant specifications).
C a q i u
N
6. Apply pipe thread sealant to the oil level/fill plug, and install the plug securely.
E r M E
r
R f o f o
EReel Bearings,
F E E
RE US US
3.11.11 Lubricate Cable Trolly Wheels and Chains
T T
Refer to Figure 3-28 and use the following procedure to lubricate the cable reel bearings, trolly wheels and chains:
O
N NO ! WARNING
1. Shut down the drilling operations, and power down the drill.
O
D DO
Working on or near the cable reel during drill operation is hazardous and can result in
prior to working on or near the cable reel.
2. Lock out and tag the electrical controls to the auxiliary hydraulic system to prevent inadvertent start-up of the
cable reel during service activities,

! WARNING
Falls from ladders can cause injuries ranging from sprains to death. You risk falling if
portable ladders are not safely positioned each time they are used. While you are on a
ladder, it may move and slip from its supports. You can also lose your balance while get-
ting on or off an unsteady ladder. (Refer to Section 1, Blasthole Drill Safety Topic 1.5.3
for additional information relating to ladder safety).
1. On both sides of the frame, lubricate the drum bearing grease fittings (01) using extreme pressure grease.
t
2. Remove the guards over the trolly wheel drive chains and right angle gear reduce.
e n
3. Lubricate the trolley wheel and roller grease fittings (03) using extreme pressure grease.
Y m
NL uip ion
4. Clean and lubricate the drive chains (03, 05 and 07).
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
01 02 LEGEND
01. Drum Bearing (one each side)
M te m 02. Right Angle Gear Reducer
E n i p
03. Level Wind Trolly Drive Chains and
i
07
C a q u
Sprockets
03 04. Level Wind Drive Chain Tensioner
E N M E
05. Drum Drive Chain and Sprockets
r r
06. Hydraulic Cabinet
R fo o
07. Right Angle Gear Reducer Drive
FE E f Chain and Sprockets
E
04
E
R U U S S
T T
O
N NO
O
D DO FRONT
06 01 05
Figure 3-28: Cable Reel Components (Top View - shown with chain guards removed)

3.12 “F” Maintenance Checks - Annually or 2000 Hours

The “F” Maintenance checks should be performed every 1000 hours or annually. If an item is checked and found to
be incorrect, the problem must be corrected prior to start-up to ensure satisfactory drill operation.
3.12.1 Perform “A”, “B”, “C”, “D” and “E” Maintenance Checks
Complete the “A”, “B”, “C, “D”, and “E” Maintenance Checks before proceeding with the “F” Maintenance Checks.
Refer to the maintenance check sheets starting with Table 3-4.
3.12.2 Change Hydraulic System Oil

n t
Y e
NOTICE
m
NL uip ion
O q t
It is recommended that a sample of oil be drawn from the hydraulic tank annually. This sample
L f E ra
should be about two quarts and should be taken when the oil is warmed through normal opera-
A
tion. If possible, the sample should be analyzed by a qualified lubrication specialist to determine
I o e
whether it is suitable for continued use. The interval between oil changes depends upon the
p
R ce O
operating conditions and on the care used in the handling oils and keeping them clean during
E t
the handling process.
AT nan en
Drain, flush, and refill the hydraulic system using the top-off system described in Section 20, Top Off Systems. Or,
M te m
refill the hydraulic system with the type and amount of oil specified in Section 12, Lubrication, Topic 12.4.
E Oil n
i i p
C a q u
3.12.3 Change Auxiliary Winch Gearcase
E N M E
r
The auxiliary winch gearcase contains a planetary-type transmission inside the winch assembly. Refer to Figure 3-
R o o r
29 and use the following procedure to change the oil in the winch gearcase:
f
F E E ! WARNING f
E S S E
R U U
T T
Working on or near the mast and/or winch during drilling operation is hazardous and can
result in injury or death. Lower the rotary carriage to the bottom of the mast and shut
O
N NO
down the drill using lockout/tagout procedures.
O
D DO
1. Shutdown the drill using lockout/tagout procedures to prevent inadvertent start-up of the drill.
2. Remove the oil fill plug (02).
NOTICE
The oil capacity of the winch gearcase is 1.3 gallons (4.9 liters).
of the oil.
4. Clean the oil drain plug, apply a coating of pipe thread sealant, and securely install the drain plug.

5. Add oil of the type specified in Section 12, Lubrication, Subtopic 12.2.3, through the fill plug opening until the
level reaches the bottom of the fill plug hole.
6. Apply pipe thread sealant to the fill plug, and securely install the plug.
LEGEND
01. Relief Breather
t
02. Fill Plug
n
03. Drain Plug
Y e 01
m
NL uip ion
02
O q t
A L f E ra
I o e
03
R ce O p
E t
AT nan en BD0554a01
M te m
E i n i p
Figure 3-29: Auxiliary Winch Gear Reducer Lubrication
C a q u
N
3.12.4 Change Air Compressor Oil
E M E
R o r o r
E E f f
NOTICE
E F S E
R U U S
It is recommended that a sample of oil be drawn from the T-Tank annually. This sample should
be about two quarts and should be taken when the oil is warmed through normal operation. If
T T
possible, the sample should be analyzed by a qualified lubrication specialist to determine
O
N NO
whether it is suitable for continued use. The interval between oil changes depends upon the
operating conditions and on the care used in the handling oils and keeping them clean during
O
the handling process.
D DO
Drain, flush, and refill the air compressor oil reservoir (T-Tank) using the top-off system described in Section 20,
Top Off Systems. Or, refill the air compressor oil reservoir (T-Tank) with the type and amount of oil specified in Sec-
tion 12, Lubrication, Subtopic 12.3.2.1.
3.12.5 Change Cable Reel Gear Reducer Oil
Refer to Figure 3-31 and use the following procedure to change the oil in the right angle gear reducer:

! WARNING
2. Lock out and tag the electrical controls to the auxiliary hydraulic system to prevent inadvertent start-up of the
cable reel during service activities,
3. Remove the oil level and vent plugs (01 and 02) from the right angle gear case.
NOTICE n t
Y e
m
NL uip ion
The oil capacity of the right angle gear reducer is 1.5 pints (0.71 liters).
O q t
L f E ra
of the oil.
I A o p e
5. Clean the oil drain plug, apply a coating of pipe thread sealant, and securely install the drain plug.
ER ce O
t
6. Add oil, of the type specified in Table 3-10, through the vent plug opening until the oil level is at the bottom of
AT nan en
the oil level plug hole.
M te m
E n i p
LEGEND
i
01
C a q u
01. Oil Level Plug
02. Vent Plug (Not Shown)
E N M E
03. Oil Drain Plug
R o r o r 02
E E f f
E F S E
R U U S
T T
03
O
N NO
O
DSC02993b
D DO Figure 3-30: Cable Reel Right Angle Drive Gear Reducer
7. Clean the oil level and vent plugs. Apply a coating of pipe thread sealant, and securely install the plugs.
CAUTION
Operating the cable reel when the gear reducer has been overfilled will cause overheat-
ing of the reducer components resulting in component damage. Never operate the cable
reel when the oil level is either below or above the lower edge of the level plug opening.

3.12.6 Change Cable Reel Hydraulic System Oil and Replace Filters
Refer to Figure 3-31 and use the following procedure to change the oil in the cable reel hydraulic system:
! WARNING
t
e n
2. Lock out and tag the electrical controls to the cable reel system to prevent inadvertent start-up of the cable reel
during service activities,
Y m
NL uip ion
O q t
01 02
A L f E ra 03 04
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
12 ~ 05
~
E N M E
R o r o r
03
E E f f
F
03
E S S E
R U U
T T
O
N NO ~
O
~
D DO
BD1063a01
11 10 09 08 07 06
LEGEND 05. Return Oil From Pump 10. Motor Suction

01. Oil Level Gauge 06. Drain Valve 11. Baffle and Mounting Bolts
02. Tank Inspection Cover 07. Pump Suction (Shown Open) 12. Return Oil From Control Valve
03. Filter/Breather (3) 08. Manual Valve (Shown Closed)
04. Hydraulic Tank 09. Check Valve
Figure 3-31: Cable Reel Hydraulic Tank
3. Open the hydraulic cabinet doors (see Figure 3-18).

4. Place a suitable container below the drain valve (06, Figure 3-31) to catch the oil.
NOTICE
The capacity of the hydraulic tank is 10 gallons (38 liters).
5. Open the drain valve and drain the oil from the tank.
6. Remove and discard the three filter/breathers (03).
7. Remove the tank inspection cover (02).
n t
e
8. Remove the baffle (11) and clean the inside of the tank.
Y m
NL uip ion
9. Close the drain valve.
O q t
10. Install the baffle (11).
11. Fill the tank with new hydraulic oil.

A L f E ra
I o p e
12. Install the tank inspection cover.
ER ce O
t
AT nan en
13. Install three new filter/breathers (03).
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

320XPC-UDC Mechanical Systems Manual Cable Reel
Section 4
Cable Reel
4.1 Cable Reel Operation
4.1.1 General
n t
Y e
This section provides the information required to operate the P&H Mining Equipment Cable Reel.
m
4.1.2 Description
NL uip ion
O q t
L f E ra
The cable reel and drum assembly (02, Figure 4-1) is mounted on the front of the drill. It is a level winding reel used
A
to retrieve and pay out the power cable to keep the length of the cable as short as practical. The cable reel is pow-
I o p e
ered by a variable volume, pressure compensated hydraulic pump. The output of the pump is applied to a hydraulic
R ce O
motor mounted on the cable reel frame. The hydraulic motor drives the cable reel through a chain sprocket
E t
arrangement which also powers the level wind mechanism through an intermediate right angle reducer and a chain
AT nan en
drive.
M te m
E i n i p
C a q u
05
CABLE REEL MAINT.
N
01 CONTROL STATION
M E
START
RE o r r
06
o
STOP
f f
02
FE E
E
PAY TAKE
OUT UP
08
E S
03
R U U S
OPERATION
NORM. MAINT.
T T
HARNISCHFEGER
P&H
07
BD1062a01
O
N NO
O
D DO 04
BD1060a01
LEGEND
01. Control Pendant 05. Right Angle Drive
02. Cable Reel Frame 06. Level Wind Trolley
03. Junction Box 07. Collector Ring Enclosure
04. Hydraulic Cabinet 08. Hydraulic Motor
Figure 4-1: P&H Mining Equipment Cable Reel

Sec04CableReel.fm -4.1- Section 4, Version 00 - 07/12
Cable Reel 320XPC-UDC Mechanical Systems Manual
4.1.3 Operation
The cable reel is not designed to pull the cable over the ground. Severe damage to the
cable or cable reel may result if this is attempted.
t
The angle of the cable in relation to the cable reel must not exceed 40°. If the angle is too
n
great, damage to the cable and/or cable reel may result. Refer to .
Y e
m
NL uip ion
O q t LEGEND
L f E ra02 01. Cable to Cable Reel Ideal
A e
Approach
I
R ce O o p
02. Cable to Cable Reel Maximum
Approach Angle (40°)
E
~
t
40° MAX
AT nan en
M te m
01
E i n i p
C a q u
~
E N M E
R o r o r
E E f f
E F S E
S
40° MAX
R U U
~
T T
O
02
N NO
O
D DO
01
BD1060a01
~
Figure 4-2: Cable to Cable Reel Maximum Approach Angle

Section 4, Version 00 - 07/12 -4.2- Sec04CableReel.fm
The correct line pull is when there is sufficient pull on the cable to wind it on the reel but not too
great to put unnecessary strain on the cable or the sub station. The line pressure is proportional
to the hydraulic pressure.
The cable reel is designed to pick up the cable as the drill moves toward the power source and pay out the cable
when moving away from it. During initial operation of the cable reel, some adjustments may be necessary to deter-
mine the correct line pull that is best suited for your particular application. For most applications, adjusting the oper-
ating pressure to 600 psi (41.4 Bar) is a good starting point. Refer to Topic 4.3, Periodic Maintenance for detailed
t
instructions.
e n
Cable reels are operated with the control valve set to the wind position. The only time the cable reel is operated in
Y m
the unwind position is when there is a need to replace or inspect the cable.
NL uip ion
When properly adjusted the cable reel operates as follows:
O q t
A L f E ra
I o p e
R ce O
If the cable reel will remain stationary for a long period of time, the drive system should be
E t
turned off.
AT nan en
• When the drill is moving toward the power source, cable tension is lessened allowing the cable reel drive to
pick up the cable.
M te m
E i n i p
C a q u
• When the drill is standing still and drilling, the drive system stalls and the cable reel will remain stationary.
E N M E
r
• When moving away from the power source, the drive system is over-powered allowing the cable to be
R
unwound from the reel.
fo o r
F E E f
E
4.1.4 Cable Reel Controls
E
R U U S S
Refer to Figure 4-3 and Table 4-1. This subtopic details the type, color, operation and/or function of the controls
T T
associated with the cable reel controls. Two sets of controls are available to operate the cable reel:
O
N NO
• A pendant control is located on the cable reel hydraulic cabinet and is used for maintenance purposes only.
O
D DO
The CABLE REEL MODE switch (08, Figure 4-3) on the upper right hand control panel in the
operator’s cab must be in the MANUAL position to enable operation of the pendant control. This
switch must be in the AUTO position for normal cable reel operation.
• Rocker switches located on the upper right hand control panel in the operator’s cab are used to operate the
cable reel during normal drill operation.

01
CABLE REEL MAINT.
CONTROL STATION
08 07
START
02 STOP
t
06
e n RAISE BACK ANCHOR MANUAL PAY-OUT
Y
03 LOWER BRACE PINS
m
PAY TAKE LOCKS AUTO TAKE-UP
NL uip ion
OUT UP
ENGAGE
DISENGAGE MODE
MAST POSITIONING CABLE REEL
O q t
04 OPERATION
L f E ra
NORM. MAINT.
05
I A o p e RAISE REMOTE NORMAL
R ce O
HORN LOWER LOCAL MAINTAIN
E
HARNISCHFEGER FAULT DUST
P&H RESET CURTAIN PROPEL MODE
t
AT nan en
M te m
E i n i p
C a q u BD1061b01
E N M E
r r
LEGEND
R fo o
01. Control Pendant (on Hydraulic Cabinet) 05. NORM - MAINT Switch (on Pendant)
FE E
02. START Pushbutton
f 06. Upper Right Control Panel (in Operator’s Cab)
E
03. STOP Pushbutton 07. PAY OUT - TAKE UP Switch (on Console)
E S S
04. PAY OUT - TAKE UP Switch (on Pendant) 08. MANUAL - AUTO Switch (on Console)
R U U
T T
Figure 4-3: Cable Reel Controls
O
N NO
O
Ref. No. Description Type Color Operation
D DO
(Figure 4-3)
03 START Pushbutton Black Press to start the cable reel pump.
START
Table 4-1: Cable Reel Controls


(Figure 4-3)
04 STOP Pushbutton Red Press to stop the cable reel pump.
STOP
n t
05 PAY OUT - TAKE UP Three-position
Y e Black The normal position for this switch is
m
Rotary in the center, or neutral position.
NL uip ion
PAY TAKE • To pay out (unwind) the cable,
turn and hold the switch knob in
O q t
OUT UP
the PAY OUT position.
A L f E ra • To take in (wind up) the cable,
I e
turn and hold the switch knob in
R ce O o p •
the TAKE UP position.
Release the switch knob to auto-
E t
matically return it to the center,
AT nan en
or neutral position.
M te m
06 OPERATION Two-position Black • For normal operation of the cable
Rotary
p
reel, place this switch knob in the
E
C a q
OPERATION
i n u i •
NORM (normal) position.
To allow control of the cable reel
N
NORM MAINT
M E
from the pendant control on the
RE o r r
hydraulic cabinet, place this
o
switch in the MAINT (mainte-
E E f f nance) position.
E F S E
07
R U U S
CABLE REEL Spring-cen- White • With the CABLE REEL MODE
T T tered, 3-posi- switch (08) in the MANUAL posi-
O
tion rocker
N NO
PAY OUT tion, press and hold this switch in
switch (Pay-out/ the PAY OUT (upper) position to
Off/Take-up) unspool trail cable from the cable
O
D DO
reel or in the TAKE UP (lower)
position to wind trail cable onto
the cable reel. This switch will
automatically return to the cen-
ter, off position when released.
TAKE UP
Table 4-1: Cable Reel Controls (Continued)


(Figure 4-3)
08 CABLE REEL MODE 2-position White • For normal operation of the cable
rocker switch reel, place this switch in the
(Manual/Auto) AUTO position.
MANUAL
• To allow control of the cable reel
from the pendant control on the
hydraulic cabinet, place this
switch in the MANUAL position.
n t
e
AUTO
Y m
NL uip ion
Table 4-1: Cable Reel Controls (Continued)
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

4.2 Trail Cable Installation

Cable is spooled onto the reel smoothly because cable reel rotation is synchronized with the motion of the level
wind assembly. Timing is accomplished by selecting the sprocket combination between the right angle reducer and
the level wind drive. Timing varies, depending on the size of the cable in use: The reel is designed to allow the use
of cable between 2 and 3 inches (50-75 mm) in diameter. Timing may also need to be changed if the cable is
spliced. Splicing will enlarge the cable and this must be taken into account when the sprocket set is selected.
Therefore, several sets of sprockets are furnished and the correct set for each individual machine must be selected
in the field.
n t
e
Table 4-2 provides the information required to select the correct sprocket set for your applica-
Y m
NL uip ion
tion. A decal showing the information in Table 4-2 is also installed on the cable reel.
O q t
L f E ra
REDUCER LEVEL WIND TROLLEY TRAVEL
A
SPROCKET SPROCKET INCH (MM)
I o p e
R ce O
80B9 80B34 2.00 (51)
E t
80B33 2.06 (52)
AT nan en 80B32 2.13 (54)
M te m
80B10 80B34 2.22 (56)
E i n i p
u
80B33 2.29 (58)
NC a q
M E
80B32 2.36 (60)
RE o r r
80B11 80B34 2.44 (62)
E E f f o 80B33 2.52 (64)
E F S E 80B32 2.60 (66)
R U U S 80B12 80B34 2.67 (68)
T T 80B33 2.75 (70)
O
N NO
80B32 2.83 (72)
O
80B13 80B34 2.89 (73)
D DO 80B33
80B32
2.98 (76)
3.07 (78)
80B14 8OB34 3.11 (79)
80B14* 80B33 3.21 (81)
*The cable reel is shipped by the original equipment manu-

facturer with this sprocket set installed on the right angle
reducer and the level wind drive.
Table 4-2: Cable Reel Level Wind Sprocket Selection

The cable reel becomes a giant coil when cable is wrapped on the reel. For that reason, never
wrap more than two layers of cable on the reel unless the consequent voltage drop is recog-
nized and acceptable.
The following trail cable installation procedure assumes that the cable reel is properly mounted on the drill, the
electrical system is properly wired, the hydraulic system piping is correctly installed, the hydraulic system is full of
the proper hydraulic oil, and the guide rollers, trolley wheels and reel bearings are properly lubricated.
t
Proceed as follows:
e n
1. Remove the chain between the right angle reducer and the level wind drive sprocket and install the correct
Y m
sprocket combination for the cable being installed. Refer to Table 4-2 to determine the appropriate sprockets.
NL uip ion
O q t
A L f E ra
e
Do not reinstall the chain on the reducer drive/level wind sprockets at this time.
I
R ce O o p
2. Feed the power cable through the level wind trolley rollers and then through the center hole in the center plate
E t
AT nan en
divider of the cable reel. Anchor the power cable to the cable reel drum using the two U-bolts provided at the
right hand end of the reel.
M te m
3. Connect the power cable to the collector ring assembly at the junction box provided within the cable reel.
E i n i p
C a q u
4. Start winding the power cable on the reel drum at the end opposite to the collector end of the reel. Allow
N
approximately 1/8 inch, (3.2 mm) clearance between wraps for cable variables.
E r M E
R o r
5. After several wraps are installed, position the level wind trolley on the centerline of the cable and install the
f o
E E f
chain between the reducer and the level wind drive sprocket.
E F S E
6. Continue winding cable on the reel slowly while checking trolley travel and cable spooling. If not correct, adjust
R U U S
the trolley position and/or sprocket ratio.
T T
O
N NO
After 48 hours of field operation, change the hydraulic oil filters and replace the oil with new
O
D DO
clean oil. Refer to Subtopic 4.4.3.

4.3 Periodic Maintenance
! WARNING
ducting inspections. Use lockout and tagout procedures prior to conducting mainte-
nance or service.
n t
!
Y e
WARNING
m
NL uip ion
O q t
L f E ra
ladder, it may move and slip from its supports. You can also lose your balance while
A e
getting on or off an unsteady ladder. (Refer to decal R12771D1 under Subtopic 1.5.3 in
I o p
Section 1 for additional information relating to ladder safety).
R ce O
E t
√
AT nan en
ITEMS TO BE VERIFIED REF Frequency
M te m
Check the hydraulic tank oil level and add oil if required Subsection Daily (8 hours)
E i n i p 4.4.3.1
C a q u
N
Check the right angle gear reducer oil level and add oil if Subsection Monthly (160 hours)
required
E r M E 4.4.1.1
R fo
Inspect the trail cable
o r Subsection Quarterly (500 hours)
FE E f 4.5
E S S E
Inspect the cable reel components Subsection
4.4.4
Quarterly (500 hours)
R U U
T T
Lubricate the cable reel bearings, trolley wheels, guide roller Subsection Semi-annually (1000
(if used), and drive chains 4.4.2 hours)
O
N NO
Change the oil in right angle gear reducer Subsection
4.4.1.2
Annually (2000 hours)
O
D DO
Change the oil in the hydraulic system and replace the filters Subsection
4.4.3.2
Annually (2000 hours)
Table 4-3: P&H Mining Equipment Cable Reel Maintenance Checks

4.4 Cable Reel Lubrication
4.4.1 Right Angle Bevel Gear Drive
4.4.1.1 Check Oil Level
! WARNING
n t
e
Y
m
NL uip ion
O q t
L f E ra
2. Remove the oil level plug (01) from the right angle gear case, and check the oil level. The oil should be at the
A
lower edge of the plug opening.
I o p e
R ce O
E t
AT nan en
M te m 01 02 03
E i n i p
C a q u
N M E
11
RE o r r
E E f f o
E F S E
R U U S
T T
10 04
O
N NO
09
05
O
D DO BD1069a01
08 07 06
LEGEND 07. Sprocket Selection Decal

01. Oil Level Plug 08. Right Angle Gear Reducer
02. Vent Plug (Not Shown) 09. Level Wind Trolley
03. Name Plate 10. Guide Roller and Bearing Assembly (Not used on
04. Collector Ring Cover all variations)
05. Left Hand Cable Reel Frame 11. Level Wind Drive Sprockets and Chains (Below
06. High Voltage Junction Box (2) Covers)
Figure 4-4: Cable Reel Components - Right Front View

should be selected according the expected extreme ambient temperatures. Refer to Table 4-4. This must be a high
quality, well-refined mineral base, multi-purpose petroleum gear oil compounded with extreme pressure additives
for higher load carrying ability.:
P&H
Specification
Maximum Ambient Temperature Number SAE Grade
warmer than -40 °F (-40 °C) 496A 75W
warmer than -15 °F (-25 °C) 496B 80W-90
warmer than 10 °F (-12 °C)
t
496C 85W-140
n
Table 4-4: Lubrication, Cable Reel Gear Reducer
Y e
m
NL uip ion
4.4.1.2 Change Oil
O q t
! WARNING L
A f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
2. Remove the oil level plug (01) and vent plug (02).
E N M E
r r
3. Remove the oil drain plug from the bottom of the right angle gear case (08) and drain the oil into a suitable con-
R fo o
tainer.
FE E f
E S S E
R U U
T T
The capacity of the right angle gear case is 1.5 pints.
O
N NO
4. Clean the oil drain plug. Apply a coating of pipe thread sealant, and install the drain plug.
O
D DO
5. Add oil of the type specified in Table 4-4 through the vent plug opening until the level reaches the bottom of the
oil level plug hole.
6. Clean the oil level and vent plugs. Apply pipe thread sealant to the threads on the plugs and install the plugs
securely.

4.4.2 Lubricate Grease Fittings
! WARNING
ladder, it may move and slip from its supports. You can also lose your balance while get-
ting on or off a ladder. (Refer to decal R12771D1 under Subtopic 1.5.3 in Section 1 for
additional information relating to ladder safety).
t
1. On both sides of the frame, lubricate the drum bearing grease fittings using extreme pressure grease.
e n
2. Lubricate the trolley wheel and roller grease fittings (and the guide roller bearings, if equipped - Refer to Item
Y m
NL uip ion
10, Figure 4-4) using extreme pressure grease.
O q t
4.4.3 Cable Reel Hydraulic System
4.4.3.1 Check Hydraulic Oil Level

A L f E ra
I o p e
ER ce O
t
AT nan en
! WARNING
M te m
p
E
C a q i n u i
E N M E
R o r o r
E E f f
F
2. Open the hydraulic cabinet doors and check the oil level on the oil level gauge (01).
E S S E
R U U
3. If the oil level is low, remove the breather (03) from the front of the tank (04) and add hydraulic oil.
T T
O
N NO
O
D DO

01 02 03 04
t
12 05
~ ~
e n
Y m
03
NL uip ion 03
O q t
A L f E ra
I o p e
ER ce O
t
~
AT na~n en
M te m
BD1063a01
11
E i n
10
i p 09 08 07 06
C a q u
N
LEGEND 05. Return Oil From Pump 10. Motor Suction
01. Oil Level Gauge
E r M E 06. Drain Valve 11. Baffle and Mounting Bolts
R o r
02. Tank Inspection Cover 07. Pump Suction (Shown Open) 12. Return Oil From Control Valve
03. Filter/Breather (3)
04. Hydraulic Tank
E E f f o 08.
09.
Manual Valve (Shown Closed)
Check Valve
E F S E
R U U S Figure 4-5: Hydraulic Tank
T T
O
4.4.3.2 Hydraulic Oil and Filter Replacement
N NO
O
D DO ! WARNING
2. Open the hydraulic cabinet doors.
3. Place a suitable container below the drain valve (06) to catch the oil.

The capacity of the hydraulic tank is 10 gallons (38 liters).
4. Open the drain valve and drain the oil from the tank.
5. Remove and discard the three filter/breathers (03).
6. Remove the tank inspection cover (02).
t
7. Remove the baffle (11) and clean the inside of the tank.
8. Close the drain valve.

e n
Y m
NL uip ion
9. Install the baffle (11).
O q t
10. Fill the tank with new hydraulic oil.
11. Install the tank inspection cover.

A L f E ra
I o p e
12. Install new filter/breathers (03).
ER ce O
t
AT nan en
4.4.4 Inspect Cable Reel Components
M te m
Visually inspect the condition of the cable reel components as defined in the following steps. Repair, adjust or
E i n i p
replace any components of the cable reel that are found faulty as revealed through this inspection.
C a q u
N
1. Test cable reel operation; Pay Out and Take Up cable.
E r M E
R o r
2. Ensure that the cable drum rotates smoothly and is concentric.
f o
F E E ! WARNING f
E S S E
R U U
T T
O
N NO
O
D DO
activities.
4. Open the door on the hydraulic cabinet (07, Figure 4-6). Inspect the hydraulic motor, pump and interconnecting
hoses and connections for leaks (also refer to Figure 4-5). Tighten connections or replace faulty components
as necessary.
5. Ensure that the motor/pump coupling is secure. Close the hydraulic cabinet door.
6. Remove the drive chain guards and inspect the drive chains (04, 06 and 09, Figure 4-6) for wear and proper
tension.
7. Inspect the chain sprockets for wear. Install the drive chain guards.

8. Inspect the right angle gear reducer (04) for leaks.
9. Inspect the cable reel structure for cracks.
01 02 03 LEGEND
01. Collector Ring Cover
02. Connecting Cable Junction Box
09 03. Right Angle Gear Reducer
04. Level Wind Trolly Drive Chains
04 and Sprockets
t
05. Level Wind Drive Chain Tensioner
n
06. Drum Drive Chain and Sprockets
e
07. Hydraulic Cabinet
Y m
08. Trail Cable Junction Box
NL uip ion
05 09. Right Angle Gear Reducer Drive
08 Chain and Sprockets
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en FRONT
M te m
E i n i p
C a q u
07
E N M E 06
R o r o r
E E f f
Figure 4-6: Component Locations (Top View - shown with chain guards removed)
E F S ! E
R U U S DANGER
T T
Hazardous high voltage will cause injury or death. Disconnect electric power to the trail
O
N NO
cable at the power substation and use lockout and tagout procedures prior to removing
the junction box or collector ring covers. Use qualified inspection personnel equipped
O
D DO
with appropriate devices for testing, handling, and personal protection.
10. Pay Out enough cable to reveal the trail cable junction box (08, Figure 4-6). Then, disconnect power to the trail
cable at the power substation and use lock out and tagout procedures.
A. Remove the covers from the junction boxes (02 and 08, Figure 4-6) and check that all wire connections
inside the junction boxes are clean and secure.
Use an electrical contact cleaner to clean cable connections inside the boxes. Make sure the
cleaner is dry before installing the covers and starting up the drill.

B. Remove the collector ring cover (01, Figure 4-6). Refer to Figure 4-7. Inspect the collector rings (02),
brushes (03), brush retainer springs (05), and brush holders (07) for wear or damage. Ensure that the cable
connections are clean and secure.
New brushes (03, Figure 4-7) are 1.75 in (44.5 mm) long. Replace the brushes when worn to
0.875 in. (22.2 mm).
t
01 LEGEND
n
01. Wire to Connecting Cable
Y e 02. Collector Ring
m
03. Brush
NL uip ion
04. Spring Mounting Screw
05. Brush Retainer Spring
O q t
06. Brush Wire Mounting Screw
L f E ra
07. Brush Holder
I A o
02
p e
R ce O
~
07
E 03
t
AT nan en
06
M te m
E i n i p 04
C a q u
05
E N M E
R o r o r
E E f f Figure 4-7: Brush Holder Assembly
E F S E
S
C. Clean dirt and debris from inside the junction box and collector ring enclosures and install the covers.
R U U
T T
D. Inspect all insulators (08, Figure 4-13) for cracks. Replace insulators if cracked or broken (refer to Subtopic
O
4.9.2).
N NO
E. Inspect all mounting hardware for being secure.
O
D DO
F. Install the covers on the junction box and collector ring enclosures.
4.5 lnspect Trail Cable
! DANGER
cable at the power substation and use lockout and tagout procedures prior to visual
inspection or handling of the trail cable. Use qualified inspection personnel equipped

Power is fed to the blast hole drill through the trail cable. It is imperative that this cable is not damaged or cut. Visu-
ally inspect the trail cable to ensure that it is not damaged, crushed, or cut. Replace the trail cable if it is damaged.
4.6 Adjustments
4.6.1 Level Wind Drive
The level wind drive trolley is driven by a chain and sprocket arrangement from the reel drum. Trolley travel speed
is determined by the gear ratio of the output sprocket on the right angle bevel drive and the level wind sprocket and
t
should not require adjustment.
e n
Y m
NL uip ion
If the trolley travel distance is too short or too long due to a change in the diameter of the trail
O q t
cable, the output sprocket and level wind sprocket can be replaced with a new set. Refer to
L f E ra
Table 4-2 to select the proper sprocket combination.
A
I o p e
4.6.2 Hydraulic Drive
ER ce O
t
AT nan en
The cable reel is driven by a 5 HP, 7 GPM, variable volume, pressure compensated hydraulic system. During initial
operation of the cable reel, some adjustments will be necessary to determine the correct line pull and speed that is
M te m
best suited for the application.
E i n i p
C a q u
E N M E
R o r o r
For most applications, adjusting the operating pressure to 600 psi (41.4 bar) is a good starting
f f
point. Refer to Subtopic 4.6.2.1
F E E
E S E
When properly adjusted, the cable reel will pick up cable as the drill moves forward toward the power source and
S
R U U
stall when the drill is stationary. When the drill is moving away (propelling in reverse) from the power source, the
cable reel drive system is over-powered to allow the cable to unwind from the reel.
T T
O
N NO
O
D DO
Normal operation of the cable reel is with the controls in the “NORM” position. The “MAINT”
position is for maintenance personnel only and used to inspect or replace the cable.
4.6.2.1 Pressure Adjustment
! WARNING
Adjust the pump pressure as follows:

1. Start the hydraulic system and let the oil circulate for approximately 5 minutes.
2. Check all hydraulic connections for leaks.
3. Refer to Figure 4-8. Close the flow control valve (06) slowly and watch the pressure gauge (01). If the pump
pressure exceeds 1100 psi (75.8 bar), adjust the pump relief valve (05) until pump pressure is 1000 psi (68.9
bar) or lower.
01 02 LEGEND
01. Pressure Gauge
n t 02. Hydraulic Tank
e
03. Manual Valve
Y
04. Pressure Hose from Pump
m
NL uip ion
09 05. Pressure Relief Valve
06. Flow Control Valve
07. Control Valve Assembly
O q t 08. Directional Solenoid Valve
L f E ra
09. Load Control Valve
I A o p e
R ce O
03
E
08
t
AT nan en
M te m
E n i p
04
C a q i u
E N M E TC0535a
R o r o r
f
07 06 05
FE E f
E
Figure 4-8: Control Valve and Components
E
R U U S S
4. Close the flow control valve (06, Figure 4-8) completely. Adjust the pump compensator adjustment screw (01,
T T
Figure 4-9) until the pressure on the gauge (01, Figure 4-8) is 900 psi (62.1 bar).
O
N NO
O
D DO

LEGEND 02
01. Pump Compensator Adjustment Screw
02. Maximum Outward Adjustment Distance
1.12 in. (28.4 mm)
While the pump is operating,

do not back compensator
adjustment screw (01) out
beyond dimension (02). The
screw is under high pressure 01
t
and will come off at a high
rate of speed if loosed too
far.
e n
Y m
NL uip ion
O q t
L f E ra
Figure 4-9: Adjusting System Pressure
I A o e
5. Loosen the lock nut on the pressure relief valve (05, Figure 4-8) adjusting screw. Open the relief valve until a
p
R ce O
pressure drop is noticed on the gauge. This is the relief valve operating pressure. Carefully tighten the lock nut
E
while making sure the adjustment screw does not move.
t
AT nan en
6. Refer to Figure 4-9. Adjust the pump compensator pressure to 600 psi (41.4 bar).
M te m
E i n i p
C a q u
N M E
The hydraulic pump compensator pressure is normally set at 300 psi (20.7 bar) below the relief
valve pressure.
RE o r r
E E f f o
7. Open the flow control valve (06, Figure 4-8) completely and leave it in this position.
E F S E
R U U S
T T
O
The flow control valve is used for setting the system operating pressure and for diagnostics
N NO
only. All system flow adjustments must be made on the pump only. During normal operation, the
flow control valve must be in the full open position.
O
D DO
8. Check the operation of the cable reel. If the cable reel tension is too great or too little, repeat steps 4 through 7,
increasing or decreasing pump pressure and relief valve settings in 100 psi (6.9 bar) increments until cable reel
operation is satisfactory.
4.7 Post Startup

Refer to Figure 4-10 which is a diagram of the cable reel hydraulic system and to Figure 4-11 which is the hydraulic
schematic for the cable reel.

After 48 hours of field operation, change the filters (01, Figure 4-10) and replace the oil with new clean oil (refer to
Subtopic 4.4.3).
01 02 03 04 01
17
n t
e
LC
T2
Y
MB
m
P
NL uip ion
14
FC 16
T1 E
O q t
L f E ra
MA
R 15
A
D
I o p e
ER ce O 05
t
AT nan en 13 06
M te m
MB
07
p
B
E n i
B2
i
D
C a q u MA
E N M E
B1 C
R o r o r
E E f f
E F S E
R U U S A
T T
A B
O
N NO
BD1064a01
12 11 10 09 08
LEGEND
O
D DO
01. Filter (2)
10.
11.
Electric Motor
Solenoid Valve
A Pump Supply
B Pump Pressure
02. Oil Level Gauge 12. Hydraulic Motor B1 Motor Port A Pressure or
03. Hydraulic Tank (10 Gal.) 13. Pressure Gauge Return
04. Breather 14. Control Valve Assembly B2 Motor Port B Pressure or
05. Drain Valve 15. Relief Valve Return
06. Manual Valve (shown closed) 16. Flow Control C Return From Pump
07. Check Valve 17. Load Control D Motor Suction (Anti-Cavita-
08. Hydraulic Pump tion)
09. Coupling E Return From Control Valve
Figure 4-10: Cable Reel Hydraulic Diagram

4.8 Cable Reel Hydraulic Schematic
LEGEND
02 01 03 01. Hydraulic Motor
02. Motor Port A (Wind Out)
03. Motor Port B (Wind In)
04. Directional Solenoid Valve
05. Relief Cartridge (Port R)
MA MB 06. Hydraulic Pump (See Note 1)
07. Filter (2)
t
16 15 08. Breather
n
LC
09. Hydraulic Tank (10 Gal.)
Y e 10. 1/4-Turn Manual Valve
m
NL uip ion
11. Check Valve
12. Electric Motor (See Table 4-5)
13. Pressure Gauge
O q t
ORF 14. Flow Control
L f E ra
15. Load Control
A
I e
04
R ce O o p Note 1: When viewed from the
E t
shaft end, the pump has clock-
AT nan en
T2 wise rotation.
14 05
M te m
13
FC
p
Motor 60 Hz 50 Hz
E
C a q i n u i
1000 PSI Frame 184TC 184TC
E N M E Phase 3 3
r
G T1
R fo o r R HP 5 3
FE E f RPM 1745 1465
E
12 P D
E
RM U U S S 06
Volts
AC
230/
460
208/
380
T T Table 4-5: Motor Specifications
O
N NO
O
D DO 10
07 08
11
BD1066a01
09
Figure 4-11: Cable Reel Hydraulic Schematic

Intentionally Blank
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

4.9 Component Repair
4.9.1 Hydraulic Pump and Motor
Refer to Figure 4-12. The hydraulic pump and electric motor are considered to be repairable. All other system com-
ponents should be replaced if faulty.
4.9.1.1 Removing Pump and Motor
! WARNING
n t
e
Y
m
NL uip ion
O q t
2. Open the hydraulic cabinet (18) doors.

A L f E ra
I o p e
! WARNING
ER ce O
t
AT nan en
Electrical current will cause serious personal injury or death. Use lockout and tagout
M te m
procedures and test before removing any electrical wiring.
E i n i p
C a q u
3. Use lockout and tagout procedure.
E N M E
4. Remove the cover from the electric motor wiring box (13) and test the wire connections for voltage. If no
R o r o r
voltage is present, disconnect the electrical wiring from the motor. Tag the wiring to make installation easier.
E E f f
F
5. Drain the hydraulic tank (03). A drain valve (07) is provided to make draining easier.
E S S E
R U U
6. Tag and disconnect the hydraulic lines from the pump.
T T
7. Remove the coupling guard (12).
O
N NO
8. Remove the motor mounting hardware from the base plate to remove the motor and pump as an assembly.
Return the pump or electric motor to a suitable repair facility for repairs.
O
D DO
4.9.1.2 Disassembly
1. Remove the pump mounting hardware to remove the pump (10) from the C-Face adapter (11).
2. Disconnect the coupling from the motor or pump shaft to remove the pump.
4.9.1.3 Installing Pump and Motor
1. Install the coupling on the motor shaft.
2. Mount the pump on the C-Face adapter and connect the coupling to the pump shaft.

3. Tighten the coupling and pump mounting hardware securely.
4. Install the pump and motor assembly on the motor base plate.
5. Connect the hydraulic lines and electrical wiring. When installation is complete, inspect for leaks and check for
proper operation of the cable reel by repeating the procedure described for preparing the system for operation.
LEGEND
01 02 03 04 05 01. Oil Level Gauge
02. Check Valve
t
03. Hydraulic Tank 10 Gal. (38
e n liter)
04. Manual Valve
Y m
NL uip ion
05. Breather (Same Part Number
as Item 06)
18 06. Filter (2)
O q t
07. Drain Valve
L f E ra
08. Junction Box
A
09. Control Pendant
I o p e 10. Hydraulic Pump (See Note 1)
R ce O
11. C-Face Adapter
E
12. Coupling Guard
t
AT nan en
13. Electric Motor (See Table 4-5)
14. Electric Motor Wiring Box
15. Directional Solenoid Valve
M te m
06 06
E n i p
17. Pressure Gauge
C a q i u
07 18. Hydraulic Cabinet
17
E N M E 08 Note 1: When viewed from the
R o r o r
shaft end, the pump has clock-
f f
wise rotation.
E E
16
E F S E
R U U S 09
T T
O
N NO
15
O
D DO 14 13 12 11 10
TC0537a
Figure 4-12: Hydraulic Cabinet Components

4.9.2 Collector Ring Assembly Repair
! DANGER
cable at the power substation and use lockout and tagout procedures prior to removing
the junction box or collector ring covers. Use qualified inspection personnel equipped
1. Disconnect power to the trail cable at the power substation and use lock out and tagout procedures.
n t
2. Remove the cover (01, Figure 4-4) from the collector ring enclosure.
Y e
m
NL uip ion
3. Refer to for component removal and installation.
O q t
A L f E ra
I e
When installing the insulators (08, Figure 4-13), the arrow (C) must be pointing down. This will
R ce O o p
ensure that the longer end of the studs will go into the deeper female threaded holes (B) of the
E
insulators. Apply Loctite on the threads of the studs.
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

06 LEGEND
28 01. Fiberglass Cover
19
02. Brush Holder Bracket
03. 3/8 Capscrew (8)
04 04. 3/8 Lockwasher (23)
09 01 05. Shoulder Bolt (6)
22
06. Brush Holder Assembly (5) (Refer
A A to Figure 4-7 for Details)
07. Collector Ring (3)
08. Insulator (9)
t
09. 3/8 Washer (20)
n
10. 1/2 Lockwasher (16)
e
11. Ground Ring Assembly
Y
m
NL uip ion
13. Insulator (3)
02 03 14. 3/8 Stud (6)
10 04
15. Ground Bracket
O q t
16 09
16. 1/2 Washer (6)
L f E ra
27
I A e
R ce O
05 o p
04
19. Insulator Plate
20. 1/2 Nut (2)
E
10
t
17 21. Spacer
AT nan en
22. 3/8 Capscrew (12)
02 01
10
23. Insulator Square (2)
M te m
27 24. Insulator Bushing (2)
07
25. Insulator Plate
E i n i p 08 26. 3/8 Stud (3)
C a q u 27. 1/2 Capscrew (6)
N
14
M E
28. Insulator Plate (2)
E
13
r
07
R fo o r A Shallow Female Thread
E E f
B Deeper Female Thread (Base)
14
F
C Arrow indicates mounting direction
23
E S S E 07
R U U
24
25 10
T T 21 12 26
O
N NO
11 A
O
C
D DO B
10 10 REEL SHAFT 34
15 18 Item 08 Orientation
16 20 SECTION A-A
27
F6335
Figure 4-13: Collector Ring Assembly

320XPC-UDC Mechanical Systems Manual Electrical System
Section 5
Electrical System
Refer to the separate manual, Centurion Drill Electrical Maintenance Manual, for electrical system descriptions,
components and maintenance.
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

Sec05Elec.fm -5.1- Section 5, Version 00 - 07/12
Electrical System 320XPC-UDC Mechanical Systems Manual
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

Section 5, Version 00 - 07/12 -5.2- Sec05Elec.fm
320XPC-UDC Mechanical Systems Manual Power Unit
Section 6
Power Unit
6.1 General
t
Refer to Figure 6-1. The power unit provides a single source of torque with which to drive the main air compressor
e n
and the three pumps for the auxiliary and propel hydraulic systems. Major components of the power unit include
two air filter assemblies (01), an I/O electrical cabinet (02), two charge filters (03), a pump drive transmission (04),
Y m
NL uip ion
two propel drive pumps (05), an auxiliary pump (06), an electric motor (07), and the main air compressor (09).
These components are mounted on a rigid base (08).
O q t
A L f E ra 02
I o p e
01
ER ce O 03
t
AT nan en
M te m 04
E i n i p
C a q u
N
05
E r M E
09
R fo o r
FE E f
E S S E 06
R U U
T T 07
O
N NO
O
D DO
08
PowerUnit_GD_LtFrtView
LEGEND
01. Inlet Air Filters 06. Propel System Hydraulic Pump (x2)
02. Power Unit I/O Electrical Cabinet 07. Main Motor
03. Hydraulic Charge Filter (x2) 08. Base
04. Pump Drive Transmission (PDT) 09. Main Air Compressor
05. Auxiliary Hydraulic Pump
Figure 6-1: Power Unit (Typical - Gardner Denver)

Sec06PowerUnit.fm -6.1- Section 6, Version 00 - 07/12
Power Unit 320XPC-UDC Mechanical Systems Manual
6.1.1 Power Unit Arrangement
Table 6-1 lists the power unit arrangement used on this drill.
Power Unit* Electric Motor Air Compressor

Part
Number Approx. Weight Type (SCFM) Weight
HP (kW) LBS (KGS) LBS (KGS)
R57827F5 700 (522) 3,550 (1,614) Gardner Denver (3,600) 3,800 (1,727)
t
* The complete power unit assembly weighs approximately 12,450 lbs (5,960 kgs)
n
Y e
Table 6-1: Power Unit Arrangement and Weight
m
NL uip ion
6.1.2 Alignment Procedures for Power Unit Components
O q t
A L f E ra
I o p e
ER ce O
The pump drive transmission (PDT) is aligned to the left and right pump drive transmission
mounts using dowels at machine assembly. The PDT should only be removed if damaged. If a
t
AT nan en
new or different PDT is installed, new holes are to be drilled and reamed for dowels in new loca-
tions. Do not use existing holes. If replacement of the PDT is required, contact your MinePro
M te m
representative for proper installation procedures. Refer to Appendix A, General Maintenance
E n
for proper coupling alignment procedures.
i i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

Section 6, Version 00 - 07/12 -6.2- Sec06PowerUnit.fm
6.2 Power Unit Maintenance
6.2.1 Main Drive Motor
n t
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m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
Figure 6-2: Main Drive Motor
6.2.1.1 General
M te m
E i n i p
C a q u
The drill is powered by a double-shafted, high-voltage AC electric motor. The motor is sized to provide the torque
N M E
needed to operate the main air compressor and the pumps for both the propel and auxiliary hydraulic systems. The
E r
motor is direct coupled to the compressor and pump drive transmission with flexible couplings.
R fo o r
E E f
6.2.1.2 Adjustment and Maintenance
F
E S S E
Only electricians who are qualified and authorized should attempt to adjust or maintain electric motors. For ques-
R U U
tions or assistance, contact your local MinePro Services representative.
T T
O
6.2.1.3 Removal
N NO
Refer to Figure 6-3 and remove the main drive motor from the power unit base as follows:
O
D DO ! WARNING
Hazardous voltage can cause burns, injury, or death. Disconnect, lock open, and tag the
power source which feeds the main drive motor to prevent power from being applied
while inspection and repairs are being performed. Before beginning repairs, try the oper-
ational controls to verify that the intended power source is disconnected.
1. Disconnect, lock out, and tag the power source to the main drive motor to prevent power from being applied
while service being performed.
2. Clean all dirt from the motor and electrical fittings.

01
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O 10 09 08
PowerUnit_GD_LSideView
t
AT nan en
M te m
E i n i p
C a q u
11
E N M E 07
r
01
R fo o r
f
06
FE E
E S S E 02
R U U
T T
O
N NO
O
D DO
MainMotor_GD_Couplings
05 04 03
LEGEND
01. Main Drive Motor 07. Coupling Guard
02. Pump Drive Transmission (PDT) 08. Motor Alignment Bolts and Jam Nuts (x2)
03. Spline-type Coupling 09. Motor Mounting Bolt and Lockwasher (x4)
04. Cushion-type Coupling 10. Coupling Guard
05. Mounting Adapter 11. Air Filter (x2)
06. Air Compressor
Figure 6-3: Power Unit (Typical - Gardner Denver)

3. Tag and disconnect the electrical wiring and conduit from the main drive motor (09).
4. Loosen the four jam nuts and motor position adjusting screws (08).
5. Remove the four mounting bolts and lockwashers (09) from the motor and base.
6. Remove the coupling guards (07 and 10).
7. Disconnect the couplings (03 and 04).
8. Remove the bolts that attach the mounting adapter (05) to the motor (01).
9. Open roof to lift the motor out.

n t
Y e
m
NL uip ion
! WARNING
O q t
Disassembling heavy components with inadequate hoisting apparatus can injure per-
L f E ra
sonnel and/or damage equipment. Use suitable rigging and hoisting equipment to stabi-
A
lize and lift heavy objects. Refer to Table 6-1 for the approximate weight of the motor.
I o p e
R ce O
10. Attach a suitable lifting device to the motor, and lift enough of the motor weight to enable sliding it away from
E t
the mounting adapter (05).
AT nan en
11. Lift the motor away from the power unit base and set it on wooden blocking to protect the mounting feet sur-
M te m
faces. Keep the motor shim set for re-use.
E i n i p
C a q u
12. Clean and inspect the motor and power unit base components in accordance with the cleaning and inspection
N
procedures described in Appendix A, General Maintenance of this manual.
E r M E
R
6.2.1.4 Installation
fo o r
FE E f
E
13. Install the main drive motor as follows (refer to Figure 6-3):
E
R U U S S
T T
O
N NO
Assembling heavy components with inadequate hoisting apparatus can injure personnel
and/or damage equipment. Use suitable rigging and hoisting equipment to stabilize and
O
lift heavy objects.
D DO
A. Attach a suitable lifting device to the motor, and position the motor on top of the base. Continue to support
most of the motor weight with the lifting device until the motor is in final position.
B. Carefully slide the motor into position against the compressor-motor mounting adapter. Rotate the motor
shaft as necessary so the coupling halves mate correctly. Be certain that the flexible insert is installed in the
coupling. Assemble the coupling. Apply grease to the coupling grease fitting.
C. Position shims as necessary under the motor feet, then install mounting bolts and lockwashers. Torque the
bolts securely.
D. Assemble the coupling for the pump drive transmission.
E. Install the covers on the compressor-motor adapter with capscrews and lockwashers.

F. Install the guard over the PDT-motor coupling.
G. Install the electrical wiring to the main drive motor.
H. Confirm alignment in accordance with Subtopic 6.1.2.
6.2.2 Air Compressor
The Air Compressor is covered in Section 7, Main Air System.
n t
e
6.2.3 Hydraulic Pump Drive Transmission
Y m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S Figure 6-4: Pump Drive Transmission (PDT) (Typical)
T T
O
N NO
6.2.3.1 Description
O
The pump drive transmission (PDT) is a multi-shafted gear reducer that distributes torque from the electric main
D DO
drive motor to the three attached hydraulic pumps. The output shafts to the pumps all rotate at the same speed.
The input shaft of the hydraulic pump drive is connected to the main drive motor shaft by means of a flexible cou-
pling. The hydraulic pumps are flange-mounted to the hydraulic pump drive transmission housing. A single pump
on the forward side of the pump drive provides flow and pressure to the auxiliary hydraulic system. The two hydro-
static pumps for the main hydraulic system are located on the rear side of the pump drive.
The pump drive transmission has a ventilated gear case. The gears are lubricated by a splash-type oil bath.
6.2.3.2 Maintenance
Daily: Check oil level using the dipstick. If oil level is low, add sufficient quantity to bring the oil to an acceptable
level using the lubricant prescribed in Subsection 12.2.2.

6.2.3.3 Repairs
Repair is limited to the replacement of worn or broken components, except that the PDT case is of mild steel and
can be welded using standard welding procedures. Pump and motor couplings can be replaced in place.
To replace components, remove the PDT from the drill so that it can be disassembled and repaired in a shop facil-
ity.
6.2.3.4 Removal
Remove the PDT as follows:
WARNING n t
e
!
Y m
NL uip ion
O q t
work.
A L f E ra
I o p e
R ce O
1. Lock out and tag the operator controls to prevent operation of the machine during maintenance work.
E t
AT nan en
2. Open the drain cock located on the bottom front side of the pump drive housing and drain the lubricating oil into
a suitable container. The housing contains approximately 2 gallons (7.6 liters) of oil.
M te m
3. Remove the guard which encloses the flexible coupling between the main drive motor and the pump drive
transmission.
E i n i p
C a q u
N M E
4. Disconnect hydraulic hoses from the charge filters; remove the bracket that holds the charge filters.
RE o r r
5. Disconnect the pump drive from the main drive motor at the flexible coupling by removing the capscrews,
E E f f o
washers, and locknuts which secure the pump drive to the coupling flange extension. Do not remove the
F E
attaching capscrews, washers, or nuts from the motor end of the flexible coupling at this time. The hydraulic
E S S
pump drive can be removed from the power unit assembly with all pumps installed. The following procedure,
R U U
however, assumes that all of the hydraulic pumps have been removed from the pump drive as described under
T T !
the topics, Auxiliary Hydraulic Pump, Removal, and Main Hydraulic Pump.
O
N N O WARNING
O
D DO
sonnel and/or damage equipment. Use suitable rigging and hoisting equipment to stabi-
lize and lift heavy objects.
6. Attach a suitable lifting device to stabilize the pump drive transmission.
7. Remove the pipe nipple, oil drain cock, hex nipple, and pipe elbow from beneath the pump drive housing.
8. Remove the four capscrews and lockwashers which secure the pump drive housing to mount.
9. Open the roof to gain access to the pump drive with a crane.
10. Remove the pump drive from the power unit assembly.

6.2.3.5 Disassembly
Disassemble the hydraulic pump drive transmission as follows:
1. Remove the coupling hub and sleeve from the pump drive input shaft as follows (refer to Figure 6-5):
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
Coupling_R9822D1
E i n i p
C a q u
E N M E
r r
LEGEND
R fo o
01. Capscrew 05. Coupling Spacer 09. Locknut
E E f
02. Sleeve 06. Gasket 10. Washer
F E
03. Hub 07. Sleeve
E S S
04. Gasket 08. Hub
R U U
T T
Figure 6-5: Pump Drive Flexible Coupling
O
N NO
O
D DO
The following equipment is required: A suitable hydraulic puller with an adjusting assembly and
a crosshead leg assembly having SAE Grade 8 studs, two rosebud torches, heat resistant
gloves and a fire extinguisher.
A. Thoroughly clean the coupling hub to be removed to avoid combustion when heat is applied.
B. Place the pump drive housing on a support with the input shaft facing up.

C. Drill and tap the face of the coupling hub for the appropriate puller leg thread size, as shown in Figure 6-6.
LEGEND
01. Gauge
02 03 02. Adjusting Screw
03. Plate
01 04. Hydraulic Cylinder
05. Bar Stock
06. Shaft
04 07. Coupling Hub
08. Torch
t
05
06
e n
Y m
NL uip ion
07
08
O q t
A L f E ra
I o e
BD0372b01
R ce O p
E
Figure 6-6: Coupling Hub Removal
t
AT nan en
D. Assemble the puller as illustrated in Figure 6-6. Check to be sure the puller has enough stroke to pull the
M te m
hub off the input shaft.
E i n i p
C a q u
E N M E
r
Surfaces will be extremely hot. Be certain to wear all appropriate personal protective equipment
(PPE).
R fo o r
FE E f
E
E. Heat the hub evenly with a rosebud torch to approximately 300 - 500°F (150-260°C) while applying pressure
E S S
with the puller. The temperature of the hub may be measured with a heat sensitive crayon.
R U U
T T
O
N NO
Excessive heat can damage hub teeth. Avoid placing the heat directly on the hub teeth.
O
Apply the heat as shown in Figure 6-6.
D DO
F. Apply puller pressure until the hub clears the shaft.
2. Refer to Figure 4-5 and disassemble the pump drive housing as follows:
A. Thoroughly clean the split housing exterior using a suitable solvent. Make sure the disassembly area is
clean. Place the assembled pump drive so the oil drain side of the housing is facing down on the work sup-
port, and the input shaft facing up.
B. Remove the dowel pins which align the two housing halves.
C. Separate the housing halves using bolts as jacking screws in the tapped holes provided in the housing
flanges.

sonnel and/or damage equipment. Use suitable hoisting equipment to stabilize and lift
heavy objects.
D. Using a suitable lifting device, remove the upper housing half. Bearings will remain on the input shaft and
pump drive (output) shafts in the lower housing half. The bearing/seal carrier will remain with the upper
housing half along with seal, O-ring and snap ring.
E. Note the orientation of the seal lip and bearing seal carrier to ensure proper reassembly. Then, remove all
n t
necessary parts from the upper housing. It is normally unnecessary to remove the pump adapters (14) from
the housings in order to disassemble the pump drive transmission.
Y e
m
NL uip ion
O q t
The disassembly method for each pump drive (output) shaft is identical. The following proce-
dure will apply equally to each.
A L f E ra
I o p e
R ce O
F. Remove snap ring and the splined adapter from each end of output shaft.
E t
AT nan en
G. Press against the lower end of the output shaft and remove the shaft with bearings in place on the shaft.
H. Remove the bearings from the shaft using a puller which contacts only the inner race of the bearings.
M te m
E n p
I. Remove the gear spacers and the gear from the shaft.
6.2.3.6 Repair
C a q i u i
E N M E
R o r o r
Clean and inspect all of the pump drive transmission components in accordance with the general cleaning and
f f
inspection procedures described in Appendix A of this manual. Replace all worn or damaged parts. Replace all
gaskets.
FE E
E S S E
R U U
6.2.3.7 Assembly
T T
Assemble the pump drive transmission as follows:
O
N NO
1. Reinstall the bearings on their respective shafts, being careful to press only on the inner race. Be sure the
O
bearings are pressed fully onto the shaft.
D DO
2. Lubricate bearings with light oil and install seal using Loctite Plastic Gasket 54931 on the outer diameter.
Assemble seal carrier with Loctite 609. Grease the seal surface before installing.
3. Install all pump drive shafts in the lower housing half and secure with snap rings.
4. Install all splined adapters and secure with snap rings.
5. Use SAF-T-LOK Silicone Sealant No. 732 to seal the pump drive housing halves and install the upper housing
half on the lower half.
6. Install the locating dowel pins in the housings.

7. Tighten bolts and nuts to 60 ft-lbs (81 Nm), following the bolting sequence illustrated in Figure 6-7.
n t
Y e
m
NL uip ion
O q t
L f E ra
BD0399a01
I A e
Figure 6-7: Bolt Tightening Sequence
R ce O o p
E
8. Reinstall the coupling hub and coupling half on the input shaft as follows:
t
AT nan en
A. Place the sleeve on the input shaft with the flange facing away from the pump drive transmission housing.
M te m
B. Heat the hub to 275°T (135°C) using one of the following methods:
E i n i p
C a q u
1). For oven heating, set the oven thermostat to 275°F (135°C) and heat the hub at least one hour for each
inch of wall thickness. Do not allow the hub teeth to come into contact with the heat source.
E N !r M E
R fo fo r
WARNING
E
F SE E
Use of an open flame in a combustible atmosphere can ignite the atmosphere or cause
E
R U US
an explosion resulting in the injury or death of personnel and damage to equipment. Do
not use an open flame in a combustible atmosphere or near combustible materials.
T T
O
2). For oxy-acetylene or blow torch heating, mark the hub with a 275°T temperature sensitive crayon in
N NO
several places near the teeth. Direct the flame toward the hub bore and keep it in motion while heating
to avoid overheating an area. Do not apply heat directly to the hub teeth. When using an oxy-acetylene
O
D DO
torch, use an excess acetylene mixture.
C. Mount the hub on the shaft as quickly as possible to avoid heat loss. Make certain that the position of the
hub teeth relative to the shaft end is correct before assembling. Line up the bore with the shaft and slide the
hub onto the shaft until the hub face is flush with the end of the shaft.
If it is necessary to drive the hub into position, tap lightly with a soft brass or lead hammer. Do
not strike the hub teeth or pound hard enough to damage bearings.
D. Allow the hub to cool.

Install the pump drive transmission as follows:
1. Using a suitable lifting sling, position the pump drive housing in mount on the power unit base, and secure it
lightly with the mounting capscrews and lockwashers. Do not tighten fully at this time.
2. Install the four dowel pins which accurately position the pump drive housing relative to the two gear box
mounts, then complete tightening of the mounting capscrews.
3. Using a dial indicator, check the alignment of the coupling hubs on the motor shaft and pump drive shaft. Align-
t
ment must be parallel within 0.002" TIR. Always rotate the hub on which the dial indicator is mounted and
n
mount the dial indicator on the most easily rotated hub.
Y e
m
NL uip ion
O q t
The coupling extension will need to be removed from the coupling assembly to enable checking
L f E ra
overall hub-to-hub alignment.
I A o p e
4. Install the coupling extension with two new gaskets, capscrews, lockwashers and locknuts.
ER ce O
t
5. Lubricate the coupling using the lubricant specified in the Lubrication Chart. To do so, fill the front section with
AT nan en
lubricant until an excess appears at an open hole. Plug that hole. Continue with the rear section until lubricant
appears out the rear hole. Plug that hole.
M te m
E n i p
6. Install the coupling guard between the motor and the pump drive housing with capscrews and lockwashers.
C a q i u
N
7. Install the pipe elbow, hex nipple, drain cock, and pipe nipple beneath the pump drive housing.
E r M E
r
8. Confirm alignment in accordance with Subtopic 6.1.2.
R
E E fo f o
F
9. Install the hydraulic pumps. Refer to Subtopic 9.3.2.6.
E S S E
R U U
10. Fill the pump drive with 2 gallons (7.6 liters) of gear oil. Refer to Subtopic 12.2.2.
T T
O
N NO
O
D DO

320XPC-UDC Mechanical Systems Manual Main Air System
Section 7
Main Air System
7.1 Major Component Locations
t
The locations of the major components in the main air system are shown in Figures 7-1 through 7-3.
e n
Y m
03
NL uip ion
01 02
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
10
M te m
11
E i n i p
09
C a q u
E N M E
R o r o r
E E f f
F
A
E
08
E
R U U S S C
B
T T
07
04
06 O
N NO 05 R57827F5_Rev04_sh2
O
D DO
E
D
LEGEND
01. Compressor Air Filter Assembly (2x) 10. Air Inlet Restriction Valve (2x)
02. Main Motor 11. Compressor Oil Stop Solenoid Valve (COSS)
03. Power Unit I/O Cabinet
04. Oil Flow Switch (COFS) Manifold A. T-tank Out Pressure to Control Air Filter/Separator
05. Compressor Oil Filter B. T-tank Scavenge Oil to Scavenger Filter
06. Compressor Air Outlet Temperature Gauge C. Hydraulic Oil from Valve Bank 4 (VB4) to Air Inlet
07. Compressor Air Outlet Temperature Transducer Restriction Valves
(CATT) D. From Oil Cooler to Compressor Oil Flow Switch
08. Scavenger Oil Filter E. Air To T-tank
09. Air Compressor
Figure 7-1: Main Air System Major Components (Power Unit - Typical)

Sec07BailAir.fm -7.1- Section 7, Version 00 - 07/12
Main Air System 320XPC-UDC Mechanical Systems Manual
01
E
03
E
10
02
04
t
D
C
e n
Y m
NL uip ion
05
O q t
11
A L f E ra
I o p e
R ce O
09
E t
AT nan en
06
M te m
E i n i p
C a q u
N
07
E r M E
R fo o r B A
FE E f
E S S E
R U U
T T
O
08
N NO
Components_Air_LHPlatformTop_GDa
LEGEND
O
D DO
01. Main (Bit Air) Butterfly Valve
02. T-tank Dump Valve
10. Left Platform with Cold Weather Oil Cooler
11. Cooler Outlet Temperature Transducer (CCOT)
03. Plugged Bit Relief Valve
04. Water Drain Valve
05. Bit Air Pressure Transducer (BAPT) A. Oil from Cooler to Oil Circulation Flow Switch
06. Muffler B. From Air Compressor Outlet to T-tank Inlet
07. Oil Circulation Pump and Motor C. Air To Mast
08. Oil Cooler Drain Down Valve D. Air Line to Water Tank
09. Left Platform with Standard Oil Cooler E. Pilot Air Line to Dump Valve
Figure 7-2: Main Air System Major Components (Left Platform - Topside Typical)

Section 7, Version 00 - 07/12 -7.2- Sec07BailAir.fm
A
05
01
D B
02
04
nt
03
e
C
Y m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
r r
Components_Air_LHPlatformBottom_GD
LEGEND
R
E E fo
01. 3 PSI Pump By-pass Check Valve
f o A. Pump Output
E F S E
02. 90 PSI Pump Relief Check Valve B. From T in Pump Output Tube to Pump Bypass
S
03. 60 PSI Pump Relief Check Valve Valve
R U U
04. 90 PSI Oil Cooler By-pass Check Valve C. To T-tank
T T
05. Check Valve Manifold D. To Oil Cooler
N O O
N
Figure 7-3: Main Air System Major Components (Left Platform - Bottom Typical)
O
D DO
7.1.1 Subsystems and Components
Table 7-1 is a grouping of the air system components into the subsystems where they are used and is based on the
air system flow diagram shown in Figure 7-4. The air compressor oil circulation subsystem is listed first because
without adequate oil flow, the compressor will not start or run. Refer to the subsection listed in the third column of
the table for operation and repair information for these components. Note that some of the components overlap in
the subsystems.

Component Subsection
Air Compressor Oil Circulation Subsystem Subtopic 7.1.2
T-tank Subtopic 7.1.2.1
T-tank Over-Pressure Relief Valve Subtopic 7.1.2.2
Shut-off Valve and Limit Switch Subtopic 7.1.2.3
Compressor Oil Temperature Transducer (COTT) Subtopic 7.1.2.4
Oil Circulation Pump and Motor
n t Subtopic 7.1.2.5
3 PSI Pump Bypass Check Valve
Y e Subtopic 7.1.2.6
m
NL uip ion
90 PSi and 60 PSI Pump Relief Valves Subtopic 7.1.2.7
Oil Cooler and Fan Motor Subtopic 7.1.2.8
O q t
L f E ra
90 PSI Oil Cooler Relief Valve Subtopic 7.1.2.9
I A o e
Oil Cooler Draindown Valve and Restrictors
p
Subtopic 7.1.2.10
ER ce O
Compressor Oil Cooler Outlet Temperature Transducer (CCOT) Subtopic 7.1.2.11
t
AT nan en
Compressor Oil Flow Switch (COFS) Subtopic 7.1.2.12
Compressor Oil Filters Subtopic 7.1.2.13
M te m
p
Compressor Oil Stop Solenoid Valve Subtopic 7.1.2.14
E
C a q i n u i
Compressor Oil Stop Valve Subtopic 7.1.2.15
N M E
Compressor Oil Pressure Switch (COPS)
E
Subtopic 7.1.2.16
R o r o r
40 PSI Oil Cooler Purge Check Valve Subtopic 7.1.2.17
E E f f
F
Optional Quick Fill System Subtopic 20.3.2
E S S E
Optional Onboard Top Off System Subtopic 20.3.1
R U U 5 PSI Return to Tank Check Valve Subtopic 7.1.2.20
T T
O
N NO
Compressor and Bearings Subtopic 7.1.2.21
Scavenger Oil Subsystem Subtopic 7.1.3
O
D DO
T-tank
Oil Separators
Subtopic 7.1.2.1
Subtopic 7.1.2.1
Scavenger Oil Filter Subtopic 7.1.3.1
Inlet Air Subsystem Subtopic 7.1.4
Air Filters Subtopic 7.1.4.2
Air Filter Indicator and Switch Subtopic 7.1.4.3
Table 7-1: Main Air Subsystems - Gardner Denver

Component Subsection
Compressor Inlet Hydraulic Unloading Subtopic: Station 7: GD Compressor

Control Valve (Station 7 on VB4) Inlet Valve Control Circuit on page
9.105.
Control Air Filter / Separator and Gauge Subtopic 7.1.4.4
Subtractive Pilot Valve, Gauge and Muffler Subtopic 7.1.4.5
Air Compressor Subtopic 7.1.2.21
Discharge (Main) Air Subsystem Subtopic 7.1.5
Main Air Pressure Transducer (MAPT)
n t Subtopic 7.1.5.1
Compressor Air Temperature Transducer (CATT)
Y e Subtopic 7.1.5.3
m
NL uip ion
Compressor Air Temperature Gauge Subtopic 7.1.5.4
T-tank and Oil Separators Subtopic 7.1.2.1
O q t
L f E ra
T-tank Dump Valve Subtopic 7.1.5.5
I
Air Muffler
A o p e
Subtopic 7.1.5.6
ER ce O
80 PSI Plugged Bit Relief Valve Subtopic 7.1.5.7
t
AT nan en
Main Butterfly Valve Subtopic 7.1.5.8
Bit Air Pressure Transducer (BAPT) Subtopic 7.1.5.9
M te m
p
Bit Orifice Subtopic 7.1.5.10
E
C a q i n u i
Table 7-1: Main Air Subsystems - Gardner Denver
E N M E
r
Figure 7-4 is a block diagram of the main air system showing the flow of air and air compressor lubricating oil.
R fo o r
FE E f
E S S E
R U U
T T
O
N NO
O
D DO

n t
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m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
Figure 7-4: Main Air System Flow Diagram

7.1.2 Air Compressor Oil Circulation Subsystem
7.1.2.1 T-Tank
T-tank (07, Figure 7-5) is the common name for the air compressor oil reservoir. It is mounted on the left platform of
the drill. The T-tank is a pressure vessel that serves two primary functions within the main air system:
• "It provides reservoir space for the oil that is circulated through the air compressor for lubrication and cool-
ing.
• "It contains the air-oil separators which remove the oil mist that remains entrained in the air flow after pass-
t
ing through the reservoir section of the T-tank.
e n
Y m
NL uip ion
LEGEND
01
01. Discharge Pipe to Mast
O q t
02. Oil Outlet to Scavenger Filter
03. Inner Oil Separator Element
L f E ra
04. Outer Oil Separator Element 02
I A o e
05. Tank Pressure Relief Valve - Factory Set at 130 PSI (9 Bar)
R ce O p
06. Air Inlet Pipe from Compressor
07. T-tank
08. Outlet - To Muffler
E t
AT nan en
09. Pilot-operated Tank Dump Valve
10. 80 PSI (5.5 Bar) Plugged Bit Relief Valve
M te m
p
10
E n i
03
i
09
C a q u
E N M E 08
R o r o r
f
01
f
04
FE E
E S S E
R U U
T T
O
N NO 07
O
D DO
06
05 T-tank_R72383F2
Figure 7-5: T-tank and Oil Separators

Refer to Figure 7-5. The t-tank assembly includes a shut-off valve with limit switch (see Figure 7-6), a tank over-
pressure relief valve (05), and inlet and discharge piping. The discharge pipe includes an 80 psi (5.5 bar) plugged
bit relief valve (10), a tank dump valve (09) and piping to the muffler. The above components are covered else-
where in this section.
T-tank Operation
The air-oil mixture from the compressor outlet enters the T-tank through the inlet pipe. The air-oil mixture hits the
far wall of the T-tank and due to the velocity change, the heavier droplets of oil drop to the bottom of the T-tank.
This oil is then recirculated through the air compressor cooling and lubrication system. Before being discharged to
the drill string, the air-oil mist passes through the two oil separator assemblies located in the towers at the top of
t
the T-tank.
e n
Some of the larger oil droplets form on the outside of the outer separator which eventually drops to the bottom of
Y m
the T-tank. Some of the remaining oil forms on the inside of the outer separator and drops into the cavity at the bot-
NL uip ion
tom of the outer separator. The remaining air-oil mist passes through the inner separator and goes through the
same process. This provides virtually oil free air to the drill string.
O q t
L f E ra
The oil that is collected inside the two oil separators does not drain into the T-tank. Instead, it is pushed by air pres-
A
sure through the scavenger oil lines and then filtered and returned directly to the air compressor.
I o p e
Maintaining the Air / Oil Separators
ER ce O
t
AT nan en
two test ports (T18 and T19) which can be used to test the pressure differential between the inlet and outlet ports of
M te m
the oil separator. When the differential pressure exceeds 35 psid (2.4 bar), the oil separator elements need to be
E n i p
replaced. As an alternative to testing, the separator element should be replaced every 2000 hours or semi-annu-
ally.
C a q i u
E N M E
r
7.1.2.2 T-tank Over-Pressure Relief Valve
R fo o r
E E f
Refer to Figure 7-5. The T-tank over-pressure relief valve (05) is located on the upper side of the T-tank. It is factory
F E
preset to open if the pressure in the T-tank becomes greater than 130 PSI (9 bar).
Maintenance E
R U U S S
T T
O
Visually inspect the valve on a regular basis. Make sure the discharge port is clear of debris and that there is no
N NO
build up of dirt around the valve. Also check for broken or missing parts. Test the valve every 6-12 months by lifting
up on the hand lever with pressure in the tank. No adjustment required.
O
D DO
7.1.2.3 Shut-off Valve and Limit Switch
Refer to Figure 7-6. The shut-off valve (04) is located on the underside of the T-tank. It is used to isolate system
components during maintenance. A position-sensing limit switch (02) indicates valve position to the AC800 control
system. If the valve is not in the OPEN position, the main motor will not start.
To turn the shut-off valve handle, first pull out the knob (A, Figure 7-6). The knob is attached to a
pin which prevents the handle from turning.

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
A
M te m
E i n i p
C a q u
E N M E
R o r o r
f
LEGEND
01. T-tank
FE E f 03. Compressor Oil Temperature Transducer COTT
E
02. Position-Sensing Limit Switch 04. T-tank Shut-Off Valve (shown in the CLOSED
E S S
position)
R U U
T T
Figure 7-6: Underside of T-tank
O
N NO
7.1.2.4 Compressor Oil Temperature Transducer (COTT)
O
D DO
Refer to Figure 7-6. The compressor oil temperature transducer (03) is located on the underside of the T-tank. This
transducer transmits the T-tank oil temperature to the AC800 control system. The AC800 will start the compressor
oil cooler fan when the oil temperature reaches 170°F (77°C). If the oil temperature exceeds 220°F (104.4°C), the
AC800 will detect an over temperature fault and shut down main motor.
Maintenance
No maintenance required.

7.1.2.5 Oil Circulation Pump and Motor
Refer to Figure 7-7. The oil circulation pump draws oil from the T-tank. Oil is pumped through the oil cooler, main oil
filters, and to the compressor. A portion of the oil flow is directed through the compressor internal passages to the
bearings, gears, and shaft oil seals. The balance of the oil is injected directly into the compression chamber to
remove the heat of compression, seal internal clearances, and to lubricate the rotors.
Oil Circulation Pump Operation
Refer to Figure 7-7. The oil circulation pump assembly includes a 20 horsepower motor (04), coupling, an adapter,
and a gear pump (05) rated at 150 GPM (568 liters per minute). The package mounts horizontally between the
t
machinery house wall and the T-tank (06) on the left hand platform.
e n
Refer to Figure 7-6. With the shut-off valve (04) in the OPEN position and the pump running, oil flows from the T-
Y m
tank (01) through the shut-off valve and tube (03, Figure 7-7) to the pump inlet. If the pump stops, a tee in tube 03
NL uip ion
provides a path for oil to flow to the 3 PSI circulation pump bypass valve (01, Figure 7-3).
O q t
Pump output oil flows through tube (01, Figure 7-7) to the check valve manifold (04, Figure 7-3). If the downstream
L f E ra
pressure is below 90 psi (6.2 bar), oil flow continues through the manifold and tube “D”, Figure 7-3 to the oil cooler.
I A o p e
If the downstream pressure is 90 psi (6.2 bar) or greater due to some problem, the pump relief valves (02 and 03,
R ce O
Figure 7-3) will open and oil will flow through the manifold, relief valve and tube “C” back to the T-tank.
E t
AT nan en
Oil from the circulation pump case drain flows back to the T-tank through hose (02, Figure 7-7).
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

02 05
n t
Y e
m
NL uip ion
01
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
02
M te m 05
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
04
R U U
03 S
T T Pump_OilCirculation
LEGEND O
N NO
O
01. Pump Output Tube 04. Oil Circulation Pump
D DO
02. Pump Drain to T-tank Hose 05. Oil Circulation Pump Motor
03. T-tank to Pump Inlet Tube 06. T-tank
Figure 7-7: Circulation Pump Plumbing
Removing the Circulation Pump and Motor Assembly

This procedure lists the steps necessary to remove the pump and motor as an assembly. For
removal and repair of either the motor or pump, refer to the Subtopic: Repairing the Oil Circula-
tion Pump and Motor on page 7.13.
Remove the pump and motor assembly from the drill as follows:
! WARNING
n t
e
tenance work on a machine without first disabling the operators controls. Lock out and
Y m
tag the operators control to prevent inadvertent machine start-up during maintenance
NL uip ion
work.
O q t
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during pump removal.
A L f E ra
I o p e
ER ce O
t
AT nan en
High pressure hydraulic or air systems can spray with extreme force and noise causing
severe injury. Shut down system and slowly release pressure or vent circuits before
M te m
loosening fittings or connections. Wear appropriate face, ear and body protective
devices while venting air or hydraulic systems.
E i n i p
C a q u
2. Vent any residual air pressure from the T-tank. The T-tank will vent through the main air system muffler when
N M E
the main air compressor is not running and the controls are de-energized.
E
R o r o r
f
3. Close the shut-off valve (04, Figure 7-6) located in the oil discharge piping below the T-tank.
FE E f
E
4. Clean all dirt from the area around the pump and hoses.
E
R U U S S
5. Refer to Figure 7-7. Disconnect the two tubes (01 and 03) and hose (02) from the circulation pump. Remove
T T
and discard the o-rings from the tube and hose ends. For pump replacement or repair, remove the elbow fitting
O
for the pump drain hose (02) from the pump. Cap or plug the fittings and pump ports to prevent the entry of
N NO !
contaminants.
O
D D O WARNING
Hazardous voltage can cause burns, injury, or death. Disconnect, lock out, and tag the
power source which feeds this device to prevent power from being applied while inspec-
tion and repairs are being performed. Before beginning repairs, try the operational con-
trols to verify that the intended power source is disconnected.
6. Tag and disconnect the wires from the motor junction box.

! WARNING
Lifting heavy components with inadequate hoisting apparatus can cause the load to
drop, resulting in personal injury and/or damage to equipment. Use suitable slings and
hoisting equipment to stabilize and lift heavy objects. The pump and motor assembly
weighs approximately 320 lbs (145 kg).
7. Properly support the pump and motor assembly with a suitable lifting device.
8. Remove the four flange-head capscrews from the pump motor feet and use a suitable lifting device to remove
t
the pump assembly.
e n
9. Tag and remove the hose adapters and pipe fittings from the pump ports.
Y m
NL uip ion
Repairing the Oil Circulation Pump and Motor
O q t
To disassemble the pump, motor adapter and motor assembly, refer to Figure 7-8 and proceed as follows:
A L f E ra
I o e
1. Remove the cover on the bottom of the motor adapter (03).
R ce O p
E
2. Through the access hole in the adapter, loosen the two set screws on the coupling (02).
t
AT nan en
3. Remove the four capscrews and slide the pump shaft out of the coupling hub (08) and remove the pump (04)
from the motor adapter (02).
M te m
E i n i p
4. Remove the four capscrews to remove the adapter from the motor.
C a q u
E N M E
R o r o r
E E f f
Refer to Figure 7-8. Two different styles of couplings are used to connect the motor and pump:
F E
Style “A” coupling uses a grid as the flexible joint between the two hubs and includes an outer
E S S
cover with a grease plug for lubricating the coupling. Style “B” coupling uses a flexible insert
R U U
between the two hubs and it does not require lubrication. Both styles have a setscrew in each
T T
hub to lock the hub to the shaft.
O
N NO
5. Disassemble the coupling and inspect it for signs of misalignment and wear. Replace parts as necessary.
O
D DO

LEGEND
04
01. 20 HP, Electric Motor
02. Coupling
03 03. Adapter
04. Gear Pump
05. Lube Plug
02 06. Capscrew and Nut (4 required)
07. Grid
01 08. Hub w/Setscrew (2 required)
t
09. Gasket (2 required)
n
10. Seal (2 required)
e
11. Cover (2 required)
Y m
05 12. Flexible Insert
NL uip ion
A Style A - Coupling with Grid
06 B Style B - Coupling with Insert
O q t
A L f E ra 07
11
I o p e
E R ce O 12
08
t
10
AT nan en
M te m 08
E i
09
n i p
C a q u
N
R56963
E StyleM E
BD1208a01
R fo for A
r Style B OR
E
F SE E
E
R U US
Figure 7-8: Pump and Motor Disassembly
T T
Cleaning, Inspection and Repair
O
N NO
Clean and inspect the oil circulation pump and coupling in accordance with the general cleaning and inspection
procedures described in Section A of this manual.
O
D DO
Inspect the pump for wear, housing cracks and leaks. Repair of the pump is limited to replacing worn seals and o-
rings. Refer to Figure 7-9 and replace parts as necessary. If any cracks are found or the pump is worn, replace the
pump.

LEGEND
01. Capscrew (8)
02. Washer (8)
03. Seal Kit (Refer to your LinkOne
Parts Manual)
04. Seal
05. Retaining Ring
06. Seal
07. O-ring
t
8. Seal (2 required)
e n
Y m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E n i p
Figure 7-9: Pump Repair
C a q i u
N
Assembling the Pump and Motor
E r M E
R o r
To assemble the pump, motor adapter and electric motor, refer to Figure 7-9 and proceed as follows:
E E f f o
E F S E
R U U S
Refer to Figure 7-8. Two different styles of couplings are used to connect the motor and pump:
T T
Style “A” coupling uses a grid as the flexible joint between the two hubs and includes an outer
O
N NO
cover with a grease plug for lubricating the coupling. Style “B” coupling uses a flexible insert
between the two hubs and it does not require lubrication. Both styles have a setscrew in each
O
hub to lock the hub to the shaft.
D DO
Assembling the Pump and Motor with “Style A” Coupling
The maximum distance between hubs for the grid-type coupling is 0.125 in. (3 mm). Pack the
gaps and grooves on the hubs with EP grease before installing the grid and again after the grid
is installed. Tighten to cover socket-head screws to 100 lb-in (11.3 Nm).
1. Assemble the coupling as shown in Figure 7-8 and in accordance with the above note. Install the coupling on
the motor shaft and tighten the set screw to secure the coupling on the shaft.

2. Install the adapter (03) on the motor (01) and secure it with the four capscrews removed during disassembly.
3. Align the pump shaft with the coupling hub (08) bore and install the pump (04) on the adapter (03). Secure the
pump to the adapter with the four capscrews removed during disassembly.
4. Through the access hole in the adapter, tighten the set screw to secure the coupling on the pump shaft.
5. Install the cover on the bottom of the adapter (03).
Assembling the Pump and Motor with “Style B” Coupling
1. Install one coupling hub (08) on the motor shaft and the other hub on the pump shaft. Do not tighten the set
screws at this time.
n t
Y e
2. Install the adapter (03) on the motor (01) and secure it with the four capscrews removed during disassembly.
m
NL uip ion
3. Position the flexible insert (12) on the motor hub half of the coupling.
O q t
4. Install the pump (04) on the motor adapter (03) while making sure the flexible coupling is in place on the motor-
L f E ra
half hub of the coupling. Secure the pump to the adapter with the four capscrews removed during disassembly.
A
I o p e
R ce O
5. Through the access hole in the adapter, move the two coupling hubs together with the insert teeth aligned to
E
the hubs and then tighten the two set screws on the coupling hubs.
t
AT nan en
6. Install the cover on the bottom of the motor adapter (03).
M te m
p
Installing the Pump and Motor Assembly
E
C a q i n u i
Refer to Figure 7-7. Install the oil circulation pump assembly as follows:
E N M E
r r
1. If the pump drain hose (02) fitting was removed, coat the male pipe threads on the fitting with pipe thread seal-
R fo o
ant and install the fitting on the pump. Position the fitting for ease of connection to the hose.
E E ! WARNINGf
E F S E
R U U S
T T
O
N NO
hoisting equipment to stabilize and lift heavy objects. The pump and motor assembly
O
D DO
2. Use a suitable lifting device to support the pump and motor assembly and position it on the left platform. Install
the pump assembly on the left platform and secure with the four flange-head capscrews removed during pump
and motor assembly removal.
3. Install new, well-lubricated o-rings on the tube ends and connect the suction and pressure tubes to the pump.
4. Connect the wires to the motor.
5. Open the shut-off valve located in the oil discharge piping below the T-tank.
6. Check the oil level in the T-tank. Add oil as necessary.

7. Operate the system and check for leaks. Also check pump rotation (the pump must turn counter-clockwise
when viewed from the motor fan). The circulation pump is non-adjustable.
7.1.2.6 3 PSI Pump Bypass Check Valve
The 3 psi (0.2 bar) check valve (01, Figure 7-3) provides a path for oil through the circulation lines should the pump
become inoperative. If removed, make sure the valve is installed with the flow arrow pointing in the proper direc-
tion.
7.1.2.7 90 PSI and 60 PSI Pump Relief Valves
t
The 90 psi check valve (Item 02, Figure 7-3) provides pump relief back to the tank in the event of excessive system
n
pressure. The 60 psi check valve (Item 03, Figure 7-3) also provides pump relief back to the tank in the event of
e
excessive system pressure. If either valve is removed, make sure the valve is installed with the flow arrow pointing
Y m
in the proper direction.
7.1.2.8 Oil Cooler

NL uip ion
O q t
L f E ra
The compressor oil cooler (04, Figure 7-10) (also see 09 or 10, Figure 7-2) is mounted on the left front of the drill.
A
I o e
Oil from the compressor is cooled by a fan drawing air through cooling fins on the cooler. The fan is driven by an
R ce O p
electric motor (06, Figure 7-10). The electric motor speed is controlled by a variable frequency drive (VFD) located
E
in the MCC cabinet.
t
AT nan en
The VFD is enabled when the cooler outlet oil temperature exceeds 100 °F (38 °C). The temperature is based on
the output signal at the compressor cooler outlet temperature transducer (CCOT) which is located on the top of the
M te m
oil cooler (02, Figure 7-10). The drive will vary the fan speed to maintain a cooler outlet oil temperature of 135 +/- 5
E i n i p
°F (57 +/- 3 °C) up to 60 Hz drive frequency. The fan motor will be disabled if the cooler outlet oil temperature drops
C a q u
below 100 °F (38 °C).
E N M E
R o r o r
f f
01 02 03
E E
LEGEND
A
F E
01. Pressure Tap T511 - Cooler Outlet Pres-
07
E S
sure
R U U S 02. Compressor Cooler Outlet Temperature

Transducer (CCOT)
T T
03. Reference - Pressure Tap T501 (Aux Hyd
O
N NO
06 System)
04. Oil Cooler
05. LH Platform
O
B
D DO
06. Electric Motor
07. Grill
A. Hose “A” - Compressor Cooler Outlet

04 B. Hose “B” - Aux Hyd Cooler Outlet
C. Hose “C” - Compressor Oil Return from
Cooler
D. Hose “D” - From Aux Valve Banks to Oil
E Cooler
E. Hose “E” - From Oil Cooler to Hyd Tank
F. Hose “F” - Oil Cooler Purge to T-tank
D
05
C R68400F1
Figure 7-10: Cold Weather Oil Cooler

7.1.2.9 Oil Cooler Relief Valve
The 90 psi check valve (Item 04, Figure 7-3) provides circulation oil flow if the cooler circuit becomes inoperative.
7.1.2.10 Oil Cooler Drain Down Valve
The oil cooler drain down valve (08, Figure 7-2) allows the oil level in the cooler to drain down to the same height
as the oil level in the T-tank when the oil circulation pump off. When the circulation pump is running, oil pressure
will shift the valve to block flow from the cooler inlet to the T-tank. No adjustments required.
7.1.2.11 Compressor Cooler Outlet Temperature Transducer (CCOT)
n t
This sensor transmits the temperature of the oil at the outlet of the cooler to the PLC. After main motor start, the
e
cooler fan motor VFD will be enabled when the outlet oil temperature exceeds 100 °F (37.7 °C). The cooler outlet
Y m
NL uip ion
oil temperature is used to control the speed of the cooler fan motor. The fan speed will be varied to maintain a
cooler outlet temperature of 135 +/- 5 °F (57 +/- 2.8 °C). After the fan motor drive is enable, it will not be disabled
until the outlet oil temperature drops below 100 °F (37.7 °C).
O q t
7.1.2.12 Compressor Oil Flow Switch (COFS)
A L f E ra
I o p e
R ce O
The compressor oil flow switch COFS is located on the left side of the main compressor (see 04, Figure 7-1). It
E
confirms flow through the system. If oil circulation flow stops, the compressor will shut down.
t
AT nan en
7.1.2.13 Compressor Oil Filters
M te m
Refer to Subtopic 3.8.11.1 in Section 3.
E i n i p
C a q u
7.1.2.14 Compressor Oil Stop Solenoid (COSS)
E N M E
r r
The compressor oil stop solenoid (COSS) valve (see 09, Figure 7-1) controls the oil stop valve. When the main
R fo o
motor contactor is closed, this valve is energized and it allows oil to flow to the oil stop valve pilot port to open the
E E f
oil stop valve. This valve will remain energized until five seconds after the main motor contactor is opened.
E F S E
S
7.1.2.15 Compressor Oil Stop Valve
R U U
T T
The oil stop valve is a two-position, piloted valve that normally blocks oil flow to the compressor. When piloted to
O
N NO
the open position, either by the compressor oil stop valve control or by air pressure from the compressor when it is
running, it allows oil to circulate through the compressor.
O
D DO
7.1.2.16 Compressor Oil Pressure Switch (COPS)
The compressor oil pressure switch (COPS) (see 04, Figure 7-13) informs the PLC if the compressor oil pressure
drops below 8 psi (0.6 bar). Set this switch to 15 psi (1.0 bar) rising pressure and 8 psi (0.6 bar) falling pressure.
7.1.2.17 40 PSI Oil Cooler Purge Check Valve
The oil cooler purge check valve is used to purge oil from the oil cooler before main motor startup. With the circula-
tion pump running, main motor off and the oil stop valve closed, the pressure at the oil filter outlet is about 150 psi
(10.3 bar). This pressure is sufficient to open the 40 psi (2.8 bar) and 5 psi (0.3 bar) series check valves because
the compressor is not making air, and therefore, there is no pressure in the T-tank. This allows the oil in the cooler
to flow back into the T-tank. In cold weather, this allows warmed T-tank oil to fill the oil cooler and then return to the
T-tank before starting the main motor.

After main motor start, the oil stop valve opens and the pressure in the T-tank is sufficient to close the series check
valve to prevent flow during normal operation.
7.1.2.18 Optional Quick Fill System
For descriptive and operational information for this system, please refer to Subtopic 20.3.2.
7.1.2.19 Optional Onboard Top Off System
For descriptive and operational information for this system, please refer to Subtopic 20.3.1.
t
7.1.2.20 Return to Tank Check Valve
e n
The 5 psi (0.3 bar) return to tank check valve (Item 03, Figure 7-11) prevents oil from being siphoned from the T-
Y m
NL uip ion
tank back into the top off tank and/or compressor.
O q t
L f E ra
01
LEGEND
I A e
01. T-Tank
o
02
p
02. Muffler
ER ce O 03. 5-PSI Return to Tank Check Valve
t
04. Grill
03
AT nan en A. Hose “A” - Compressor Cooler Outlet
M te m
B. Hose “B” - Aux Hyd Cooler Outlet
p
C. Hose “C” - Compressor Oil Return from
E
C a q i n u i
Cooler
D. Hose “D” - From Aux Valve Banks to Oil
N M E
Cooler
E r
E. Hose “E” - From Oil Cooler to Hyd Tank
R fo o r F. Hose “F” - Oil Cooler Purge to T-tank
FE E f
E S S E
R U U
T T
O
N NO
O
D DO
CheckValve_5psi_TopOff
Figure 7-11: Return to Tank Check Valve
7.1.2.21 Compressor and Bearings
Refer to Figure 7-1. The main air compressor (07) is a single-stage, positive-displacement oil-flooded, rotary screw
compressor using two meshing helical rotors to effect compression. The compressor is protected against dust con-
tamination by a pair of two-stage air filters (01), which are attached to the air inlet restriction valves (08). The com-
pressor is ported to accept an external, re-circulating supply of oil for cooling and lubrication.

Air Flow
Air enters the compressor after first passing through the main compressor air cleaners and the air inlet restriction
valves. After compression, the air/oil mixture passes into the oil reservoir in the bottom of the T-tank, where most of
the entrained oil is removed by velocity change and impingement. The air and any remaining oil -- now a mist --
then pass through the oil separators in the two towers of the T-tank; the separated oil is returned to the system
through tubing connecting the separator to the compressor. The air passes through the T-tank discharge manifold
and bailing air control (butterfly) valve.
Lubrication, Cooling, And Sealing
t
An oil circulation pump draws oil from the oil reservoir. Oil is pumped through the oil cooler, main oil filters, and dis-
n
charges into the main oil gallery of the compressor. A portion of the oil flow is directed through internal passages to
e
the bearings, gears, and shaft oil seal. The balance of the oil is injected directly into the compression chamber to
Y m
remove heat of compression, seal internal clearances, and to lubricate the rotors. The oil flowing to the bearings is
NL uip ion
filtered by an additional spin-on filter located on the motor-end face of the compressor.
Replacing the Main Compressor Bearing Oil Filter

O q t
A L f E ra
I e
Refer to Subtopic 3.9.13 in Section 3.
R ce O o p
E
Replacing the Main Compressor Oil Filter
A
Refer to Subtopic 3.8.11.1 in Section 3.
T an nt
7.1.3 Scavenger Oil Subsystem M ten me
E i n i p
C a q u
Oil recovered from the T-tank oil separators returns to the compressor through the scavenger lines.
E N M E
7.1.3.1 Scavenger Oil Filter
R o r o r
E E f f
Scavenger oil is filtered by a spin-on filter (06, Figure 7-1) located on the air control panel. This filter cleans oil
F S E
scavenged from the two oil separator elements. To replace the filter, refer to Subtopic 3.11.5 in Section 3.
E
R U U
7.1.4 Air Intake Subsystem S
T T
7.1.4.1 General
O
N NO
O
Refer to air flow diagram shown in Figure 7-4. Also, refer to the air schematic (available in LinkOne) and the
D DO
LinkOne parts manual for component part numbers, names and locations.
Air from atmosphere is filtered through two dual-stage air cleaners prior to entering the compressor. The inlet
restriction valves are closed at main motor start and modulate during operation.

7.1.4.2 Main Compressor Air Cleaners
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
Figure 7-12: Main Compressor Air Cleaner - Gardner Denver
t
AT nan en
Refer to Figure 7-12. An air cleaner assembly is installed ahead of the air intake restriction valves to filter the air
M te m
entering the compressor. Refer to Subsection 3.8.9 for additional information and maintenance details.
7.1.4.3 Filter Monitor

E i n i p
C a q u
N M E
Refer to Figure 7-13. A filter monitor (02) is plumbed between the air cleaner (01) and the inlet restriction valves
E r r
(02). The monitor sends a signal to the PLC when a filter needs to be changed.
R
E E fo f o
E F S E
R U U S
T T
O
N NO
O
D DO

01
03
05
04
n t 02
Y e
m
NL uip ion
O q t
A L f E ra Compressor_GD_RtSideView
I o p e
R ce O
LEGEND
01. Air Cleaner Assembly (x2)) 04. Compressor Oil Pressure Switch (COPS)
02. Air Filter Condition Monitor
E t
05. Compressor Inlet Pressure Switch (CIPS)
AT nan en
03. Air Inlet Restriction Valve (x2)
M te m
Figure 7-13: Compressor Right Side
E i n i p
C a q
7.1.4.4 Control Air Filter / Separator
u
E N M E
r r
The control air filter (01, Figure 7-14) removes moisture from the air before the air is used for controlling the air
R
intake restriction valves.
E E fo f o
F E
7.1.4.5 Subtractive Pilot Valve and Gauge
E S
R U U S
The subtractive pilot valve (09, Figure 7-14) controls the air pressure used to close the compressor inlet restriction
T T
valves. To adjust the valve, make sure the main motor is running and the bit air butterfly valve is closed. Adjust the
O O
valve to give a pressure of 65 psi (4.5 bar) on pressure gauge 34A (10, Figure 7-14) or pressure test port T16 (11,
N
Figure 7-14).
N System
O
D DO
7.1.5 Air Compressor Discharge
7.1.5.1 Main Air Pressure Transducer (MAPT)
The main air pressure transducer (MAPT) (see 07, Figure 7-14) measures the compressor outlet air pressure and
indicates to the PLC that sufficient air pressure exists for using the bailing air system.

7.1.5.2 Filter Monitor
n t
Y e
m
NL uip ion
01
02
O q t
03
L f E ra
PowerUnit_GD_LtFrtView
I A o
15
p e
ER ce O
t
AT nan en
04
14
M te m
E i n i p
C a q u
13 07
E N M E
12
R o r o r
E E f f 11
E F S E
05
R U U S
T T
10
09 06
O
N NO
08 07
R57827F5_Rev04_Detail
LEGEND O
D DO
01. Control Air Filter / Separator 09. Scavenger Oil Filter
02. $5 PSI (0.3 Bar) COSS Inlet Check Valve 010.Subtractive Pilot Valve
03. Compressor Oil Stop Solenoid Valve (COSS) 11. Gauge - Subtractive Pilot Valve Inlet Pressure
04. Pressure Test Port T18 12. Pressure Test Port T16
05. Compressor Oil Flow Switch (COFS) 13. Gauge - Subtractive Pilot Valve Outlet Pressure
06. Pressure Test Port T25 14. Pressure Test Port T17
07. 5 PSI (0.3 Bar) COSS Check Valve 15. Compressor Oil Filter Indicator
08. Main Air Pressure Transducer (MAPT) 16. Pressure Test Port T25
Figure 7-14: Compressor Left Side Detail

7.1.5.3 Compressor Air Temperature Transducer (CATT)
The compressor air temperature transducer (CATT) (see 07, Figure 7-1) measures the compressor outlet air tem-
perature and relays this information to the PLC. The PLC will cause a compressor over temperature fault if the tem-
perature exceeds 220 °F (104.4 °C). This will shut down the main motor. Normal operating temperature is
approximately 180 °F (82 °C).
7.1.5.4 Compressor Air Temperature Gauge
The compressor air temperature gauge (06, Figure 7-1) shows the compressor outlet air temperature. Normal
operating temperature is approximately 180 °F (82 °C).
7.1.5.5 T-tank Dump Valve

n t
Y e
m
NL uip ion
The T-tank dump valve (02, Figure 7-2) is a normally open, pressurize to close check valve. When pressure from
the main air system acts on the valve, the valve closes. When the pressure is removed, the valve opens to allow air
to exhaust without going through the drill string.
O q t
L f E ra
With the compressor running and the main butterfly valve closed, approximately 800 SCFM of air at 65 psi is
I A e
exhausted to atmosphere through the dump valve and muffler. With the butterfly valve open, air pressure closes
R ce O
the dump valve which blocks the air flow.
o p
E t
AT nan en
7.1.5.6 Air Muffler
M te m
The air muffler (06, Figure 7-2) is used to help silence the load noise from the air being discharged to atmosphere
when the dump valve opens.
E i n i p
C a q
7.1.5.7 Plugged Bit Relief Valve
u
E N M E
r r
The plugged bit valve (03, Figure 7-2) is preset to 80 psi (5.5 bar). No adjustments necessary.
R
E E fo
7.1.5.8 Main Butterfly Valve
f o
E F S E
S
The main butterfly valve (01, Figure 7-2), which is sometimes referred to as the bit air valve, is an electric motor
R U U
controlled butterfly valve that allows or blocks air to the bit. The T-tank pressure must be at least 40 psi (2.8 bar)
T T
before the valve will open. No adjustments necessary.
O
N NO
7.1.5.9 Bit Air Pressure Transducer (BAPT)
O
D DO
The bit air pressure transducer (05, Figure 7-2) is mounted on the air pipe going to the mast. Sensing after the but-
terfly valve, it indicates to the PLC the pressure of air going to the bit. No adjustments necessary.
7.1.5.10 Bit Orifice
The bit orifice is amount of restriction determined by the air hole openings in the drill bit.

320XPC-UDC Mechanical Systems Manual Water Injection System
Section 8
Water Injection System
8.1 Theory of Operation
8.1.1 General
n t
Y e
Refer to Figure 8-1. The water injection system injects a metered amount of water to the bit air to help control dust
m
NL uip ion
from drilling operations. The water flow is regulated and monitored by a control potentiometer and flow meter in the
operator’s cab. The system consists of a 1000 gallon (3785 liter) water tank (11), motor-driven pump (12), check
O q t
valve (13), orifice (14), water flow transducer (01), water dump valve (02), butterfly valve (04), bit air pressure
L f E ra
transducer (06), relief valve (07), tank dump valve (09), muffler (08), and related lines and fittings.
I A o p e
ER ce O
t
AT nan en
The water injection system should not normally be operated in sub-freezing ambient conditions.
M te m
The motor, pump and check valve assembly (04 and 05), orifice (02), manual drain valve, and water level float
p
switch are mounted in or on the water tank.
E
C a q i n u i
Water from the pump flows through the water flow transducer (01) is discharged through the relief valve, which is
N M E
factory preset at 55 psi (3.8 bar).
E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

Sec08Water.fm -8.1- Section 8, Version 00 - 07/12
Water Injection System 320XPC-UDC Mechanical Systems Manual
01 02 03
18
04
t
05
e n
Y m
NL uip ion
O q t
17
L f E ra
16
06
I A o p e
ER ce O 15
07
t
14
AT nan en 09
M te m
08
E i n i p
C a q u
N
13
E r M E
r
10
R
E E fo f o
12
11 BD1252a02
E F S E
R U U S Figure 8-1: Water Injection System
T T
Ref. # O
N NO
Circled # Triangled # Description
O
D DO
01 40 n/a 1000 Gal. (3800 L) Water Tank
02 44 28 0.0125 Diameter Bleed Down Orifice
03 42 29 Water Injection Flow Transducer (WFT)
04 n/a n/a Check Valves (Part of Pump, Item 05)
05 39 27 Submersible Motor and Pump: 0-10 GPM (0-38 LPM), 110 PSI
(7.6 Bar)
06 n/a n/a Pressure Tap T512
07 3, 4 21 Oil Separators
Table 8-1: Schematic References

Section 8, Version 00 - 07/12 -8.2- Sec08Water.fm
Ref. # Circled # Triangled # Description
08 13 22 Plugged Bit Relief Valve: 80 PSI (5.5 Bar)
09 2 n/a Dual Tower T-tank
10 21 20 Air Piloted Tank Dump Valve
11 n/a n/a To Air Compressor Oil Circulation System
12 20 n/a Muffler
13 23 n/a Water Drain Valve
t
14 n/a n/a Bit Orifice
15 10B n/a
e n
Bit Air Pressure Transducer (BAPT)
Y m
NL uip ion
16 22 19 Main Air Butterfly Valve
17 n/a n/a Pressure Tap T513
18 41 n/a
O q t
Water Level Sensor
A L f E ra
I o e
Table 8-1: Schematic References
R ce O p
Refer to Figure 8-1. The water injection system injects a metered amount of water to the bit air to help control dust
E t
AT nan en
from drilling operations. The water flow is regulated and monitored by a control potentiometer and flow meter in the
operator’s cab. The system consists of a 1000 gallon (3785 liter) water tank (11), motor-driven pump (12), check
valve (13), orifice (14), water flow transducer (01), water dump valve (02), butterfly valve (04), bit air pressure
M te m
transducer (06), relief valve (07), tank dump valve (09), muffler (08), and related lines and fittings.
E i n i p
C a q u
E N M E
R o r r
The water injection system should not normally be operated in sub-freezing ambient conditions.
o
E E f f
F
The motor, pump and check valve assembly (12 and 13), orifice (14), manual drain valve, and water level float
E S E
switch are mounted in or on the water tank.
S
R U U
Water from the pump flows through the water flow transducer (01) and is discharged through the relief valve, which
T T
is factory preset at 55 psi (3.8 bar).
O
N NO
O
D DO

A level switch is mounted inside the water tank.
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
BD1252a02
E E f f
E F S E
S
Figure 8-2: Level Switch
R U U
T T
The GUI in the operator’s cab indicates the level of water in the tank as well as the flow rate to the bit. Refer to Fig-
O
ure 8-3.
N NO
O
D DO

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
BD1136b01
M te m
Figure 8-3: Water Level Indicators
E i n i p
The water pump is operated from the cab by turning the water injection switch ON. Water flow is adjusted with the
C a q
flow control knob (03, Figure 8-4).
u
E N M E
R o r o r
E E
01
f f 02
03 04
LEGEND
F E
01. Bit Lube Switch (Optional)
E S
05
S
02. Spare Switch
R U U
03. Water Flow Adjust Control
04. Water Injection LED
T T 05. Water Injection Switch
O
N NO
MARCHE
ARRET
MARCHE
ARRET
06. Cup Holder (Ref.)
TREPAN D‘EAU
LUBRICATION INJECTION
O
D DO
06
TC0631c
Figure 8-4: Lower Left Control Panel
For the water injection pump to operate, bit air must be ON, bit air pressure must be at least 15 psi, the tank level
must be above empty, and the drill must be in drill or hoist mode.

8.2 Water Injection System Components
n t
Y e
m
SECTION A-A
NL uip ion
A
A
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
B
M te m
B
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
SECTION B-B
F8070
BD1252a02
Figure 8-5: Water Tank and Components

8.2.1 1000 Gallon Water Tank R33238F3
Never weld on the water tank. The tank is lined with epoxy on the inside. Epoxy will burn,
causing corrosion on the inside of the tank.
The water tank is mounted on the left-hand platform. It is a steel tank, lined with epoxy on the inside, and is heated
(where required) and insulated. The tank holds the pump and motor assembly and associated components.
8.2.1.1 Installation and Removal

n t
Y e
L ip nm
The tank is mounted to the left-hand platform by 12 hex head capscrews, nuts and washers. Torque fasteners as
N
indicated in Table 3-1 in Section 3 of this manual.
O qu tio
L f E ra
8.2.2 Submersible Water Pump 37U152D3
I A o p e
The submersible water pump has an integral sealed electric motor, check valve and suction screen. The unit is not
R ce O
field repairable and must be replaced as an assembly if failure occurs.
E t
AT nan en
The pump rests in a 15° angle support cradle at the bottom of the tank. The angle provides drainage when the tank
is emptied to prevent trapped water from freezing and damaging the water pump. The water pump can produce 10
M te m
gpm (37.9 lpm).
E i n i p
C a q u
8.2.2.1 Removal
E N M E
R o r o r
E E f f
! WARNING
E F S E
R U U S
Hazardous voltage can cause burns, injury, or death. Disconnect, lock open, and tag the
T T
O
N NO
O
1. Disconnect, lock open, and tag the power source which feeds the system to prevent power from being applied
D DO
while service is being performed.
2. Tag and disconnect the wiring to the pump at the electrical junction box on the top of the tank.
3. Disconnect the water discharge hose from the access cover on the tank.
4. Pull the lock pins that secure the access cover to the tank.
! WARNING
Some blasthole drill components are extremely heavy. Dropping or mishandling of these
parts can cause severe personal injury or death, and damage to the equipment. Always

support heavy components using a suitable hoist or other means for removal, disassem-
bly, assembly and installation. Provide appropriate support for any components which
are not supported by the machinery during any maintenance.
5. Attach a suitable hoist to the lifting chains attached to the access cover. Lift the cover, pump and related hose,
valve, cradle, frame and fittings from the tank, tanking care not to damage parts in the process.
6. Remove the hose, electrical wiring and fittings from the pump. Use these parts to install the new pump.
7. Remove the pump caps and pump.
t
8.2.2.2 Repair
e n
Clean and inspect parts as specified in Appendix A. Replace deteriorated hose, gasket and wiring.
Y m
NL uip ion

O q t
A L f E ra
I o e
1. Install the new pump on the cradle with the pump caps. Be sure that the check valve is pointed straight up
R ce O p
before locking the pump in the cradle.
E t
AT nan en
2. Install the hose, electrical wiring and fittings on the pump. Use pipe thread sealant in threaded fittings.
M te m
3. Attach a suitable hoist to the lifting chains attached to the access cover. Lower the cover, pump and related
hose, valve, cradle, frame and fittings into the tank, tanking care not to damage parts in the process.
E i n i p
C a q u
4. Position the access cover on the tank. Use a new cover gasket if necessary.
E N M E
r
5. Install the lock pins to secure the cover.
R fo o r
E E f
6. Connect the water discharge hose to the access cover.
F
E S S E
7. Connect the wiring to the pump at the electrical junction box on the tank.
R U U
T T
8. Operate the system to verify proper operation.
O
N NO
O
D DO

8.2.3 Pressure Relief Valve R12410D1
01
02
03
n t
Y e
m
NL uip ion
04
O q t
A L f E ra 05
I o p e
R ce O
06
E
07
t
AT nan en BD0550a01
M te m
LEGEND 04. Outlet Port
E i n
01. Cap
i p 05. Poppet
C a q u
02. Spring 06. Valve Body
N M E
03. Locknut 07. Inlet Port
RE o r r
f o
Figure 8-6: Pressure Relief Valve
FE E f
E S S E
R U U
T T
O
N NO
O
D DO

8.2.3.1 Replacement
Pressurized water systems can spray with extreme force, causing severe injury. Shut
down the system and slowly release pressure or vent circuits before loosening any fit-
tings or connections. Wear appropriate face, ear and body protective devices while vent-
ing pressurized water systems.Inadvertent operation of the blasthole drill during
t
maintenance could cause severe bodily injury and/ or death. Lockout and tagout the drill
operating controls to prevent accidental operation.
e n
Y m
NL uip ion
1. Lockout and tagout the drill operating controls to prevent inadvertent start-up of the drill during maintenance
activities.
O q t
2. Disconnect the water discharge hose from the access cover on the tank.
A L f E ra
I o e
3. Pull the lock pins that secure right side of the access cover to the tank. Swing the cover open.
R ce O p
E
4. Remove the pressure relief valve and close nipple.
t
AT nan en
5. Check the pressure setting of the relief valve or its replacement on a test stand. The correct relief pressure set-
ting is 80 psi (5.5 bar). Adjust as necessary. If a test stand is not available, check and adjust as specified in
M te m
topic, Relief Valve Adjustment.
E i n i p
C a q u
6. Install the relief valve and nipple.
E N M E
r
7. Close and secure the tank cover. Connect the water discharge hose.
R fo o r
FE E f
E S S E
R U U
T T
O
N NO
O
D DO

8.2.3.2 Adjustment
07 08 07 09 10 LEGEND
01. Pressure Relief Valve
02. Water Tank Access Cover
03. Reducer, 1.00" - .50"
06 04. Pressure Gauge 0 - 150 psi
(0-10 bar)
05. Reducer .50" - .25"
05 06. ½" Valve
07. ½" Nipple
t
08. ½" Elbow
n
04
09. Hose Clamp
e
10. Drain Hose
Y m
NL uip ion
07
03
O q t
02
A L f E ra
I o p e
01
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
N
BD0551a01
E r M E
R o r
Figure 8-7: Relief Valve Adjustment
E E f f o
F
The pressure relief valve is set to 55 psi (3.8 bar). The valve can be adjusted on a test stand or using a setup simi-
E S E
lar to the one shown in Figure 8-7. To adjust the valve on the drill, proceed as follows:
S
R U U
1. Lock and tag out the drill and relieve pressure. Open the tank cover as described under Subtopic 8.2.3.1.
T T
O
N NO
2. Assemble test components as shown in Figure 8-7.
3. Remove the elbow from the cover and install the test equipment. Place the free end of the hose in the tank,
O
D DO
open the test valve.
4. Turn ON the water injection system switch to start the water pump. Adjust water flow with the control potenti-
ometer.
5. When water is flowing through the test equipment and back into the tank, partially close the test valve until the
pressure gauge reads 80 psi (5.5 bar).
6. Confirm that the valve starts to vent at 80 psi (5.5 bar). Tighten the locknut after adjustment to retain the set-
ting.
7. Check the pressure setting by opening and partially closing the test valve several times to be sure that the
relief valve continues to vent at the setting.

8. Shut down the water injection system.
9. Remove the test equipment from the tank.
10. Remove the jumper from the MAPS.
8.3 Sensing Components

The sensing components such as the level switches, flow sensor and two-way valve should be inspected in place
t
before service. If these parts do not function, check the electrical connections and lines to other electrical parts
n
before replacement. Replace any faulty parts. The location and method of installation are shown on the applicable
e
exploded view illustrations. After replacement check all joints and connections for security.
Y m
NL uip ion
8.4 Troubleshooting
O q t
A L f E ra
I o e
The following table provides general troubleshooting information on the water injection system.
R ce O p
E
Problem Possible Cause Remedy
t
AT nan en
Pump does not run. No water in tank Check if tank empty light (red) is
on. Add water to tank as required
M te m Bit air off Turn on bit air
E i n i p
C a q u
Drill in propel mode Place drill in hoist or drill mode
E N M E
Insufficient bit air pressure Investigate cause of low bit air
r r
pressure. Correct deficiency
R
E E fo f o No power to pump Check power and control circuits
F
to pump. Correct deficiency
E S S E Faulty bit air pressure transducer Check pressure transducer and
R U U (BAPT) replace if faulty
T T Faulty pump or pump motor Replace pump or motor
O
N NO
Pump runs erratically Faulty relief valve Check relief valve setting and
adjust as required. If valve will
O
D DO
not hold setting, disassemble and
clean valve. Repair or replace
valve
Low voltage or control circuit mal- Check power and control circuits
function to pump. Correct deficiency.
Faulty pump or pump motor Remove and inspect pump and

motor. Replace faulty pump or
motor.
Table 8-2: Troubleshooting Guide

Tank will not vent Faulty check valve Inspect check valve and replace if
faulty.
Faulty two-way valve Check two-way valve and replace

if faulty.
Water flow is low Leak at hoses or connections Check condition of hoses and
tightness of connections. Replace
faulty hoses. Tighten all connec-
tions.
t
Faulty flow control valve Inspect flow control valve and cir-
n
cuits. Repair valve
Y e
Faulty control potentiometer Inspect control potentiometer and
m
NL uip ion
circuits. Correct deficiency
Obstructed pump inlet Remove and inspect inlet strainer.
O q t Clean strainer as required. Drain
L f E ra
and clean tank interior to remove
A
debris as required.
I o p e
R ce O
Faulty pump or pump motor Remove and inspect pump.
E
Replace faulty pump or motor
t
AT nan en
Water flow meter does not regis- Open circuit between water flow Inspect and check wiring between
ter transducer (WFT) and flow meter the transducer and flow meter.
M te m
Correct deficiency.
E i n i p
Faulty water flow transducer Replace transducer
C a q u
Faulty flow meter Replace flow meter.
E N M E
r
Water being added to bit air with Faulty check valve Clean check valve or replace if
pump off
R fo o r damaged
FE E f Table 8-2: Troubleshooting Guide (Continued)
E S S E
R U U
T T
O
N NO
O
D DO

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

320XPC-UDC Mechanical Systems Manual Hydraulic System
Section 9
Hydraulic System
9.1 General
t
This section describes the hydraulic system supply and controls, and provides information for adjustment, removal,
e n
and installation of the major hydraulic system supply and control components. Description and repair information
for the components associated with individual controls can be found in the section of this manual that pertains to
Y m
NL uip ion
the control. For example, mast raise cylinders are included in the mast section, but the hydraulic control functions
for it is included in this section.
O q t
The hydraulic system is comprised of four major groups of components or subsystems as shown in Table 9-1.
A L f E ra
I o e
Group or Subsystem Component Subsection
Shared Components
R ce O p Topic 9.2
E t
AT nan en
Hydraulic Tank and Filters Subtopic 9.2.1
M te m
Hydraulic Tank Components Subtopic 9.2.2
E n i p
Hydraulic Oil Cooler Subtopic 9.2.3
C a q i u Thermostatic Mixing Valve Subtopic 9.2.4
E N M E
r
Oil Replenishment Systems Subtopic 9.2.5
R fo o r
f
Propel (Main) Hydraulics
E E
Topic 9.3
E F S E
Valve Bank 4 Subtopic 9.3.1
R U U S Hydraulic Pumps and Motors Subtopic 9.3.2
T T Towing System (Option) Subtopic 9.3.3
O
N NO
Auxiliary Hydraulics Topic 9.4
O
Auxiliary Hydraulic Pump
D DO
Subtopic 9.4.2
Valve Banks Subtopic 9.4.3
Valve Bank 1 Subtopic 9.4.3.1
Low Pressure Hydraulics Topic 9.5
Low Pressure Hydraulic Pump Subtopic 9.5.2
Valve Bank 4 Subtopic 9.5.3
Table 9-1: Hydraulic Groups and Subsystems

Sec09Hyd.fm -9.1- Section 9, Version 00 - 07/12
Hydraulic System 320XPC-UDC Mechanical Systems Manual
A block diagram of the hydraulic system is illustrated in Figure 9-1. The diagram shows the common relationships
between components and the flow of hydraulic oil through them.
320XPC Hydraulic Flow
P2
P1
VB2 P2
VB1
Spare VB3 VB4
Pipe Rack 2 Head Brake Enable
Spare
Mast Anchor Pins
Pipe Rack 1 Pipe Rack Holdback
Spare
Spare
Spare GD Main Air
t
Compressor Inlet
RH Rear Jack T1
n
P1
Back Brace Lock
Spare T2
e
P2 T1 Deck Hatch
LH Rear Jack
Y
Spare
m
Spare
NL uip ion
RH Pipe Rack Gate
Front Jacks P1 P2
Deck Wrench
Mast Hoist
LH Pipe Rack Gate
O q t
Unloader/Relief
Breakout Wrench
Auxiliary Winch In/Out
L f E ra
Spare
T2
A
Relief Unload /
I e
Breakout Wrench
o
Oil Divert Propel Speed
Engage/Disengage
R ce O p
B1
RH Propel Brake
E t
AT nan en
Auxiliary Pump LH Propel Brake
22.0 GPM Output
M te m
Section T1
p
B
E n i
Inlet
i
Low
Oil Cooler Hydraulic
Hyd Oil Case Pressure
C a q u
Relief Valve C System A
Cooler Drain Pump
90 PSI Thermostatic
37.7 GPM Output
N
Mixing Valve
Section
E r M E
R fo o r
FE E f From Oil
From Front
E
Main Return Jacks Regen
Topoff Check Valve
Filters Valve Drain
E S
System
R U U S
Towing System
Brake Release
(Option)
T T
Hydraulic
LH Suction Strainer
Tank
O
N NO RH Suction Strainer
Low Pressure
Return Filter
O
D DO
VB6
Boarding Stairs
Cylinder(s)
(Option)
Pump Case
Return Filter
From Right and

From Winch and Left Rear Jack
Mast Drains Regen Valve
D1 D1
Drains
H
LH Main Pump RH Main Pump
C C
A or B A or B
High Pressure
320xpc hyd flow Low Pressure

LH Propel Motor RH Propel Motor
Suction
Return to Tank
Figure 9-1: Block Diagram - Hydraulic System

Section 9, Version 00 - 07/12 -9.2- Sec09Hyd.fm
Figure 9-2 shows the locations of the major components in the hydraulic system.
01 02 03 04 05 06 07 08
19
18
n t
Y e
m
NL uip ion
17
16
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
BD1130b01
15 14 13 12 11 10 09
LEGEND
E N M E
r r
01. Left Rear Leveling Jack 10. Oil Top Off System (Option)
R
02. Valve Bank #3
E E
03. Valve Bank #4
fo f o
11.
12.
Main Pumps (2)
Valve BAnk #1
F E
04. Low Pressure Pump (Below VB4) 13. Mast Hoist Cylinders (2)
E S S
05. Auxiliary Hydraulic Pump 14. Mast Hydraulic Components
R U U
06. Hydraulic Reservoir 15. Right Rear Leveling Jack
T T
07. Hydraulic Oil Cooler (Part of Main Air Compressor 16. Deck Hydraulic Components
Oil Cooler 17. Auxiliary Winch
O
N NO
08. Left Front Leveling Jack
09. Right Front Leveling Jack
18.
19.
Valve Bank #2
Valve Bank #6 (only used with optional hydraulic
stairs)
O
D DO Figure 9-2: Hydraulic System Layout

9.2 Hydraulic System Shared Components
Assembly or Component Sub-Component Subsection
Hydraulic Tank Subtopic 9.2.1

Hydraulic Tank Components Subtopic 9.2.2
Suction Strainers Subtopic 9.2.2.1
t
Temperature Detector Subtopic 9.2.2.2
e n
Low Oil Level Switch Subtopic 9.2.2.3
Y m
NL uip ion
Hydraulic Tank Breather Subtopic 9.2.2.4
Return Filters Subtopic 9.2.2.5
O q t
Oil Level and Temperature Gauges
L f E ra
Subtopic 9.2.2.6
Oil Cooler
I A o p e
Subtopic 9.2.3
Thermostatic Mixing Valve
ER ce O Subtopic 9.2.4
t
AT nan en
Oil Replenishment Systems Subtopic 9.2.5, Topic
(optional) 20.3
M te m
Table 9-2: Hydraulic System Shared Components
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

9.2.1 Hydraulic Tank
01 02 03 04
19
05
18
n t
Y e
m
NL uip ion
06
15
O q t 07
16
A
17
L f E ra
I o p e
ER ce O 08
t
AT nan en
M te m R57523D1_01
E i n i p
C a q u
N
11 10 09
14
E r M E
R fo o r
FE E f R57523D1_01a
E
13 12
LEGEND
01. Breather
E
R U U S S 10. Oil Temperature Gauge
T T
02. Low Pressure Return Filter - Main Pump Case 11. RH Suction Strainer - Output To Main and Low
O
N NO
Drain Circuit Pressure Pump Inlets
03. Low Pressure Return Filter - Winch, Mast, Propel 12. Shutoff Valve Handwheel (2)
Motor and Misc. Drain Circuits 13. Filter Vacuum Switch (2)
O
D DO
04. Main Return Filter (2) 14. Handwheel Position Limit Switch (2)
05. Main Return Filter Condition Indicator (Gauge) 15. LH Suction Strainer - Output To Auxiliary Pump
06. 23 PSI Filter Condition Switch (3) Inlet and Optional Towing System Brake Release
07. OIl Level Nameplate 16. Pressure Tap (2)
08. Covers and Gaskets (3 sets) - Remove for Mount- 17. Oil Temperature Detector
ing Optional Oil Heater(s) 18. Top Cover
09. Oil Level Sight Glass 19. Low Oil Level Switch
Figure 9-3: Hydraulic Tank Components
9.2.1.1 Description
The hydraulic tank, located on the left side in the machinery house (06, Figure 9-2), provides oil for all hydraulic
functions on the drill, except the cable reel which has its own hydraulic system.

Refer to Figure 9-3. The hydraulic tank includes a breather (01), four return filters (02, 03, and 04), a filter condition
indicator (05) for items 04, a temperature gauge (10), two suction filters (11 and 14), a temperature detector (16),
an oil level sight glass (17) and a low oil level switch (19).
9.2.1.2 Periodic Maintenance
Refer to subsection 3.5, Maintenance Schedule Check Sheets in Section 3 of this manual for
proper oil change and filter service intervals and procedures.
9.2.1.3 Repair
n t
Y e
m
NL uip ion
! WARNING
O q t
Hydraulic oil is flammable and could explode if exposed to welding heat, open flames
L f E ra
and/or sparks, resulting in serious injury or death. Always be certain that the tank is
A
I o e
properly cleaned of any flammable material before welding.
R ce O p
E
The hydraulic tank is made of mild steel. Any repairs can be accomplished by draining the tank and welding in
t
AT nan en
accordance with accepted welding practices.
M te m
9.2.2 Hydraulic Tank Components
E i n i p
u
9.2.2.1 Suction Strainers
N C a q
E r M E
Two suction strainers (11 and 15, Figure 9-3) are flange-mounted at the rearward end of the hydraulic tank. They
r
feature a handwheel-operated valve which serves as a shutoff valve for the suction lines to the hydraulic pumps.
R
E E f o f o
To shut off the oil flow, turn the handwheel counterclockwise until it stops. The handwheel valve includes a limit
F S E
switch (14) which informs the AC800 control system of the position of the shutoff valve. This is to prevent drill start-
E S
up when the valve is closed. Both shutoff valves must be closed to start the main motor.
R U U
T T
Each suction strainer is also equipped with a vacuum switch (13) to detect if the strainer requires cleaning. The
O
N NO
indicator switch is not a visual switch. Instead, the switch will inform the AC800 control system that the strainer filter
requires cleaning when it detects a -3 psi (-0.2 bar) vacuum. The AC800 control system will then alert the operator
of this condition on the GUI. An internal bypass valve permits oil to flow around the strainer element if the element
O
D DO
becomes excessively dirty.
Service
proper service intervals and procedures.

9.2.2.2 Temperature Detector
The temperature detector (Figure 9-4) is a resistive temperature device (RTD) that detects the temperature of the
hydraulic oil in the tank and transmits that information to the AC800 control system. It is installed on the rear of the
hydraulic tank above the suction strainers.
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
R ce O
R57523D1e
E t
AT nan en
Figure 9-4: Hydraulic Tank Temperature Detector
M te m
Service and Repair
E i n i p
No service is required. The temperature detector is not repairable. If the unit fails, it must be replaced.
C a q u
Replacement
E N M E
R o r o r
E E f f
! WARNING
E F S E
S
Electric current can cause burns, injury, or even death. Disconnect, lock open, and tag
R U U
the power source which feeds this device to prevent power from being applied while
T T
inspection and repairs are being performed. Before beginning repairs, try the opera-
O
N NO
tional controls to verify that the intended power source is disconnected.
Step 1: Lock out and tag out the controls to the hydraulic pumps to prevent activation while the temperature
Step 2:
O
D DO
probe is being serviced.
Tag and disconnect the electrical wiring to the temperature detector.
Step 3: Remove the temperature detector from the hydraulic tank.
The temperature detector assembly is not repairable, and must be replaced if damaged or inop-
erable. Refer to the LinkOne electronic parts manual for temperature detector identification.
Step 4: Pack the well with grease. The grease will act as a thermal conductor. Thread the detector into the well.

Step 5: Install the electrical wiring to the detector in accordance with the identification tags placed during removal.
9.2.2.3 Low Oil Level Switch
The low oil level switch (18, Figure 9-3) is located under a protective cover on the top of the hydraulic tank.
! WARNING
t
n
Y e
m
NL uip ion
Testing the Switch
O q t
A L f E ra
I o e
Thoroughly clean the top of the hydraulic tank before disconnecting or removing any of the
hydraulic components.
R ce O p
E t
AT nan en
To check the function of the switch, remove the protective cover and unthread the float switch assembly from the
tank. Pull the float switch and rod assembly out of the tank just far enough so that the float is above the oil. The GUI
M te m
should register a fault. If it does not register a fault, replace the float switch.
Service and Repair

E i n i p
C a q u
N M E
No service is required, and the low level switch is not repairable. If the unit fails, it must be replaced.
E
R o r o r
f
Replacement
FE E ! WARNINGf
E S S E
R U U
T T
O
N NO
Step 1: O
D DO
Lock out and tag out the controls to the hydraulic pumps and the level switch to prevent activation while
the level switch is being serviced.
Step 2: Tag and disconnect the electrical wiring to the level switch.
Step 3: Remove the level switch from the hydraulic tank.
The level switch assembly is not repairable, and must be replaced if damaged or inoperable.
See the LinkOne electronic parts manual for switch identification.

Step 4: Apply a thin film of pipe sealant to the male pipe threads on the level switch, then install the switch in the
tank.
Step 5: Install the electrical wiring to the switch in accordance with the identification tags placed during removal.
Step 6: Add oil as necessary to attain the correct operating level.
9.2.2.4 Hydraulic Tank Breather
n t 01
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
R57523D1d
M te m
Figure 9-5: Hydraulic Tank Breather
E i n i p
C a q u
General
E N M E
Refer to Figure 9-5. The hydraulic tank breather is threaded onto an adapter on the top of the hydraulic tank.
R o r o r
Service
E E f f
E F S E
S
Replace the breather when the pop-up indicator (01, Figure 9-5) appears.
R U U
T T
Replacement
O
N NO
Turn the breather counterclockwise to remove it from the adapter. Coat the threads on the new breather with
thread sealant and install it onto the adapter until tight.
O
D DO
9.2.2.5 Return Filters
General
Refer to Figure 9-3. The two low pressure return filters (02 and 03) are each provided with a 23 psi (1.7 bar) pres-
sure switch to detect when the filter requires cleaning. The two main return filters (04) share a 23 psi (1.7 bar) pres-
sure switch to detect when either filter requires cleaning. If a filter requires cleaning, the pressure switch relays that
information to the AC800 control system which, in turn, alerts the operator on the GUI. The two main return filters
(04) also share a gauge (05) for a visual indication of the condition of both filters.
All four return filters are flange-mounted on top of the hydraulic tank. The can be serviced without removal from the
tank.

Inspection, Service and Repair
proper service intervals and procedures.
9.2.2.6 Oil Level and Temperature Gauges
n t
Y e
m
NL uip ion
O q t
WITH COLD OIL
A L f E ra MINIMUM MAST DOWN AND JACKS FULLY RETRACTED
I o p e
ER ce O MAXIMUM MAST UP AND JACKS FULLY RETRACTED
t
AT nan en MAXIMUM MAST UP AND JACKS FULLY RETRACTED
M te m
WITH COLD OIL
E i n i p MINIMUM MAST UP AND JACKS FULLY RETRACTED
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO MINIMUM MAST UP AND JACKS FULLY EXTENDED
| | | | | |
| | | |
| |
|
| |
| |
R5644101
| | | | | | |
| | | | |
|
Figure 9-6: Hydraulic Oil Level Sight Glass and Temperature Gauge
Refer to Figure 9-6. The level gauge is a sight glass used in conjunction with the associated placard to determine
the appropriate oil level based on the condition of the drill (i.e., mast up or down, jacks up or down, etc.) A ther-
mometer at the bottom of the sight glass indicates the hydraulic oil temperature.

9.2.3 Hydraulic Oil Cooler.
01
02
03
t
04
e n
Y m
NL uip ion
O q t
05
A L f E ra
I o p e
ER ce O
t
AT nan en
06
M te m
R58736D1a
E i n i p
u
LEGEND
NC a q
01. 30 HP Electric Motor and Fan 04. Oil Cooler
M E
02. Air Compressor Oil Outlet (Ref.) 05. Left Platform
E r r
03. Hydraulic Oil Outlet 06. Hydraulic System Thermostatic Mixing Valve
R
E E fo f o Figure 9-7: Hydraulic Oil Cooler
E F S E
R U U S
Refer to Figure 9-7. The hydraulic system oil cooler is part of the air compressor oil cooler assembly. The oil cooler
assembly (04) is mounted near the front on the left platform. Cooling is provided by a 30 HP, AC electric motor-
T T
driven fan (01) which is controlled through the AC800 control system. The cooler has a rated operating pressure of
O
N NO
150 psi (10.5 bar).
Only oil from the auxiliary hydraulic circuit is routed through the hydraulic oil side of the cooler. During cold startup,
O
D DO
a thermostatic mixing valve (06) directs the hydraulic system oil directly back to the hydraulic tank and bypasses
the oil cooler. Refer to Subtopic 9.2.4 for additional information on the thermostatic mixing valve.

9.2.4 Thermostatic Mixing Valve.
01 02 03
04
B
08
04 A C
t
05
e n
Y m
NL uip ion
07 06
04b
09
O q t
L f E ra
02
03
I A e
01 04a
o
08 B
R ce O p
E t
AT nan en 06 C
M te m A
E i n i p
C a q u
07 R58674F1a
LEGEND
E N M E
R o r o r
01. Oil Flow From T Ports on Valve Banks1, 2 and 3 05. Oil Flow From Drain Ports on Front Jacks
f f
02. Test Fitting T501 Regeneration Valve
FE E
03. Hydraulic System Thermostatic Mixing Valve 06. Test Fitting T502
E
04. Oil Cooler 07. Oil Flow to Main Return Filters
E
R U U S S
04a. Oil Flow To Oil Cooler
04b. Oil Flow From Oil Cooler
08. Oil Cooler Bypass Relief Valve [90 PSID (6.2 Bar)]
09. Air Compressor Thermostatic Mixing Valve (Ref.)
T T
O
N NO
Figure 9-8: Thermostatic Mixing Valve
O
Refer to Figure 9-8. The drill has two thermostatic mixing valves mounted just below the oil cooler. The front mixing
D DO
valve (03) is used to control hydraulic system oil flow to the oil cooler (03). Refer to (07, Figure 9-2) for location.
Only oil from the auxiliary hydraulic circuit is routed through the hydraulic system oil side of the cooler. During cold
startup, the thermostatic mixing valve directs the hydraulic system oil directly back to the hydraulic tank and
bypasses the oil cooler.
Hydraulic oil temperature is sensed at port B on the thermostatic mixing valve. Below an oil temperature of 130ºF
(50ºC), port B is connected to port A with port C blocked. As the oil temperature continues to rise, port C begins to
open to port B and port A begins to be restricted to port B. Above 130ºF (50ºC), port C is open to port A and port B
is blocked to port A.
The relief valve (08) provides a bypass in the event that the oil cooler circuit becomes inoperative. The valve opens
when the pressure differential between pressure taps T501 (02) and T502 (06) reaches 90 psi (6.2 bar).

9.2.5 Oil Replenishment Systems
Refer to Section 20 for operational details for the oil top off system.
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

9.3 Propel System Hydraulic Components

Figure 9-9 is a block diagram that shows the oil flow between the propel system hydraulic components.
High Pressure
To Aux
Pump Inlet Hand Pump Pressure
Suction
Return to Tank
To Low
Hydraulic Low Pressure
Pressure
t
LH Suction Strainer Tank Return Filter
Pump Inlet
n
Towing System Manual
e
Brake Release
RH Suction Strainer (Option)
Y m
NL uip ion
Pump Case
Return Filter
O q t
VB4 - Propel Control Valves Only
L f E ra
B3
Propel Speed
A
Solenoid Valve
e
D1 D1
I o
H
p
LH Main Pump RH Main Pump
R ce O
T1
C C
A or B A or B
E
Manual Brake Manifold
t
A or B A or B
AT nan en
T1 T1 B2
LH Propel Motor RH Propel Motor RH Propel Brake
Solenoid Valve
PB X X PB HP
M te m B1
p
LH Propel Brake
E n i
Solenoid Valve
C a q i u
E N M E
r r
P1
R
E E fo f o 320xpc propel flow v2
E F S E
R U U S Figure 9-9: Propel System Hydraulic Components Block Diagram
T T
The propel hydraulic system consists of two independent closed loop hydrostatic drives, which provide the torque
O
N NO
to operate the propel motors. The major components include: a hydraulic tank, two identical variable-displacement
hydraulic pumps, two variable-displacement hydraulic motors, system control valves, and hydraulic oil filters. The
propel motors and brakes are an integral part of the propel transmissions. An optional tow valve circuit may also be
O
D DO
included. This circuit is used to release the brakes for towing the drill.
Each of the propel circuits is pressurized by a small-volume charge pump, which is tandem mounted on the main
piston pump drive shaft. In addition to maintaining the basic loop system pressure, the charge pump provides pres-
sure for the pump servo controls, motor displacement control, and the brake release circuits. Refer to the Main
Hydraulics Schematic Diagram in your LinkOne Parts manual for the propel system hydraulic schematic.
When the drill is operating in propel mode, and the operator moves the joystick controller away from the NEUTRAL
position, the electro-hydraulic servo control on the pump is energized. Energizing the servo control causes the
pump pistons to begin to stroke. The direction and amount of movement of the joystick away from NEUTRAL posi-
tion determines the direction of oil flow from the pump main ports (through “A” or “B”) and establishes the volumet-
ric displacement of the pump pistons. When the displacement of the pistons is increased, the flow rate of oil
discharging from the pump into the motor circuit increases, causing the propel motor to turn faster.

9.3.1 Valve Bank 4 (VB4)
Valve bank 4 (VB4) is mounted toward the rear on the machinery house left wall (see Item 04, Figure 9-25).
Refer to Figure 9-10. Although a total of nine hydraulic circuits are controlled by the valve assemblies mounted on
the 10-station, VB4 (station 10 is available for a future valve assembly), only stations 1 through 3 are supplied with
oil from port H on the left hand main hydraulic pump and are used in the propel system. Stations 4 through 10 are
supplied with oil from the low pressure pump and are discussed in the low pressure system (see Topic 9.5). A plug
is installed in the main pressure passage on VB4 between stations 3 and 4 to prevent oil flow from the wrong cir-
cuit.
n t
Y e
m
03 02 01
NL uip ion
LEGEND
01. Station 1: Left Propel Brake Circuit
O q t
02. Station 2: Right Propel Brake Circuit
L f E ra
03. Station 3: Propel High Speed Circuit
A
04. Valve Bank 4 Manifold
I o e
05. Pressure Gauge (Not included - shown
R ce O p for typical mounting purposes only)
E
06. Manual Brake Manifold
t
AT nan en
M te m
E i n i p
C a q u
E N M E06
R o r o r
E E f f
04
E F S E
R U U S
T T
05
O
320-VB4_02a
N NO
O
Figure 9-10: Propel Control Valves (Stations 1-3 on VB4)
D DO
Figure 9-11 shows the hydraulic schematic for first three stations on VB4 which are used to control the propel
speed and brake release functions. The schematic also includes the optional tow valve circuitry. Refer to Figure 9-
9 for a block diagram showing the flow between VB4 and the propel pumps and motors.
Servo pressure from port H on the left hand main pump is used to release the propel brakes and to adjust the dis-
placement (speed) of the propel motors through valve bank 4 (VB4). The pump provides a control pressure of 400
to 500 psi (27.6 to 34.5 bar) while the pump is in neutral to a maximum of 570 to 670 psi (39.3 to 46.2 bar) while the
pump is at full pressure (fully stroked). Refer to Subtopic 9.3.2.3 to measure and adjust the control pressure.
Each propel transmission is a three-stage planetary reducer with an integral, spring set/hydraulically released mul-
tiple-disc brake.

The following topics describe the functions of the propel system control circuits on VB4 in detail. For reference,
refer to the main hydraulic schematic in the LinkOne parts manual for your drill.
The MODE switch on the operator console must be in the PROPEL mode to enable propel and
brake release functions.
n t
The operator must move the joystick control on the console off of neutral to enable hydraulic oil
e
flow to port P1 on valve bank 4. This will cause internal passages in the left hand pump to open
and allow oil to flow out of port H.
Y m
NL uip ion
Propel Brake Set and Release. When the operator presses the PROPEL BRAKE SET/RELEASE switch on the
O q t
operator’s console to the SET (upper) position, both propel brake release solenoids (LPBS and RPBS) will de-
L f E ra
energize. Oil from the P1 port on the manifold cannot flow through port P and port A on the valve because port A is
A e
blocked. This will prevent oil flow to the PB ports on the propel motors and the brakes will set or remain set by
spring pressure.
I
R ce O o p
E t
When the operator presses the PROPEL BRAKE SET/RELEASE switch on the operator’s console to the
AT nan en
RELEASE (lower) position, both propel brake release solenoids (LPBS and RPBS) will energize. Oil from the P1
port on the manifold flows in port P and out port B on valve and exits the manifold at port B1 (LH Brake) and B2
M te m
(RH Brake). From the B1 and B2 ports, oil flows to the PB ports on the propel motors to release the brakes.
E i n i p
C a q u
If power is not available on the drill and the drill is equipped with the optional tow kit, the brakes can be released
N
using the hand pump provided.
E r M E
R o r
Below the directional control valve in the valve stack is a check valve and set of pilot operated check valves. The
E E f f o
purpose for these valves is to allow manual brake release with the use of the optional tow system hand pump.
E F S E
Propel Speed Control. When the operator presses the PROPEL SPEED HIGH/LOW switch on the operator’s
R U U S
console to the LOW (lower) position, the propel speed solenoid (PSS) will de-energize. Oil from the P1 port on the
VB4 manifold cannot flow through port P and port A on the valve because port A is blocked. This will prevent oil
T T
flow to the X ports on the propel motors and the propel speed will be set to low-speed/high-torque.
O
N NO
When the operator presses the PROPEL SPEED HIGH/LOW switch on the operator’s console to the HIGH (upper)
position, the propel speed solenoid (PSS) will energize. Oil from the P1 port on the VB4 manifold flows into port P
O
D DO
and out port B on valve and exits the manifold at port B3. From the B3 port, oil flows to the X ports on the propel
motors and the propel speed will be set to high-speed/low-torque.

03 02 01
VALVE BANK 4 RH LH
3 OF 10 STATIONS SHOWN
PROPEL PROPEL
PROPEL BRAKE BRAKE
HIGH RELEASE RELEASE
SPEED RPBS B LPBS B
CONTROL 1.27.1.1 1.27.1.0 04
A P A P
t
PSS B B T B T
1.27.1.2
n
FROM WINCH AND
A P
5
e
MAST DRAINS
HP
Y
B T P1G
m
T422 0-4 GPM
NL uip ion
P2 PASSAGE 0-15 L/MIN
P1
O q t
T1
0-5 GPM
B3 B3G B2 B2G B1G GT 0-19 L/MIN
B1
09
L f E ra
T416 T418 T420 T421
A e
LOW PRESSURE FILTER 2
I o
LOW PRESSURE RETURN
p
08 07 06 05 FRONT FILTER
ER ce O
t
AT nan en
10 11 12
M te m
E i n i p
ACCUMULATOR PRESSURE GAUGE
8 7 HAND PUMP
u
68 IN3
C a q
6 0-600 PSI 9
200 PSI
11
N
13.8 BAR
M E
PRE-CHARGE .9IN 3 /STROKE
E
14.7 CC/STROKE
r
13
R fo o r
E E f T
X P 350 PSI
F
24.1 BAR
E S E
B A
S
8 BREAK AWAY VALVE 9 X
11
R U U
HAND PUMP
VENT VALVE 10
TRIP PLATE
T T
CABLE TO TOW VEHICLE
O
N NO 55.7 GPM
L H STRAINER
STRAINER 1 2
R60985_02a
O
D DO
211.7 L/MIN
TO AUXILIARY HYDRAULIC
PUMP INLET
LEGEND 08. To Port X on Both Motors

01. LH Propel Brake Solenoid Valve 09. Pressure Passage Plug (between VB4, stations 3
02. RH Propel Brake Solenoid Valve and 4 to isolate low pressure hydraulic pressure
03. Propel Speed Control Solenoid Valve from propel hydraulic pressure)
04. Brake Manifold Port HG (normally plugged 10. Accumulator
except when optional Tow Kit is used) 11. Gauge
05. From Port H on LH Main Pump 12. Hand Pump
06. To Port PB on LH Motor 13. Breakaway Valve
07. To Port PB on RH Motor
Figure 9-11: Valve Bank 4 Propel Control Schematic (Shown with optional Tow Kit)

9.3.2 Main Hydraulic Pumps
n t
Y e
m
NL uip ion
O q t
L f E ra
R57523D1
I A o p e
ER ce O Figure 9-12: Main Pumps
t
AT nan en
Refer to Figure 9-12. The two main hydraulic pumps are mounted on the rear of the pump drive transmission
(PDT). The two pumps are identical. They are axial piston pumps with a rotary servo, trimmer, adjustable volume
M te m
stops, and a neutral bypass with detent (not spring or pressure centered). The pumps are configured to supply
E n p
hydraulic fluid to the hydraulic motors and brakes for the propel system. The pumps also provide braking for the
C a q i u i
propel motors when the controls are placed in neutral position. Servo pressure from Port H on the left pump is used
to release the propel brakes and to adjust the displacement (speed) of the propel motors through valve bank 4
N M E
(VB4). Refer to Subtopic 9.3.1 for additional information regards operation of these controls.
E
R o r o r
f f
When the main motor starts, the PDT causes the pumps to turn; however, during normal start-up, the pumps are in
E E
their neutral positions and oil pressure does not develop in the propel hydraulic circuit. When the operator places
F
E S S E
the drill in PROPEL mode and moves the joystick, a signal is provided to the electro-hydraulic stroker (servo). The
servo causes the swash plate within the pump to rotate. The movement of the swash plate causes oil to move
R U U
through the propel hydraulic circuit. The amount of movement of the servo determines the rate of oil flow through
the circuit.
T T
O
N NO
Figure 9-13 is the schematic for the left hand propel pump and motor. The right hand propel pump and motor sche-
matic is similar. Refer to Subtopic 9.3.2.1 for schematic data sheet descriptional information or Subtopic 9.3.2.2 for
O
D DO
pressure tap information. Refer to Figure 9-9 for a block diagram showing the flow between VB4 and the propel
pumps and motors.

01
02
nt
03
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E n i p
04
C a q i u
E N M E
r r
05
R
E E fo f o
F
06
LEGEND
E S S E
R U U
01. To VB4, Port P1 11
T T
02. Charge Flow Filter
03. LH Main Pump
O
N NO
04. To Pump Case Return Filter
05. From RH Suction Strainer
O
06. Propel Transmission
D DO
07. From VB4, Port B1 (LH Propel
Brake)
08. To Low Pressure Return Filter 10
09. To RH Propel Motor, Port X 07
10. From VB4, Port B3 (Propel
Speed)
11. Propel Motor 09
08
R60069_04
Figure 9-13: Main Hydraulic Pump / Motor Schematic (LH Shown; RH Similar)

9.3.2.1 Propel (Main) Hydraulic System Data Sheet
Test Item Description / Setting

Point*
1 Pump Main Pressure The compensator limits the main pump maximum pressure.
Compensator To set do the following:
1. Disconnect both propel brake solenoid electrical connectors on
VB4.
2. Connect a 0-6000 psi (0-400 bar) pressure gauge to either AG,
forward, or BG, reverse pressure tap.
t
3. Engage propel in the proper direction for the gauge connection.
n
4. Set the compensator pressure to 4200 psi (290 bar). Only one
e
Y
direction is required to set the pump compensator.
m
NL uip ion
5. Reconnect the propel brake solenoids.
2 Suction Strainer The strainer has an integral shut-off valve and limit switch. The shut-
O q t
off valve must be open to start main motor.
3 Charge Flow Filter
A L f E ra
Filters the oil supplied by the main pump charge pump.
I o p e
R ce O
4 Charge Pressure Pilot The charge pilot relief valve controls the pump charge pressure. The
E
Relief Valve valve is located under a port access plug (17, Figure 9-14) on the
t
AT nan en
rear face of the pump valve block.
To set:
M te m
1. Install a 0-600 psi (0-42 bar) pressure gauge on the pressure tap
p
for port KG (T50 on the RH pump or T54 on the LH pump).
E
C a q i n u i 2. Run the main motor.
N
3. The pressure at the pump KG port pressure tap should be 200 to
E r M E 250 psi (13.8 to 17.2 bar).
R fo o r 4. If the pressure needs adjustment, stop the main motor and
E E f
remove the port access plug (17, Figure 9-14) on the rear face of the
F
pump valve block. Then remove the pilot relief valve.
E S S E 5. Loosen the locknut and then turn the opposite end with a screw-
R U U
driver to adjust the pilot relief as required. One full turn on the
adjustment screw will cause pressure to change approximately 50
T T psi (3.4 bar). Turning the screw clockwise will increase pressure.
O
N NO
6. Re-assemble the parts and start the main motor.
7. Check the pressure at the KG port pressure tap.
O
D DO
If the pressure is still not correct repeat the adjustment procedure
until the pressure is correct.
5 Charge Pressure Relief This poppet maintains charge pressure by restricting charge pump
Main Poppet oil flow from the charge oil pressure passages into the pump case.
The poppet is controlled by the charge pressure pilot relief valve. No
adjustment required.
Table 9-3: Propel (Main) Hydraulic System Data Sheet


Point*
6 Control Pressure Relief This poppet maintains pump control pressure by restricting the oil
Main Poppet flow from the charge pump to the charge pressure passages. The
valve will maintain control pressure at twice the charge pressure.
The poppet is also acted on by a piston that is exposed to the highest
outlet pressure. The piston adds 40 psi (2.8 bar) for every 1000 psi
(69.0 bar) to the control pressure.
Control pressure = 2 x charge pressure + (40 x highest outlet pres-
sure/1000) psi).
At 200 psi (13.8 bar) charge pressure, the main control pressure will
t
be approximately 408 psi (28.1 bar).
n
e
At 4200 psi (290 bar) charge pressure, the main control pressure will
Y
be approximately 568 psi (39.2 bar).
m
NL uip ion
Measure the main control pressure at the corresponding charge
pressure filter pressure tap T58 or T59 (01 or 02, Figure 9-14). No
O q t
adjustment required.
7 Motor Flushing Valve

L f E ra
This valve removes oil from the closed circuit when the circuit is
A
I e
pressurized. This allows clean cool oil from the charge pump to enter
o p
the high pressure loop. The removed oil is fed into the motor case to
R ce O
cool and flush the motor during operation. If the pressure differential
E t
between the A and B motor ports exceeds 230 psi (16 bar), the spool
AT nan en
shifts connecting the low pressure side of the motor to the flow con-
trol valve. The flow control valve discharges 2.6 gpm (10L/min.) into
M te m
the motor case. The case drain line returns the oil to the hydraulic
p
reservoir. No adjustment required.
8 E
C a q
Manual Propel Brake
i n u i
With the main motor off, the propel brakes can be manually released
N
Release (drills without by applying pressure to the HP port on VB4. This port can be
E M E
the towing option)
r
accessed at an unconnected bulkhead fitting in the main frame floor
r
below valve bank 4. A minimum of 280 psi, 19.3 bar, is required to
R
E E fo f o release the brake. The brake is rated for a maximum pressure of 750
psi (51 bar). Pressure above the maximum will cause brake failure.
E F S E To set, refer to Subtopic 9.3.2.3.
8
R U U S
Breakaway Valve Assy
(drills with the towing
The breakaway valve will set the propel brakes if the tow vehicle
becomes separated from the drill during towing. With the trip plate in
T T
option) place, the valve is shifted and propel brake pressure will build. The
O
N NO
trip plate is connected to the tow vehicle with a cable. If the tow
vehicle separates from the drill, the trip plate pulls out which returns
the brake valve the spring-set position. This, in turn, sets the drill
9
O
D DO
Hand Pump (drills with
propel brakes. To set, refer to Subtopic 9.3.3.3.
Provides oil pressure to release the propel brakes with no power to

the towing option) the drill. The pump has an internal relief valve to limit pressure to
350 psi (24.1 bar). The pump is provided with a screw-type vent
valve to release pump outlet pressure. To operate, refer to Subtopic
9.3.3.3.
10 Hand Pump Vent Valve The vent valve is a screw-type valve that vents pump outlet pressure
(drills with the towing when open (rotated fully counterclockwise). To allow pressure to
option) build up, rotate the valve fully clockwise. This valve should be open
at all times except when towing.


Point*
11 Accumulator (drills with The accumulator stores oil under pressure during towing operations
the towing option) to compensate for normal oil leakage while the propel brakes are
released. The accumulator is pre-charged with dry nitrogen gas to
200 psi (13.8 bar). The accumulator is shipped with no pre-charge
and must be charged to the specified pressure before using.
* Test Point references are shown as numbers in triangles on the schematics
9.3.2.2 Propel (Main) Hydraulic System Pressure Taps
n t
Tap No. Location
Y e
Purpose Expected Reading
m
NL uip ion
T1 Inlet Strainer 1 Outlet To measure auxiliary 0 - 6 in hg vacuum
pump inlet pressure.
O q t
L f E ra
T2 Inlet Strainer 2 Outlet To measure auxiliary 0 - 6 in hg vacuum
pump inlet pressure.
I A o p e
R ce O
T50 Right Hand Main Pump KG To measure right hand With the main motor running, 200 to
Port (see 15, Figure 9-14) main pump charge pres- 250 psi (13.8 to 17.2 bar).
E t
sure.
T51
AT nan en
Right Hand Main Pump DG To measure right hand With the main motor running, 50 psi
M te m
Port (see 11, Figure 9-14) main pump case pres- (3.5 bar) maximum.
sure.
E i n i p
C a q u
T52 Right Hand Main Pump AG To measure right hand With the main motor running:
N
Port (see 13, Figure 9-14) main pump port A In Neutral - should be same as
E r M E (reverse) pressure. charge pressure
r
In Reverse Propel - should be 4,200
R
E E fo f o
psi (290 bar) maximum
In Forward Propel - should be same
E F S E
as charge pressure.
T53
R U U S
Right Hand Main Pump BG
Port (see 12, Figure 9-14)
To measure right hand
main pump port B (for-
With the main motor running:
In Neutral - should be same as
T T ward propel) pressure. charge pressure
O
N NO
In Forward Propel - should be 4,200
In Reverse Propel - should be same
T54
O
D DO
Left Hand Main Pump KG To measure left hand
as charge pressure.
With the main motor running, 200 to

Port (see 15, Figure 9-14) main pump charge pres- 250 psi (13.8 to 17.2 bar).
sure.
T55 Left Hand Main Pump DG To measure left hand With the main motor running, 50 psi
Port (see 11, Figure 9-14) main pump case pres- (3.5 bar) maximum.
sure.
Table 9-4: Propel (Main) Hydraulic System Pressure Taps

Tap No. Location Purpose Expected Reading
T56 Left Hand Main Pump AG To measure left hand With the main motor running:
Port (see 13, Figure 9-14) main pump port A In Neutral - should be same as
(reverse) pressure. charge pressure
In Reverse Propel - should be 4,200
In Forward Propel - should be same
as charge pressure.
T57 Left Hand Main Pump BG To measure left hand With the main motor running:
Port (see 12, Figure 9-14) main pump port B (for- In Neutral - should be same as
ward propel) pressure. charge pressure
n t In Forward Propel - should be 4,200

Y e In Reverse Propel - should be same
m
NL uip ion
as charge pressure.
T58 Right Hand Charge Filter Cap To measure right hand Main pump control pressure is twice
O q t
(see 01, Figure 9-14) pump control pressure. charge pressure plus 40 psi (2.8 bar)
L f E ra
for every 1,000 psi (69 bar) pressure
in the high pressure loop:
I A o p e In Neutral: pressure should be 400-
R ce O
500 psi (27.6-34.5 bar)
E
At 4200 psi (290 bar): pressure
t
AT nan en
should be 570-670 psi (39.3-46.2
bar).
M te m
T59 Left Hand Charge Filter Cap To measure left hand Main pump control pressure is twice
p
(see 02, Figure 9-14) pump control pressure. charge pressure plus 40 psi (2.8 bar)
E
C a q i n u i for every 1,000 psi (69 bar) pressure
in the high pressure loop:
E N M E
In Neutral: pressure should be 400-
r
500 psi (27.6-34.5 bar)
R fo o r At 4200 psi (290 bar): pressure
E E f
should be 570-670 psi (39.3-46.2
F
bar).
T416
E S S E
Valve Bank 4 (VB4), B3G To measure the propel With the solenoid valve (PSS) off,
R U U
Port speed control signal. pressure should be 0 psi (0 bar).
T T With the solenoid valve (PSS) on
O
N NO
(propel in high speed), pressure
should be the same as left hand
main pump control pressure (see
O
D DO
T50, above and T422, below).
T418 Valve Bank 4 (VB4), B2G To measure the right With the solenoid valve (RPBS) off,
Port hand propel brake sig- pressure should be 0 psi (0 bar); RH
nal. brake should be set.
With the solenoid valve (RPBS) on,
pressure should be the same as left
hand main pump control pressure
(see T50, above and T422, below);
RH brake should be released.

T420 Valve Bank 4 (VB4), B1G To measure the left hand With the solenoid valve (LPBS) off,
Port propel brake signal. pressure should be 0 psi (0 bar); LH
brake should be set.
With the solenoid valve (LPBS) on,
pressure should be the same as left
hand main pump control pressure
(see T50, above and T422, below);
LH brake should be released.
T421 Valve Bank 4 (VB4), GT Port To measure VB4 tank Pressure should be 0 psi (0 bar).
t
passage pressure.
T422 Valve Bank 4 (VB4), P1G

n
To measure the VB4
e
Pressure should be the same as left
Y
Port input passage pressure. hand main pump control pressure
m
NL uip ion
(also see T50, above).
O q t
L f E ra
9.3.2.3 Pump Start-up, Adjustment and Functional Testing
I A o p e
This procedure is to be used for start-up and functional testing of the main hydraulic pumps and propel system
R ce O
after installation on the drill. The procedure is suitable for periodic testing of the pumps to confirm normal operation.
E t
AT nan en
On-the-drill testing of these pumps is limited to a few basic pressure measurements, observations and adjust-
ments. More thorough testing can be done only by removing the pumps from the system, installing them on a
hydraulic test stand, and implementing complete pressure, flow, and controls functional tests to rated design
capacity.
M te m
E i n i p
C a q u
Refer to Figure 9-14 and proceed with pump start-up and functional checkout as follows:
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

LEGEND 01
01. Pressure Tap T59
02. Pressure Tap T58
02
03. RH Charge Filter
04. D Port Caps 10
05. RH Propel Pump
06. C Port (Inlets from RH Suction Strainer)
07. D Port (Case Drains to LP Filter #1)
08. A and B Ports (To and From Propel Motors) 03
09. H Port (LH Pump only) - To Port P1 on VB4
10. LH Charge Filter
n t
e
11. DG Port Pressure Tap - T51 (RH Pump) or T55 (LH
Y
Pump)
m
NL uip ion
12. BG Port Pressure Tap - T53 (RH Pump) or T57 (LH
Pump)()
04
13. AG Port Pressure Tap - T52 (RH Pump) or T56 (LH
Pump)
O q t
L f E ra
14. Acorn Nut
A e
15. KG Port Pressure Tap - T50 (RH Pump) or T54 (LH
Pump)
I
R ce O o
16. Charge Pressure Pilot Relief Adjustment Screw
p 05
17. Access Plug
E t
AT nan en
18. Compensator Adjustment Screw
M te m
E p
06
i n i
09
C a q u
E N M E 06
R o r o r
11
E E f f 08
F
07
15
E S S E
14
R U U R57926F1_01b
T T
13
O
N NO 16
O
D DO 12
B A
17
14
18
Figure 9-14: Pump Start-up and Functional Check

! WARNING
2. Fill the hydraulic oil tank to the correct level with oil as specified in Topic 12.4.
t
3. Confirm that all of the propel hydraulic system suction and pressure filters are clean.
e n
WARNING
Y
!
m
NL uip ion
O q t
L f E ra
I A e
o p
R ce O
E
t
AT nan en
4. Be sure that no pressure exists in any of the hydraulic system circuits.
M te m
5. Remove the hydraulic fitting caps (04) to confirm that there is hydraulic oil present at the top drain ports D. If oil
E i n i p
is present, the pumps are primed. If no oil is present, add oil through the cap opening as needed. Install the
caps when done.
C a q u
E N M E
r
6. Remove the acorn nut (14). Turn the compensator adjustment screw (18) on the pump valve block assembly
R fo o r
counter-clockwise until there is no spring resistance.
FE E f
E S S E
R U U
T T
Do not over-tighten the compensator adjustment screw assembly when making adjust-
O
ments, or damage to the screw may result.
N NO
7. Refer to Figure 9-15. Disconnect the electrical connectors from the right and left propel brake solenoid valves
O
D DO
(03 and 04) on valve bank 4 (01).
With the electrical connectors disconnected from the brake valves, the propel brakes should not
be able to release and the propel drive should not be able to rotate.

02
03
04
t
05
e n 06
Y m
NL uip ion
01
O q t
A L f E ra
I e
07
R ce O o p 08
E t
AT nan en
M te m R58948F1a
E i n i p 09
C a q u
LEGEND
N
01. Valve Bank 4 (VB4) 07. Pressure Tap T418 (B2G Port)- Right Propel Brake
E M E
02. Propel Speed Solenoid (PSS)
r
Pressure
r
03. Right Propel Brake Solenoid (RPBS) 08. Pressure Tap T421 (GT Port) - VB4 Return to Tank
R fo f o
04. Left Propel Brake Solenoid (LPBS)
E E
05. Pressure Tap T422 (P1G Port) - VB4 Input Pressure
Pressure
09. Pressure Tap 416 (B3G Port) - Propel Speed Con-
E F S E
06. Pressure Tap T420 (B1G Port) - Left Propel Brake trol Signal Pressure
S
Pressure
R U U
T T
Figure 9-15: Propel Control Valves
O
N NO
8. Install a 0 to 3000 psi (0 to 200 bar) gauge on the charge filter pressure taps: T58 (02, Figure 9-15) on the RH
filter and T59 (01, Figure 9-15) on the LH filter.
O
D DO
9. Install a 0 to 5000 psi (0 to 345 bar) (minimum) pressure gauge on the AG port of each pump - pressure tap
T52 on the RH pump and T56 on the LH pump (see 13, Figure 9-15).
Operating the pump with low charge pressure could cause substantial damage to the
pump. If the gauge does not register the specified pressure within a few seconds, shut
down the drill and determine the cause. Do not operate the drill if charge pressure is low.
10. Start the main drive motor.

11. Confirm charge pressure readings on the 0 - 3000 psi (0 to 200 bar) gauges of 400 to 500 psi (27.6 to 34.5 bar)
with the pump in neutral.
12. Raise and level the drill on the jacks. The drill must be raised until the crawler belts are completely clear of the
ground.
13. Operate the hydraulic systems until normal operating temperature is reached (usually about 15 minutes).
14. Set the PROPEL MODE NORMAL/MAINTENANCE switch to the MAINTENANCE position.
! WARNING
n t
e
Unexpected machine movement or operation can cause serious injury or death. When
Y m
necessary to operate the drill to make an adjustment or perform a check on the propel
NL uip ion
drive system, position a person to watch the crawler mechanism and to keep personnel
at a safe distance from the drill. Always use the cab horn (in accordance with local pol-
O q t
icy) to signal that the drill is about to move.
A L f E ra
I e
15. Set the drill MODE switch to the PROPEL position.
R ce O o p
16. Assign someone to watch the crawler mechanism for motion, and to keep others away from the drill during pro-
E t
AT nan en
pel drive adjustment and testing.
17. Have the operator move the propel joystick to the FORWARD position, and turn the pump compensator adjust-
M te m
ment screw (18, Figure 9-14) inward until the pump port “A” circuit pressure reads 4,200 psi (290 bar).
E i n i p
C a q u
18. Confirm that there is no rotation of the crawler tumblers.
E N M E
19. Move the 0 to 5000 psi (0 to 345 bar) (minimum) gauges to the “BG” port on each pump - pressure tap T53 on
R o r r
the RH pump and T56 on the LH pump (see 12, Figure 9-14).
o
E E f f
F
20. Move the propel joystick to the REVERSE position. Pressure in the pump port “B” circuit should now be 4,200
E
psi (290 bar).
S S E
R U U
21. Confirm that there is no rotation of the crawler tumblers.
T T
O
N NO
22. Return the propel joystick to NEUTRAL position, and confirm that the pressures at ports “AG” and “BG” are
equal. If they are not, adjust the NULL of the pump (see Subtopic 9.3.2.4).
O
D DO
23. Make sure that the PROPEL BRAKE SET/RELEASE switch is in the SET position.
24. Reconnect the electrical connectors to the right and left propel brake solenoid valves on valve bank 4.
25. Move the 0-3000 psi (0 to 200 bar) gauges to the propel brake release pressure taps on valve bank 4: T418
(07, Figure 9-15) for the RH propel brake and T420 (06, Figure 9-15) for the LH propel brake.
26. Set the PROPEL BRAKE SET/RELEASE switch in the RELEASE position.
27. Check the hydraulic pressure on the gauges at pressure taps T418 and T420.

Brake operating pressure must be at least 218 psi (15 bar) at pressure test points T418 and
T420.
28. Move the PROPEL SPEED HIGH/LOW switch to the LOW position.
! WARNING
t
Unintentional machine movement or operation can cause serious injury or death. When
n
necessary to operate the drill to make an adjustment or perform a check on the propel
e
drive system, position a person to watch the crawler mechanism and to keep personnel
at a safe distance from the drill.
Y m
NL uip ion
29. Be sure that someone is still positioned to watch the crawler mechanism for motion, and to keep others away
O q t
from the drill during the propel drive adjustment and testing.
A L f E ra
I e
30. Move the propel joystick to the full FORWARD position and check the rotational speed and direction of the left
R ce O o p
and right crawler drive tumblers. Both should rotate at 3.8 rpm in the forward direction.
E t
AT nan en
31. Return the propel joystick to the NEUTRAL position. There should be no movement of the crawler drives.
32. Move the propel joystick to the REVERSE position and check the rotational speed and direction of the left and
M te m
right crawler drive tumblers. Both should rotate at 3.8 rpm in the reverse direction.
E i n i p
C a q u
E N M E
r
34. Move the PROPEL SPEED HIGH/LOW switch to the HIGH position.
R fo o r
E E f
35. Move the propel joystick to the full FORWARD position and check the rotational speed and direction of the left
F E
and right crawler drive tumblers. Both should rotate at 6.3 rpm in the forward direction.
E
R U U S S
T T
37. Move the propel joystick to the REVERSE position and check the rotational speed and direction of the left and
O
N NO
right crawler drive tumblers. Both should rotate at 6.3 rpm in the reverse direction.
O
D DO
39. Move the PROPEL BRAKE SET/RELEASE switch to the SET position.
40. Lower the drill off the jacks, and raise the jacks to fully stored position.
41. Check the pump compensator adjustment to be certain the locknut is tight and the acorn nut is securely in
place on the adjustment screw.
Over-tightening of the locknut can damage the compensator adjustment.

42. Remove the test gauges from the pressure tap fittings, and check the entire system for leaks.
When the main pumps and the propel motors are set up and functioning correctly, the appropriate
speeds will be achieved in the propel system. If the crawlers still do not track straight after the pumps
have been adjusted (and proper flow and pressures have been confirmed), refer to the motor adjustment
procedure in Subsection 10.3.1.4
9.3.2.4 Pump Null Adjustment
Refer to Figure 9-16 and adjust each pump’s NULL setting as follows:
n t
Y e
m
NL uip ion
01
02
O q t
A L f E ra
I o p e 03
ER ce O
t
AT nan en
LEGEND
M te m
01. Electric Stroker Control
02. Trimmer Locknut
03. Trimmer
E i n i p
C a q u
04. BG Port - Pressure Tap T53
N
(RH Pump) or T57 (LH Pump)
E M E
05. AG Port - Pressure Tap T52
r
R o r
(RH Pump) or T56 (LH Pump)
E E f f o
E F S E
S
04
R U U
T T
O
N NO
O
D DO
05
BD1145a01
Figure 9-16: Pump NULL Adjustment
1. Install two equally matched 5000 psi (345 bar) (minimum) pressure gauges on the AG and BG port of the
pump:
LH Pump - pressure tap T56 for the AG port and T57 for the BG port (see 12 and 13, Figure 9-14).
RH Pump - pressure tap T52 for the AG port and T53 for the BG port (see 12 and 13, Figure 9-14).
2. Verify propel joystick controller is in neutral. Start motor and compare pressures between both gauges.

3. Remove both gauges, swap positions, and re-verify A and B port pressures again. This will verify that both
gauges are calibrated the same. If the gauges are not equal, use only one gauge and swap between port A
and port B while making adjustments.
4. Refer to Figure 9-16. Hold the trimmer (03) in position and loosen the trimmer locknut (02).
5. Adjust the trimmer until both gauges read as close as possible. Manufacturer’s specifications indicate that
within 50 psi (3.5 bar) is acceptable (change in pressure between pump ports A and B should be within ~50 psi
(3.5 bar), with no motion of the actuator). Tighten the trimmer locknut after the setting is made.
6. Repeat steps 1 through 5 for the other pump.
9.3.2.5 Pump Removal

n t
Y e
m
To remove either of the hydrostatic pumps from the pump drive transmission, proceed as follows:
! WARNING NL uip ion

O q t
A L f E ra
I o p e
R ce O
E t
AT nan en
work.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
M te m
E i n i p
2. Clean all dirt away from the pump, hose, and electrical fittings.
C! WARNING
a q u
E N M E
R o r o r
E E f f
F E
E S S
R U U
T T
O
N NO
3. Check to be certain that the hydraulic pressure is completely vented from the high-pressure and control pres-
O
D DO
sure circuits.
4. Close both hydraulic tank suction strainer handwheel valves.
5. Tag and remove the hydraulic hoses from the pump. Cap or plug all hose fittings and pump ports.
6. Tag and disconnect the electrical control wiring from the stroker control on the pump.

hoisting equipment to stabilize and lift heavy objects. The main pump weighs approxi-
mately 335 lbs (152 kg).
7. Attach a suitable hoist to the pump to prevent an overhung load on the shaft when the mounting bolts are loos-
ened. Protect the external tubing on the pump from being bent or crushed.
t
8. Mark the pump, if more than one is being removed, to assure that it is remounted at the same shaft position on
n
the transmission.
Y e
m
9. Remove the capscrews and lockwashers from the mounting flange of the pump, and pull the pump away from
NL uip ion
the pump drive transmission. Use care to prevent binding of the shaft or damage to the spline teeth when with-
drawing the pump from its mounting.
O q t
L f E ra
10. Inspect the pump and pump drive transmission splines for damage.
I A o p e
R ce O
9.3.2.6 Pump Installation
E t
AT nan en
To install the pump on the pump drive transmission, proceed as follows:
M te m
E i n i p
C a q u
N M E
E r
hoisting equipment to stabilize and lift heavy objects. The main pump weighs approxi-
R fo
o r
FE E f
E
1. Using a suitable hoist, lift the pump into position at the rear of the pump drive transmission. Be careful to avoid
E S S
bending or pinching the external tubing on the pump with the sling.
R U U
T T
2. Grease the female spline with lithium grease before inserting the splined pump shaft.
O
N NO
3. Insert the shaft of the pump into the bore of the pump drive transmission. Be careful to avoid side loading and/
or binding of the shaft as the pump is moved into position against the transmission.
O
D DO
4. Install two hex nuts and hardened washers to fasten the pump to the pump drive transmission.
5. Fill the pump case with clean oil, then install the hydraulic hose assemblies in accordance with the identifica-
tion tags placed during pump removal.
6. Install the electrical wiring to the electro-hydraulic stroker control in accordance with the identification tags
placed during pump removal.
7. Open the handwheel valves.
8. Start the pump and monitor charge pressure. Refer to the start-up procedure in steps 6 through 9 in Subtopic
9.3.2.3.

9.3.2.7 Charge Pressure Pilot Relief Valve Adjustment

To set, refer to test point #4 under Subtopic 9.3.2.1.
9.3.3 Towing System (Option)
9.3.3.1 Description
The optional towing system package is used to provide brake release power when a drill needs to be towed and
power is not available to the drill to run the hydraulic system.
A hand pump is used to build up enough pressure in the brake release circuits to release the brakes. The pump
n t
has an internal relief valve to limit the pressure to 350 psi (24.1 bar). Actual output pressure can be observed on
e
the pressure gauge located in the brake enclosure.
Y m
NL uip ion
An accumulator is pre-charged to 200 psi (13.8 bar) and is used to store pressurized oil in the towing circuits to
compensate for normal oil leakage with the propel brakes released.
O q t
L f E ra
Below the directional control valve in the valve stack on VB4 is a check valve and a set of pilot operated check
A
valves. The purpose for these valves is to allow manual brake release with the use of the optional tow system hand
pump.
I o p e
ER ce O
A breakaway valve is included and is used to set the propel brakes in the event that the tow vehicle becomes sep-
t
AT nan en
arated from the drill. One end of a tether cable is attached to the tow vehicle and the other end is attached to a trip
plate in the valve. The valve is mounted on the drill and if the vehicles separate, the trip plate will be pulled out
M te m
causing oil flow to stop which will reset the brakes.
E i n i p
u
9.3.3.2 Components
NC a q
E r M E
The optional towing system is made up of the following major components: a brake release enclosure, an emer-
r
gency brake valve assembly, and a tow bar. A hand pump, pressure gauge and instruction decal are located inside
R
E E fo f o
the brake release enclosure. An accumulator is mounted on the outside of the brake enclosure. Although valve
bank 4 (VB4) is also used, it is included with the drill, even if the towing package is not installed. The only differ-
F S E
ence is that the output oil flow from the hand pump is input to VB4 through port HP on the brake valve manifold,
E S
otherwise port HP is plugged (refer to the schematic in Figure 9-11).
R U U
T T
9.3.3.3 Towing Procedure
O
N NO
O
D DO
Towing the drill requires an optional towing package to be installed. Do not use these
instructions for, and do not attempt to tow a drill that does not have the towing package
installed.
To tow the drill, proceed as follows:

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o e
Figure 9-17: Tow Bar
R ce O p
E
1. Install the tow bar on the two towing lugs attached to the drill frame at either the front or the rear of the drill.
t
AT nan en
2. Connect the other end of the tow bar to a suitable towing vehicle.
M te m
3. Attached the safety chains to the brackets mounted on the drill frame and tow bar.
E i n i p
C a q u
4. Insert the trip plate into the emergency brake valve as shown in Figure 9-18
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
BD0522a01
Figure 9-18: Emergency Brake Valve with Trip Plate

5. Secure the towing tether to the side of the tow bar as shown in Figure 9-19.
n t
Y e
m
NL uip ion
O q t
LEGEND
A L f E ra
01. Emergency Brake Valve
I o p e 05. 15-foot Wire Rope
R ce O
02. Anchor Shackle 06. Snap Spring
E
03. Rope Clamp and Thimble 07. Eye Pad
t
AT nan en
04. Chain Link 08. Brake Valve Mount
M te m
E i n i pFigure 9-19: Towing Tether
C a q u
N M E
6. Attach one end of the tether to the towing vehicle. Use a shackle to attach the other end of the tether to the trip
E r r
plate in the brake valve (refer to Figure 9-18).
R
E E fo f o
E F S E
R U U S
T T
O
N NO
O
D DO

7. Refer to Figure 9-20 and disengage the propel motor coupler as follows:
01 02 03 04
05
06
07
08
n t 09
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
R ce O
BD0377a01
E t
AT nan en
LEGEND 05. Cover
M te m
01. Propel Motor 06. Bolt
02. Input Shaft Sleeve 07. Cap
E n i p
03. Coupler 08. Hex Head Bolts
C a q
04. Propel Transmission
i u
09. Shift Sleeve
E N M E
R o r r
Figure 9-20: Transmission Disconnect for Towing
o
f
E E ! WARNINGf
E F S E
R U U S
Unexpected drill movement could result in serious bodily injury or death. Disengage the
T T
motor coupler only while the drill is at standstill. Set the brakes on the tow vehicle and
O
N NO
chock the tow vehicle.
O
D DO
Step 1: Remove bolts, spacer, and cap.
Step 2: Clean the sealing surfaces.
Step 3: Remove the two hex head bolts, insert them 90° offset into the shift sleeve, and turn them in, evenly and
in steps, to pull out the shift sleeve.
Travel of the shift sleeve is approximately 13/16 inch (30 mm) outward.
Step 4: Assemble the spacer and cap, in that order, with bolts. The coupler and input shaft are now disengaged,
with the propel motor disconnected from the gear drive.

Step 5: Repeat the procedure for the other propel motor coupler.
! WARNING
Unexpected drill movement could result in serious bodily injury or death. Disengage the
motor coupler only while the drill is at standstill. Set the brakes on the tow vehicle and
chock the tow vehicle.
8. Open the door on the manual brake release enclosure, mounted on the left side of the frame near the forward
end of the drill.
n t
Y e LEGEND
m
NL uip ion
01. Pressure Gauge
02. Pressure Release Valve
03. Hand Pump
O q t 04. Instructions
A L f E ra
I o p e
R ce O
01
E t
AT nan en
M te m
02
E i n i p
C a q u
E N M E
r r
03
R
E E fo f o
E F S E 04
R U U S
T T
BD0029-01
O
N NO
Figure 9-21: Brake Manual Release Enclosure
O
D DO
9. Close the manual pump pressure release valve located on the manual pump.
10. Start pressurizing the tow brake circuit. Continue to pump until the gauge reads 350 psi (24.1 bar).
11. Test the emergency release valve by removing the trip plate (refer to Figure 9-18). The pressure reading
should reduce to zero.
12. Install the trip plate back into the brake valve.
13. Re-pressurize the circuit, using the manual pump to pressurize until the reading on the gauge is 350 psi (24.1
bar).

Low hydraulic pressure could allow the brakes to drag, causing damage to the propel
transmission. Monitor the pressure during the towing process. Keep pressure at 350 psi
(24.1 bar).
9.3.3.4 Tow the Drill to the New Location
Using an appropriate towing vehicle, follow the warnings and cautions below:
t
1. Confirm that the towing tether line is connected to the towing vehicle so that it will set the propel brake if the
n
towing connection is broken.
Y e
m
NL uip ion
O q t
Excessive towing speed can cause significant damage to the drill. The drill must not be
L f E ra
towed faster than it was designed to propel. Do not exceed 1 mph (1.6 kph).
A
I o p e
! WARNING
ER ce O
t
AT nan en
Blasthole drill tipover due to steep grades can cause severe injury, death or machine
damage. Never tow the drill on grade values greater than recommended for machine
M te m
configuration. Follow the guidance on the stability chart in the operator’s cab for towing
E i n i p
as well as for propelling. If uncertain contact your P&H MinePro Services representative
for consultation.
C a q u
E N M E
r r
2. Tow slowly over even terrain. Station guides on the ground to alert the towing vehicle of any obstructions,
R
E E fo o
including overhead obstructions. Maintain communications with the towing vehicle operator at all times.
f
E F S E
R U U S
T T
Lack of lubrication to the crawler assemblies during towing will result in component
O
damage. Before towing and while the drill is being towed, be sure that the moving parts
N NO
of the crawler assemblies have been and will continue to have the lubrication applied in
the correct amount and frequency.
O
D DO
3. Tow a short distance (100 meters) and check the temperature of the bushings on the lower rollers. If tempera-
ture is excessive, allow the bushings to cool to an acceptable temperature before continuing.

4. Lubricate the bushings by installing a grease gun on the injector manifold at the side of the crawler frame.
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
Figure 9-22: Crawler Frame Manual Lubrication
M te m
E i n i p
C a q u
N M E
Do not touch the transmission with bare hands to check temperature. This can cause
severe burns.
RE o r r
E E f f o
E F S E
R U U S
The propel transmission can overheat when being towed. As a general precaution, mon-
T T
itor transmission temperature and do not allow it to exceed 190° F (90° C).
O
N NO
5. Also check to be certain that the propel transmissions are not overheating. If the transmissions are too warm,
allow them to cool to an acceptable temperature (near ambient) before continuing.
O
D DO
6. Continue towing and checking at 100-meter intervals until the drill is at the new location.
9.3.3.5 Restore Drill to Operational Condition
1. Refer to Figure 9-20 and engage the propel motor coupler as follows:
A. Remove bolts, cap and spacer.
B. Clean the sealing surfaces.
C. Remove the two hex head bolts, insert them 90° offset, and draw the shift sleeve into cover by tightening the
bolts equally.

D. Assemble cap and spacer, in that order, into cover with bolts. Coupler and input shaft are now engaged, and
the hydraulic motor and gear drive are connected.
E. Repeat the procedure for the other propel motor coupler.
2. Uncouple the towing vehicle and stow the tow bar assembly.
! DANGER
Hazardous voltage will cause burns, injury, or death. The trail cable that supplies electric
power to the drill carries high voltage. Turn off power to the trail cable at the power sub-
t
station, and use lockout/tagout procedures before installing the high voltage trail cable
n
e
on the drill.
Y m
NL uip ion
3. Install the high-voltage trail cable between the power substation and the drill. Inspect the cable connections
and the cable for damage prior to restoring main power from the substation.
O q t
L f E ra
4. Start the drill.
9.3.4 Accumulator Pre-Charging

I A o p e
ER ce O
t
On a new drill or when a replacement accumulator is installed, the accumulator is not pre-charged. For the accu-
AT nan en
mulator to work properly, it must be pre-charged to 200 psi (13.8 bar) with Nitrogen. To pre-charge an accumulator,
follow the instructions provided with your accumulator charger.
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

9.4 Auxiliary Hydraulic System Components

Oil Cooler Subtopic 9.2.3
Thermostatic Mixing Valve Subtopic 9.2.4
Auxiliary System Flow Diagram Subtopic 9.4.1
Auxiliary Hydraulic Pump Subtopic 9.4.2
Valve Banks
n t Subtopic 9.4.3
Y e
m
Valve Bank 1 (VB1) Subtopic 9.4.3.1
NL uip ion
Station 1: Relief/Unload Oil Diverter Valve Circuit
O q t
Station 2: Auxiliary Winch Control Circuit
A L f E ra
Station 3: Mast Hoist Circuit
I o p e
R ce O
Station 4: Optional Hydraulic Dust Curtain Control Circuit
E t
AT nan en
Stations 7 and 8: Pipe Rack Control Circuits
M te m
Stations 1 and 2: Breakout Wrench Circuits
E i n i p
C a q u
Station 3: Deck Wrench Circuit
E N M E Station 5: Back Brace Lock Circuit
R o r o r
f
Station 7: Mast Anchor Pins Circuit
F E E f
E
E
R U U S S Station 1: Unloader Relief Circuit
T T
Station 2: Front Jacks Circuit
O
N NO
Stations 3 and 4: Rear Jack Circuits
Table 9-5: Auxiliary Hydraulic System Components
O
D DO Flow Diagram
9.4.1 Auxiliary System
Figure 9-23 is a block diagram that shows the oil flow between the auxiliary hydraulic system components.

P2
P1
VB2 P2
VB1
Spare VB3 320XPC Auxiliary
Pipe Rack 2 Hydraulic Flow
Spare
Mast Anchor Pins
Pipe Rack 1
Spare High Pressure

Spare
t
Spare Suction
n
RH Rear Jack T1 Return to Tank
e
P1
Back Brace Lock
Spare
Y
T2
m
P2 T1
NL uip ion
LH Rear Jack
Spare
Spare
O q t
Front Jacks
L f E ra
Deck Wrench
Mast Hoist
I A o e
Unloader/Relief
p
Breakout Wrench
R ce O
Auxiliary Winch In/Out
E
T2
t
AT nan en
Relief Unload /
Oil Divert Breakout Wrench
Engage/Disengage
M te m
B1
E i n i p
C a q u
N
Auxiliary Pump
E r M E
r
22.0 GPM Output
R fo o
Section
f
P2
FE E
E
B
Inlet
E S S
Oil Cooler Hydraulic
Hyd Oil C
Relief Valve
R U U
Cooler System A
90 PSI Thermostatic
37.7 GPM Output
T T
Mixing Valve
Section
P1
O
N NO
O
D DO From Oil
Topoff Check Valve
Main Return
Filters
From Front
Jacks Regen
Valve Drain
System
Hydraulic
Tank
320xpc aux hyd flow
LH Suction Strainer
Figure 9-23: Auxiliary Hydraulic System Block Diagram

9.4.2 Auxiliary Hydraulic Pump
P1
P2
01
02
t
08 07 03
e n
Y m
NL uip ion
R61261a
06
LEGEND
O q t
L f E ra
01. Auxiliary Pump 05
A
02. Pump Drive Transmission (PDT)
03. Main Hydraulic Pump (Ref.)
I o p e 04
R ce O
04. Low Pressure Pump (Ref.)
E
05. Main Drive Motor
t
AT nan en
06. Pump Spline Adapter
07. Snap Ring
R58621F1_02a
M te m
08. Inlet Port
P1 Displacement = 37.7 GPM (143.3 LPM)
E i n
P2 Displacement = 22 GPM (83.5 LPM)
i p
C a q u
E N M E Figure 9-24: Auxiliary Pump Location
R o r o r
9.4.2.1 Description
E E f f
E F S E
R U U S
T T
Only the hydraulic control portions of the various subsystems are described in this section. The
O
N NO
mechanical components that take their movement from the hydraulic circuit will be discussed in
the mechanical sections that pertain to them. For example, the hydraulic circuit that moves the
O
mast anchor pins is discussed here; discussion of the mast anchor pins themselves is in the
D DO
mast section.
Refer to Figure 9-24. Hydraulic oil flow and pressure for the auxiliary hydraulic system is produced by a vane-type,
double hydraulic pump (01). This pump is driven by the mechanical pump drive transmission (PDT). The PDT (02)
is driven by the power unit electric motor (05). Oil to the auxiliary hydraulic pump is drawn from the hydraulic tank,
through the left hand suction strainer and into the pump inlet (08). The pump delivers 22 gpm (83.5 lpm) from the
lower-volume, cover-end pump section (P2), and 37.7 gpm (143.3 lpm) from the higher-volume, shaft-end pump
section (P1). The pump shaft is driven at 2030 rpm through the gear ratio of the PDT.
The output flow from pump port P1 is directed into the pressure inlet port P2 on valve bank 1 (VB1). Oil flow contin-
ues through VB1 manifold, exits through port P1 on VB1 and enters valve bank 2 (VB2) through port P2. The out-
put flow from pump port P2 is directed into the pressure inlet port P1 on valve bank 3 (VB3). (also refer to flow
diagram in Figure 9-23).

When the Auto Level System is operating, or when the operator manually operates all four of the leveling jacks
simultaneously, the oil supply to VB3 comes from two sources:
• full output from the higher volume port P1 on the auxiliary pump
• an interruptible flow of high pressure oil from the port B1 on valve bank 1 (VB1).
Hot oil discharged from the three valve banks flows through the hydraulic system thermostatic mixing valve (unless
the oil temperature is too low (refer to Subtopic 9.2.3), an oil cooler, and returns to the tank though the two main
return filters. The oil cooler has a built-in relief valve to provide oil bypass if oil flow through the cooler core is
restricted.
9.4.2.2 Maintenance and Repairs

n t
Y e
m
No periodic maintenance is required. Repairs in the field are not recommended. If the pump requires service,
NL uip ion
remove it and send it to a qualified repair facility.
9.4.2.3 Removal
O q t
A L f E ra
I o e
Remove the pump from the system as follows:
R ce O p
! WARNING
E t
AT nan en
M te m
E i n i p
work.
C a q u
E N M E
r r
R
E E fo f o
2. Clean all dirt away from the pump, hose assemblies, and fittings.
E F S E
S
3. Turn the handwheel valve on the hydraulic tank left hand suction filter assembly fully counterclockwise to the
R U U
closed position.
T T ! WARNING
O
N NO
O
D DO
Hot hydraulic oil can spray, causing injury or death. Use lockout and tagout procedures
to guard against inadvertent hydraulic system or machine start up during service or
maintenance. Allow the hydraulic system to cool before maintenance or repair. Slowly
release pressure or vent circuits before disconnecting hydraulic lines. Wear appropriate
face and body protective devices while carefully loosening any connection or fitting.
sure circuits.To vent system pressure, attach a Microbore hose from the hydraulic test kit between the appro-
priate test port and the test port that is open to the tank.
5. Tag and remove the hydraulic hoses from the pump. Cap plug all hose fittings and pump ports to prevent the
entry of foreign material into the pump or hydraulic system.

6. Support the pump (pump weighs approximately 60 lbs [27.3 kg]) so that its entire weight will not be supported
by the shaft when the mounting capscrews are removed. Remove the two capscrews and lockwashers that
secure the pump to the pump drive transmission. Slide the pump back from the pump drive until the driveshaft
is clear of the pump drive, and remove the pump.
7. Remove the snap ring and remove the spline adapter. Check the spline adapter and shaft splines for excessive
wear or damaged teeth. Replace as necessary.
n t
e
Exercise care when installing the pump on the pump drive transmission to prevent mis-
Y m
alignment, which can lead to premature pump failure.
Install the pump on the pump drive as follows:

NL uip ion
O q t
L f E ra
1. Check the mounting flange on the pump drive, the pilot diameter on the pump, and the splined shaft and bore
A e
for burrs and imperfections that would prevent the pump from seating correctly on the pump drive. Carefully
remove any imperfections by lapping.
I
R ce O o p
E t
2. Make sure the snap ring (07) is installed in the middle groove of the spline adapter (06).
AT nan en
3. Apply a light coat of grease to the pilot diameter and spline adapter splines. Position the gasket on the pump.
M te m
E n i p
4. Carefully install the pump on the drive, and install the mounting capscrews and lockwashers. Be careful to pre-
C a q i u
vent misalignment when tightening the capscrews.
E N M E
5. Install the suction and pressure lines, then turn the suction line valve to the open position.
R o r o r
E E f f
6. Start the pump drive with no load applied to the pump to prime the pump. Operate the system at moderate
F
loading (such as the deck wrenches or the deck hatch) for a short period of time.
E S S E
R U U
7. Check the reservoir oil level, and add oil if required.
T T
O
N NO
O
D DO

9.4.3 Valve Banks
03
04 05
02
01
06
n t
Y e
m
~
NL uip ion
O q t
A L f E ra
I o p e
ER ce O 07
t
AT nan en
M te m 08
E i n i p
C a q u
BD1310a01
LEGEND
E N M E
r r
01. Valve Bank 1 (VB1) 05. Machinery House Left Side Wall
R
02. Valve Bank 2 (VB2)
E E
03. Valve Bank 3 (VB3)
fo f o
06.
07.
Machinery House Rear Wall
Low Pressure Hydraulic Pump and Motor
F E
04. Valve Bank 4 (VB4) 08. Hydraulic Tank
E
R U U S SFigure 9-25: Valve Bank Locations (Inside Machinery House)
T T
O
N NO
O
D DO
All directional control valves on the valve banks in this system are operated by 24 VDC electri-
cal solenoids. The solenoids receive operating signals from the AC800 control system located
in the main control cabinet in the machinery house.
This section only covers valve banks 1 through 4 (VB1-VB4). Valve bank 6 (VB6) is only used
on drills with the optional hydraulic boarding stairs. This valve is located above and between
valve banks 3 and 4 on the machinery house left wall. Details for VB6 are described in Section
20, Subtopic 20.2.1.

9.4.3.1 Valve Bank 1 (VB1)
When facing the valve banks, VB1 is mounted on the left side of the machinery house rear wall (see Item 01, Fig-
ure 9-25).
Refer to Figure 9-26. Five hydraulic circuits are controlled by the valve assemblies mounted on VB1: Unloader/
Diverter, Auxiliary Winch, Mast Hoist, Hydraulic Dust Curtain (option) and Pipe Racks 1 and 2. Stations 5 and 6 are
available for future valve assemblies. The following topics describe the functions of these six circuits in detail.
Refer to the auxiliary hydraulic schematic in the LinkOne parts manual for your drill for reference.
08 07 06 05 04 03 02 01
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
09
O
D DO 320-VB1_01
LEGEND
01. Station 1: Relief Unload/Oil Diverter Circuit 06. Station 6: Available Circuit - Blank Cover
02. Station 2: Auxiliary Winch Circuit 07. Station 7: Left Hand Pipe Rack Circuit (Pipe Rack
03. Station 3: Mast Hoist Circuit #1)
04. Station 4: Optional Hydraulic Dust Curtain Circuit 08. Station 8: Right Hand Pipe Rack Circuit (Pipe Rack
(shown here with a blank cover - for details, see #2)
Subtopic: Station 4: Optional Hydraulic Dust Cur- 09. Adjustable 3000 psi (207 bar) Pressure Relief
tain Control Circuit on page 9.55.) Valve
05. Station 5: Available Circuit - Blank Cover
Figure 9-26: Valve Bank 1

Station 1: Relief/Unload Oil Diverter Valve Circuit
UNLOADER
01 DIVERTER
B
VB1DS
1.21.1.1 15
A P
B T
VB1RS
05 1.21.1.0 14 3000 PSI
t
FROM AUXILIARY PUMP 16
207 BAR
n
SMALL SECTION A
e
PRESSURE PORT
Y
SEE SHEET 1
m
GP
NL uip i02on
T117
X
P1
O q t
A L f E ra T1
I o e
X X X X
A1G B1G
p
A1 B1 GT
R ce O
04 T115 T116
T118
0-22.0 GPM
E
0-83.5 L/MIN
7
t
AT nan en
3600 PSI
248 BAR 17
M te m
03 0 OR 22.0 GPM TO VALVE
E n i p
0 OR 83.5 L/MIN BANK 2
C a q i u
TO OIL COOLER P2 PORT
INLET SEE SHEET 2 & 4
N M E
SEE SHEET 2
RE o r r
TO VALVE BANK 3
f o
P PORT BD1223a01
E E f
SEE SHEET 5
E F S E
Numbers in the circles refer to the Bill of Material (Refer to the
R U U S
LinkOne Parts manual for your machine).
Numbers in the triangles refer to the System Data Sheet (Table 9-7).
T T
Txxx is a reference to pressure taps listed in Table 9-8.
LEGEND
O
N NO
01. Solenoid B 04. Adjustable 3000 PSI (207 Bar) Pressure Relief
O
D DO
02. 3600 PSI (248 Bar) Overload Relief Valve Valve
03. Check Valve 05. Solenoid A
Figure 9-27: Relief/Unload Oil Diverter Valve Circuit
Refer to Figure 9-27. One of the primary functions of VB1 is to control the maximum hydraulic pressure available to
VB1 and VB2, and to implement the timing of when high pressure is available for system operation. This function is
managed by the relief/unload oil diverter valve. This valve is a three-position, four-way, open center solenoid oper-
ated valve with manual override in both directions. It is spring-centered, and the center is open. When in the spring-
centered open position, this valve allows oil from the auxiliary pump to bypass the system pressure relief valve
(04), flowing through the oil cooler system and back to the tank without building pressure. This is an energy-saving
provision for periods when the auxiliary hydraulic circuits are at rest.

The overload relief valve (02) protects VB1, VB2 and VB3 from excessive pressure either while the relief/unload oil
diverter valve is shifting or if a system failure occurs. This relief valve is factory preset to 3600 psi (248 bar) and
must not be adjusted or pressure tested.
When the operator initiates movement for any auxiliary function supplied by VB1 or VB2, the AC800 control system
causes solenoid B (05) to energize. This causes the valve spool to shift so that oil from the P port of the valve flows
to the A port and to the blocked port A1. Oil flow backs up against the pressure relief valve (04) and system pres-
sure builds to 3000 psi (207 bar) which is the maximum setting of the relief valve. This establishes the maximum
pressure available to the equipment associated with VB1 and VB2.
! WARNING
n t
e
Do not exceed the maximum relief valve setting of 3000 psi (207 bar). Overpressurizing
Y m
the system could result in equipment failure, which could result in severe personal
NL uip ion
injury or death.
O q t
When the operator activates the auto level system, or when all four leveling jacks are manually operated simulta-
L f E ra
neously, the AC800 control system causes the A solenoid (05) to de-energize (if energized) and the B solenoid (01)
A
to energize. Oil flows from the valve P port, through the B port and out of the VB1 manifold B1 port. The diverted oil
I o p e
then flows to port P2 on VB3 to merge with oil from the high volume side of the auxiliary pump. The check valve
R ce O
(04) prevents reverse flow back through VB1.
E t
AT nan en
VB1 / VB2 Pressure Relief Valve Adjustment.
M te m
1. Install a 0-5000 psi (345 bar) pressure gauge on VB2 pressure tap T217.
E i n i p
C a q u
2. Start the drill and activate any function on valve bank 1 or 2. The pressure gauge should indicate 3000 psi (207
N
bar). If necessary, adjust the pressure relief valve following the steps below.
E M E
! r WARNING
R fo o r
FE E f
S E
E S
R U U
work.
T T
O
N NO
O
D DO ! WARNING
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Allow
the hydraulic system to cool before maintenance or repair. Slowly release pressure or
vent circuits before disconnecting hydraulic lines. Wear appropriate face and body pro-
tective devices while carefully loosening any connection or fitting.
4. Be sure that no pressure exists in any of the auxiliary hydraulic system circuits.

Clean any dirt away from the relief valve assembly (09, Figure 9-26) before loosening any of the
components.
5. Refer to Figure 9-28. Hold the body (04) of the valve with a wrench to prevent it from turning and then use a
hex wrench to remove the end plug (01).
6. Use a hex wrench to turn the spring cap (03) in or out. Turning the cap in will increase pressure.
t
7. Make sure the o-ring (02) is not damaged and securely install the end plug.
e n
8. Start the drill, operate any function on VB1 or VB2 and check the pressure at T217. If necessary, repeat steps
Y m
3 through 7 until a pressure of 3000 psi (207 bar) is obtained.
NL uip ion
O q t
A L f E ra
I o e
LEGEND 01 02
01. End Plug
R ce O p
E
02. Spring Cap 03
t
AT nan en
03. Valve Body
M te m
04
E i n i p
C a q u
E N M E
R o r o r
E E f f
R57905D1
E F S E
R U U S Figure 9-28: VB1 and VB2 Pressure Relief Valve
T T
O
N NO
O
D DO

Station 2: Auxiliary Winch Control Circuit
01 LEGEND
01. Solenoid B
02. Solenoid A
03. Pressure Reducing Valve
03 04. Proportional Flow Control
Valve
02 05. Brake and Orifice Circuit
FROM AUXILIARY PUMP
SMALL SECTION 06. Auxiliary Winch
t
PRESSURE PORT
e n
Y
L ip nm
N
O qu tio
0-22.0 GPM
04 0-83.5 L/MIN
A L f E ra
I o p e
R ce O
TO OIL COOLER
TO VALVE
INLET
E
BANK 2
t
P2 PORT
AT nan en
06
M te m
E i n i p
C a q u
E N M E
R 05fo
r o r
E E f
BD1222a01
E F S E
S
R U U
T T
O
N NO Figure 9-29: Auxiliary Winch Control Circuit
O
D DO
Refer to Figure 9-29. The auxiliary winch valve controls the direction and maximum pressure of the oil flow to the
auxiliary winch hydraulic motor. This is a three-position, four-way, motor center valve. The valve is spring centered,
and the center is blocked at port P and open to tank at ports A and B. When in the spring-centered position, this
valve blocks pressure from the pump. All other circuits are open back to the tank.
An electro-proportional, pressure-compensated flow control valve (04) delivers flow to the winch motor that is pro-
portional to the applied electric current. The amount of applied current is determined by how far the winch remote
pendant control pushbutton is depressed (see the following Notice). With a current of 0 amps (pushbutton not
pressed), there is no flow through the valve. By pressing the pendant pushbutton slowly all the way down, flow will
increase until a maximum output flow of 22 gpm (83.5 lpm) is reached. This will produce a maximum drum rotation
speed of 15.8 rpm while hoisting. During maximum lowering, drum rotation speed is reduced by a brake and orifice
circuit (05) which limits the speed to 13 to 14 rpm. The flow rate set points can be modified by adjusting the Lynch
connector on the valve (refer to Lynch Connector Adjustment in Section 5).

The UP and DOWN pushbuttons on the auxiliary winch pendant control are proportional. The
speed that the winch hook travels up or down is controlled by pressing the pushbutton more or
less to increase or decrease the speed. For slow speed, press the pushbutton slightly; for high
speed, press the pushbutton completely. For additional information, please refer to the operator
manual.
A 2000 psi (138 bar) pressure reducing valve (03) determines the maximum pressure in the circuit. The lifting
capacity of the winch is based on an operating pressure of 2000 psi (138 bar) as determined by the reducing valve
t
setting, 0.0625 inch diameter wire rope, and by the number of layers of wire rope on the winch drum:
Number of 0.625 Inch

e n
Line Pull Rating Total Drum Storage
Y
Diameter Wire Rope Layers lbs. (kg) Feet (Meters)
m
NL uip ion
1 15,867 (7,212) 35 (10.7)
2 14,184 (6,447) 68 (20.7)
3
O q t12,824 (5,829) 106 (32.3)
4
A L f E ra
11,702 (5,319) 147 (44.8)
5
I o p e
10,760 (4,891) 191 (58.2)
6
ER ce O 9,959 (4,527) 239 (72.9)
A T an nt
Table 9-6: Winch Lifting Capacities
M ten me
! WARNING
E i n i p
C a q u
Always maintain at least five wraps of wire rope on the winch drum. Failure to heed this
N M E
warning may result in the wire rope coming off of the drum which could result in serious
E
injury or death.
R o r o r
E E f f
F
Auxiliary Winch Pressure Reducing Valve Adjustment. Limits the winch operating pressure to 2000 psi (138
bar). To check:
E S S E
R U U
1. Install a 0-5000 psi (345 bar) pressure gauge on VB1 pressure tap T119 located on the wall side of this valve
T T
(see 02, Figure 9-26).
O
N NO
2. Disconnect both winch solenoid valve electrical connectors to AWLS and AWRS on VB1.
O
D DO
3. Operate the winch at full speed in either direction using the auxiliary winch remote tether control. This will ener-
gize both VB1RS and AWPV which both need to be on to generate winch pressure.
4. Measure the pressure at T119. The pressure should be 2000 psi (138 bar). If the pressure is too low or too
high, proceed with step 5, below.
5. Loosen the locknut and use a small-bladed screwdriver to adjust the pressure reducing valve, as required.
Tighten the locknut when finished.
6. Reconnect the winch solenoid valve electrical connectors.

Station 3: Mast Hoist Circuit
01
03
FROM AUXILIARY PUMP
SMALL SECTION
PRESSURE PORT 02
n t
Y e
m
NL uip ion 0-22.0 GPM
O q t
0-83.5 L/MIN
A L f E ra
I o p e
R ce O 04
TO OIL COOLER
TO VALVE
E
INLET
BANK 2
t
05
AT nan en
P2 PORT
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
BD1221a01
E F S E
R U U S
T T
LEGEND
O
N NO
O
D DO
01. Solenoid B 04. Hoist Cylinders
02. Solenoid A 05. Counterbalance Valves
03. Proportional Flow Control Valve
Figure 9-30: Mast Hoist Control Circuit
Refer to Figure 9-30. The mast hoist valve controls the direction and maximum raise/lower pressure of the oil flow
to the mast hoist cylinders. This is a three-position, four-way, motor center valve. The valve is spring centered, and
the center is blocked at port P and open to tank at ports A and B. When in the spring-centered position, this valve
blocks pressure from the pump. All other circuits are open back to the tank.

An electro-proportional, pressure-compensated flow control valve (03) delivers flow to the hoist cylinders that is
proportional to the applied electric current. On current drills, the amount of applied current is 0 amps when the
Hoist Positioning Switch on the upper right control panel is OFF. When the operator holds the switch in the RAISE
or LOWER position, this valve will open to a maximum output flow of 22 gpm (83.5 lpm). This will produce a mast
raise cycle time of 139 seconds and a mast lower cycle time of 93 seconds. The raise and lower cycle times can be
made longer by adjusting the Lynch connector on the valve (refer to Lynch Connector Adjustment in Section 5).
Counterbalance valve pressures are pre-set at the factory. Changing the settings can
cause severe equipment damage. Do not adjust counterbalance valve pressure settings.
n t
If adjustments are necessary, contact your local P&H MinePro Services.
Y e
m
Each mast cylinder (04) circuit is equipped with dual counterbalance valves (05) to prevent uncontrolled movement
NL uip ion
in either the up or down direction should a malfunction disrupt oil flow. Counterbalance valve pressures are pre-set
at the factory and are not to be adjusted.
O q t
L f E ra
When the operator presses and holds the mast hoist switch in the RAISE position, the AC800 control system
A
causes solenoid A (02) to energize. The valve spool shifts so that oil from the small section of the auxiliary pump
I o p e
flows through the flow control valve (03), P port of the valve to the A port of the valve and out the A3 port of the
R ce O
valve bank. Oil flow continues over the check valve portion of the counterbalance valves (05) into the head end of
E t
the hydraulic cylinders. As pressure increases, the crossover ports on the counterbalance valves cause the valve
AT nan en
ports on the opposite line to open. Oil from the rod end of the cylinders is then able to flow through the counterbal-
ance valves, manifold port B3, directional control valve port B to T and back to tank.
M te m
E n i p
When the operator presses and holds the mast hoist switch in the LOWER position, the AC800 control system
C a q i u
causes solenoid B to energize. The valve spool shifts so that oil from the small section of the auxiliary pump flows
N
through the flow control valve (03), P port of the valve to the B port of the valve and out the B3 port of the valve
E M E
bank. Oil flow continues over the check valve portion of the counterbalance valves (05) into the rod end of the
r r
hydraulic cylinders. As pressure increases, the crossover ports on the counterbalance valves cause the valve ports
R fo f o
on the opposite line to open. Oil from the head end of the cylinders is then able to flow through the counterbalance
E E
F
valves, manifold port A3, directional control valve port A to T and back to tank.
E S S E
R U U
T T
O
N NO
O
D DO

Station 4: Optional Hydraulic Dust Curtain Control Circuit
B
DUST CURTAIN DCLS
1.21.1.7 01
A P
B T
DCRS
1.21.1.6 02
63
A
03a
1000 PSI
69.0 BAR
80
03
t
62 350 PSI
79
n
24.1 BAR
03b 04
05 Y
61
e 1.5 GPM
m
NL uip ion
78 5.7 L/MIN
FROM AUXILIARY PUMP 60
O q t
SMALL SECTION
77
PRESSURE PORT
59
A L f E ra
I o p e
ER ce O
t
AT nan en
A4G A4 B4 B4G
T109 T110 0-22.0 GPM
M te m
0-83.5 L/MIN
E i n i p
C a q u
N
TO OIL COOLER
T125
M E 06
T124 TO VALVE
68 68 INLET
E
BANK 2
r r
P2 PORT
R fo f o
2.00", 51mm Ø BORE
E E
1.00", 25mm Ø ROD
58
F
8.00", 203mm STROKE
E
BD1237a01
E S
LOWER RAISE
R U U S
T T
O
N NO
O
LEGEND
D DO
01. Solenoid B 03b. Adjustable 350 PSI (24.1 Bar) Pressure
02. Solenoid A Relief Valve for B Circuit (Extend)
03. Pressure Relief Valve Manifold Assembly 04. Adjustable Flow Control Valve
03a. Adjustable 1000 PSI (69 Bar) Pressure 05. Dual Check Valve Assembly
Relief Valve for A Circuit (Retract) 06. Dust Curtain Cylinder
Figure 9-31: Optional Hydraulic Dust Curtain Control Circuit
Refer to Figure 9-31. The dust curtain circuit controls the direction, rate of flow, and maximum operating pressure
of the oil flow available for operation of the dust curtain raising and lowering cylinder. The directional control valve
is a three-position, four-way, solenoid actuated valve with manual override in both directions. The valve is spring
centered, and the center is blocked at port P and open to tank at ports A and B. When in the spring-centered posi-
tion, this valve blocks pressure from the pump. All other circuits are open back to the tank.

The second valve down (03) in the stack is a manifold with a pair of adjustable pressure relief valves. These valves
are used to limit the pressure to the dust curtain cylinder. The raise and lower pressures are different due to the
weight of the curtain and the different forces required. Adjust the pressure relief valves as follows:
Dust Curtain Lower (Cylinder Extend) Adjustment
Step 1: Attach a 0-1500 psi (0-103 bar) gauge to pressure tap T110 on VB1.
Step 2: Start the main motor.
! WARNING
n t
e
Make sure all personal are clear of the dust curtain. Failure to head may result in serious
Y m
injury or death.
Step 3:
NL uip ion
Have an assistant press and hold down the dust curtain LOWER switch in the operator’s cab. Have the
O q t
assistant continue to hold down the switch after the cylinder is fully extended and read the pressure on
L f E ra
the gauge. The pressure should be 350 psi (24.1 bar). If necessary, loosen the lock nut and adjust the
A
valve (03b) until the pressure is correct. Tighten the lock nut after the adjustment is made.
I o p e
R ce O
Dust Curtain Raise (Cylinder Retract) Adjustment
E t
AT nan en
Step 1: Attach a 0-1500 psi (0-103 bar) gauge to pressure tap T109 on VB1.
M te m
!E WARNING
i n i p
C a q u
E N M E
R o r o r
f f
injury or death.
FE E
Step 3:
E S E
Have an assistant press and hold down the dust curtain RAISE switch in the operator’s cab. Have the
S
R U U
assistant continue to hold down the switch after the cylinder is fully retracted and read the pressure on the
gauge. The pressure should be 1000 psi (69 bar). If necessary, loosen the lock nut and adjust the valve
T T
(02a) until the pressure is correct. Tighten the lock nut after the adjustment is made.
O
N NO
The third valve down (04) in the stack is an adjustable flow control valve. This valve is used to limit the amount of
oil flow to the dust curtain cylinder to 1.5 gpm (3.8 lpm) which in turn, controls the speed at which the cylinder
O
D DO
extends and retracts. Adjust the flow control valve as follows:
Dust Curtain Flow Control Valve Adjustment
! WARNING
injury or death.

Step 2: Have an assistant press and hold down the dust curtain RAISE switch in the operator’s cab until the cylin-
der is fully retracted.
Step 3: Have an assistant press and hold down the dust curtain LOWER switch in the operator’s cab until the cyl-
inder is fully extended. The time to extend should be 4.4 seconds. If necessary, adjust the flow control
valve (05) depending on actual extend time: turn the screw in for more flow (faster time) or out for less
flow (slower time).
Step 4: Have an assistant press and hold down the dust curtain RAISE switch in the operator’s cab until the cylin-
der is fully retracted. The time to retract should be 3.3 seconds. If necessary, adjust the flow control valve
(05) depending on actual retract time: turn the screw in for more flow (faster time) or out for less flow
(slower time).
n t
e
Step 5: If necessary, repeat steps 3 and 4 until the extend and retract times are correct.
Y m
NL uip ion
The fourth valve down (05) is a manifold with a pair of pilot-operated check valves. These valves lock the dust cur-
tain cylinder (06) in any position it is left in. Energizing the directional control valve delivers oil through one check
O q t
valve and to one side of the cylinder while opening the opposite check valve to allow oil from the other side of the
L f E ra
cylinder to flow to the tank.
I A o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

Stations 7 and 8: Pipe Rack Control Circuits
FROM AUXILIARY PUMP

SMALL SECTION
PRESSURE PORT
RH LH
PIPE RACK PIPE RACK
PIPE RACK 2 PIPE RACK 1 01
B B
PR2SS PR1SS
1.22.1.6 1.22.1.4
A P A P 02
PR2OHS B T PR1OHS B T
t
1.22.1.7 1.22.1.5
n
A A
P2
22.0 GPM
Y e
m
NL uip ion
83.5 L/MIN X
T2
A8 B8 B8T A7 B7 B7T
O q t
A8G B8G A7G B7G 0-22.0 GPM
T101 T102 T103 T104 0-83.5 L/MIN
A L f E ra
e
26
I
26
o p
TO OIL COOLER
R ce O
TO VALVE
INLET
BANK 2
E
P2 PORT
t
AT nan en
T120 T121 T122 T123 FROM VALVE BANK 4 PIPE
68 RACK HOLDBACK SECTION
68 68
M te m
B PORT
EXT RET EXT RET
E i n i p
C a q u
32 32
3000 PSI 3000 PSI
N
03
M E
207 BAR 207 BAR
3:1 RATIO 3:1 RATIO
E r r
24 24
R
E E fo f o PRPS2 PRPS1
F
1.15.5.2 1.15.4.5
E S S E
STOWED
OVER
HOLE
STOWED
OVER
HOLE
7.00 BORE
23 2.75 ROD 21
R U U
18.12 ROD
T T
7.00 BORE
23 2.75 ROD 21
O
18.12 ROD
N NO
R H PIPE RACK L H PIPE RACK BD1220a01
CYLINDER CYLINDER
O
D DO Numbers in the circles refer to the Bill of Material (Refer to the
LEGEND
01. Solenoid B (Typical) 04. Check Valve
02. Solenoid A (Typical) 05. Adjustable 3000 PSI (207 Bar) Pressure Relief
03. 3600 PSI (248 Bar) Overload Relief Valve Valve
06.
Figure 9-32: Pipe Rack Control Circuits

Refer to Figure 9-32. Each pipe rack valve controls the direction and maximum pressure of the oil flow to the pipe
rack cylinder. This is a three-position, four-way, A to T with B and P blocked style valve. The valve is spring cen-
tered, and the center is open from port A to port T. When in the spring-centered position, this valve blocks pressure
from the pump and port B, but also provides a passage for oil at port A to return to tank.
n t
Each pipe rack cylinder circuit is equipped with dual counterbalance valves (03) to prevent uncontrolled movement
e
should a malfunction disrupt oil flow. Counterbalance valve pressures are pre-set at the factory and are not to be
adjusted.
Y m
NL uip ion
With the pipe rack select switch set for the desired pipe rack and when the operator presses and holds the pipe
O q t
rack over hole switch in the OVER HOLE position, the AC800 control system causes solenoid A (02) to energize.
L f E ra
The valve spool shifts so that oil from the small section of the auxiliary pump flows through the P port and A port of
A
the valve and out of the A2 port of the valve bank. Oil flow continues over the check valve portion of the counterbal-
I o p e
ance valve into the head end of the hydraulic cylinder. As pressure increases, the crossover port on one counter-
R ce O
balance valve causes the valve port on the opposite counterbalance valve to open. Oil from the rod end of the
E t
cylinder is then able to flow through the counterbalance valve, directional control valve port B to T and back to tank.
AT nan en
The availability of high pressure oil to operate these circuits is dependent upon the position of the relief unload/oil
M te m
diverter valve on valve bank 1, as described under Subtopic: Station 1: Relief/Unload Oil Diverter Valve Circuit on
E n i p
page 9.48.
C a q i u
N
When the pipe rack is in the stowed position, the pipe rack holdback circuit on valve bank 4 uses oil from the low
E M E
pressure pump to maintain pressure on the pipe rack cylinder to keep the pipe rack cylinder retracted (refer to Sub-
r r
topic: Station 8: Pipe Rack Holdback Circuit on page 9.107.). A limit switch which is located near the bottom of the
R fo f o
pipe rack causes an LED indicator on the operator’s console to illuminate when the rack is in the stowed position.
E E
E F S E
R U U S
T T
Because the solenoid on the pipe rack holdback valve is energized whenever the pipe rack is
O
N NO
“stowed”, which is the majority of the time that the machine is operating, it will feel hot to the
touch. This does not mean that the solenoid is faulty, just that it is working a lot.
O
D DO

When facing the valve banks, VB2 is mounted on the center of the machinery house rear wall (see Item 02, Figure
9-25).
Refer to Figure 9-33. Five hydraulic circuits are controlled by the valve assemblies mounted on VB2: Breakout
Wrench Engage/Disengage, Breakout Wrench IN/OUT, Deck (Slide) Wrench, Back Brace Lock and Mast Anchor
Pins (stations 4, 6 and 8 are available for future valve assemblies).The following topics describe the functions of
the five circuits in detail. Refer to the auxiliary hydraulic schematic in the LinkOne parts manual for your drill for ref-
erence.
08 07 06 05
n t 04 03 02 01
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO 320-VB2_01
LEGEND
01. Station 1: Breakout Wrench Engage/Disengage 05. Station 5: Back Brace Lock Circuit
Circuit 06. Station 6: Available Circuit - Blank Cover
02. Station 2: Breakout Wrench In/Out Circuit 07. Station 7: Mast Anchor Pins Circuit
03. Station 3: Deck Wrench Circuit 08. Station 8: Available Circuit - Blank Cover
04. Station 4: Available Circuit - Blank Cover

Stations 1 and 2: Breakout Wrench Circuits
01
02 10
03
n t
Y e
m
NL uip ion11
O 09q t
A L f E ra
04
I o p e
E R ce O
05 T
t
A nan en
M te m
p
LEGEND
E i n
01. Breakout Wrench Stow Solenoid
C 06 a q
02. Breakout Wrench Over Hole
u i
N M E
Solenoid
E r
03. Adjustable 800 PSI (55.2 Bar)
R o
Pressure Relief Valve
f o r
E E f
04. Adjustable Flow Control Valve
F
05. Breakout Wrench Swing Cylinder
E S
06. Dual Sequence Valves
07. Break Cylinder
S E
R U U
08. Jaw Cylinder
T T
09. Breakout Wrench Disengage
O
Solenoid
N NO
10. Breakout Wrench Engage Sole-
noid
O O
11. VB1 Pressure Transducer
D D
07
08
BD1227a01

Figure 9-34: Breakout Wrench Circuits

Breakout Wrench Engage/Disengage Circuit. This circuit is used after the breakout wrench has been moved out
to the drill pipe. It is a three-position, four way valve. The valve is solenoid actuated with manual override in both
directions. It is spring-centered, and the center is closed. When this valve is in its centered position, all ports are
blocked.
Refer to Figure 9-34. When the operator places the breakout wrench switch in the BREAK JOINT position, the
AC800 control system causes the B solenoid, BOW2BPS (10) to energize and the valve spool shifts. Oil from the P
port passes through the B port on the valve, out the B1 port on the valve bank and to the head end of the jaw cylin-
der (08). When the jaw cylinder extends, the jaws of the breakout wrench close around the pipe. Oil from the rod
end of the cylinder returns unrestricted to the valve (port A to port T) and back to tank.
Once the jaws are in contact with the pipe and cannot move anymore, hydraulic pressure builds. When hydraulic
n t
pressure reaches 2400 psi (166 bar), which is the setting of the sequencing valve (06), the sequencing valve
e
opens. Oil flows to the head end of the break cylinder (07), causing the cylinder to extend. As the cylinder extends,
Y m
the breakout wrench jaws rotate anticlockwise to break the pipe joint. Oil from the rod end of the break cylinder
NL uip ion
passes through the check valve on the sequencing valve, through the solenoid valve (port B to port T) and back to
tank. To check or adjust the dual sequence valve, refer to Breakout Wrench Dual Sequence Valve (06) Adjustment.
O q t
L f E ra
When the operator places the breakout wrench switch in the OPEN position, the AC800 control system causes the
A
A solenoid, BOW2RPS (09) to energize and the valve spool shifts. Oil from the P port passes through the A port on
I o e
the valve, out the A1 port on the valve bank and to the rod end of the jaw cylinder. When the jaw cylinder retracts,
p
to port T) and back to tank.
ER ce O
the jaws of the breakout wrench open. Oil from the head end of the cylinder returns unrestricted to the valve (port B
t
AT nan en
Once the jaws are completely open and cannot move anymore, hydraulic pressure builds. When hydraulic pres-
M te m
sure reaches 2400 psi (166 bar), which is the setting of the sequencing valve, the sequencing valve opens. Oil
E p
flows to the rod end of the break cylinder. When the cylinder retracts, the breakout wrench jaws rotate back to their
C a q i n u i
original position. Oil from the head end of the break cylinder passes through the check valve on the sequencing
valve, through the solenoid valve (port B to port T) and back to tank.To check or adjust the dual sequence valve,
N M E
refer to Breakout Wrench Dual Sequence Valve (06) Adjustment.
E
R o r o r
f f
Breakout Wrench In/Out Circuit. The breakout wrench in/out circuit causes the breakout wrench to move to and
E E
away from the drill pipe. The valve is solenoid actuated with manual override in both directions. It is spring-cen-
F
E S E
tered, and the center is closed. When this valve is in its centered position, all ports are blocked. This circuit oper-
S
ates at 800 psi (55.2 bar) as determined by the pressure reducing valve (03). To check or adjust this pressure,
R U U
refer to Breakout Wrench IN/OUT Pressure Reducing Valve (03) Adjustment.
T T
O
N NO
Refer to Figure 9-34. When the operator places the breakout wrench switch in the OVER HOLE position, the
AC800 control system causes the A solenoid, BOW1ES (02) to energize and the valve spool shifts. Oil from the P
port passes through the A port on the valve, out the A2 port on the valve bank, and to the rod end of the cylinder.
O
D DO
When the cylinder retracts, the breakout wrench moves toward the pipe. Oil from the head end of the cylinder
returns through the control valve (port B to T) and back to tank. If necessary, adjust the flow control valve (04) so
that the time to fully retract the cylinder is approximately 6 seconds.
When the operator places the breakout wrench switch in the STORE position, the AC800 control system causes
the B solenoid, BOW1SS (01) to energize and the valve spool shifts. Oil from the P port passes through the B port
on the valve, out the B2 port on the valve bank and to the head end of the cylinder. When the cylinder extends, the
breakout wrench moves back to the stowed position. Oil from the rod end of the cylinder returns through the control
valve (port A to T) and back to tank. If necessary, adjust the flow control valve (04) so that the time to fully extend
the cylinder is approximately 5 seconds.

Breakout Wrench IN/OUT Pressure Reducing Valve (03) Adjustment. Limits the breakout wrench In/Out oper-
ating pressure to 800 psi (55.2 bar). To check or adjust:
gize both VB1RS and AWPV which both need to be on to generate pressure.
4. Measure the pressure at T220. The pressure should be 800 psi (55.2 bar). If the pressure is too low or too
n t
Y e
m
NL uip ion
O q t
A L f E ra
Breakout Wrench Dual Sequence Valve (06) Adjustment. The dual sequence valve moves and applies force to
I o e
the jaw cylinder first. After the jaw is tight, it maintains force on the jaw cylinder while moving the break cylinder. For
p
proceed as follows:
ER ce O
resetting the wrench, the jaw cylinder first releases and then the break cylinder resets. To set the sequence valve
t
AT nan en
1. Remove the cap from the tee on the break cylinder base port.
M te m
E p
2. Remove the break cylinder rod hose and connect it to the tee.
C a q i n u i
3. Install the cap on the break cylinder rod port fitting.
E N M E
R o r o r
4. Connect a gauge to test port T222 (VA port).
E E f f
5. Place the breakout wrench switch in the BREAK JOINT position to turn on VB1RS and BOW2RPS.
E F S E
S
6. Set the pressure to 2400 psi (166 bar) as required.
R U U
T T
7. Connect a gauge to test Port T221 (VB port).
O
N NO
8. Place the breakout wrench switch in the BREAK JOINT position to turn on VB1RS and BOW2BPS.
O
D DO
9. Set the pressure to 2400 psi (166 bar) as required.
10. Reconnect the rod side of the break cylinder.

Station 3: Deck Wrench Circuit
01
02
n t
Y 04 e
L p m
N ui ion
O q t
L f E ra
03
I A o p e
R ce O
06 LEGEND
E
01. Solenoid B
t
AT nan en
02. Solenoid A
03. Adjustable 2000 PSI (138 Bar)
M te m 04. VB1B1 Pressure Transducer
E n i p
05. Deck Wrench Cylinders
C a q i u
06. Dual COunterbalance Valves
E N M E
R o r o r
E E f f
E F S E
05S
R U U
BD1226a01
T T
O
N NO
O
D DO
Figure 9-35: Deck Wrench Circuit
The deck wrench circuit controls the direction and maximum operating pressure of oil flow to the two deck wrench
cylinders. The control valve is a three-position, four-way, solenoid operated valve with manual override in both
directions. It is spring-centered, and the center is partially open. When this valve is in its centered position, pres-
sure from the pump is blocked at port P and the remaining ports are open to the tank. This circuit operates at 2000
psi (138 bar) as determined by the pressure reducing valve (03). To check or adjust this pressure, refer to Breakout
Wrench IN/OUT Pressure Reducing Valve (03) Adjustment.
When the operator presses the deck wrench switch to the EXTEND position, the AC800 control system causes the
A solenoid, DWES (02) to energize and the valve spool shifts. Oil from the P port passes through the A port on the

valve, out the A3 port on the valve bank, through the counterbalance check valve and into the head end of the both
deck wrench cylinders (05) which extends the cylinder rod. Oil from the rod end of the cylinder returns through the
control valve (port B to T) and back to tank.
When the operator presses the deck wrench switch to the STORE position, the AC800 control system causes the
B solenoid, DWDS (01) to energize and the valve spool shifts. Oil from the P port passes through the B port on the
valve, out the B3 port on the valve bank, through the counterbalance check valve and into the rod end of the both
deck wrench cylinders (05) which retracts the cylinder rod. Oil from the head end of the cylinder returns through the
control valve (port A to T) and back to tank.
n t
e
Y m
NL uip ion
O q t
A dual counterbalance valve (06) is used in the cylinder circuit to prevent the deck wrenches from extending into
L f E ra
the drill string when the control valve is in the spring-centered neutral position. It also provides a means to help
A
hold the drill pipe when the pipe is uncoupled from the rotary carriage (the cylinder pressure is maintained by the
counterbalance valve).
I o p e
ER ce O
t
Deck Wrench Pressure Reducing Valve (03) Adjustment. Limits the deck wrench operating pressure to 2000
AT nan en
psi (138 bar). To check or adjust:
M te m
E n i p
C a q i u
N
E r M E
r
R fo f o
gize both VB1RS and AWPV which both need to be on to generate pressure.
E E
E F S E
4. Measure the pressure at T219. The pressure should be 2000 psi (138 bar). If the pressure is too low or too
R U U S
T T
O
N NO
O
D DO

Station 5: Back Brace Lock Circuit
01
02
n t
e
03
Y m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
04
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
F E
BD1226a01
E S
05
R U U S
T T
O
N NO
LEGEND
O
D DO
01. Solenoid B
02. Solenoid A
04. Back Brace Lock Cylinders (6 total)
05. Proximity Switches (2 total)
03. VB1B1 Pressure Transducer
Figure 9-36: Back Brace Lock Circuit
The back brace lock circuit controls the direction of oil flow to the back brace lock cylinders. Each back brace has a
lock that slides over the articulating joint; each lock is controlled by three cylinders. The proximity switches (05)
inform the AC800 control system that the back brace lock is not locked.

Station 7: Mast Anchor Pins Circuit
01
02
03
n t
Y e
m
NL uip04 ion
O q t
A L f E ra
I o p e
ER ce O
t
AT n05an en
M te m
E i n i p
C a q u
N
06
E r M E
R fo o r
FE E f
E S S E
R U U
BD1226a01
T T
O
N NO
O
LEGEND
D DO
01. Solenoid B
02. Solenoid A
04.
05.
VB1B1 Pressure Transducer
Mast Anchor Pin Cylinders (2 total)
03. Adjustable Flow Control Valve 06. Proximity Switches (4 total)
07. Pilot-operated Check Valves
Figure 9-37: Mast Anchor Pins Circuit
The mast anchor pins are mounted at the drilling deck level. They engage slots in the main frame and assist in
maintaining the mast in the vertical position.
The mast anchor pin flow control valve is preset to 15 gpm (57 lpm). When this valve is properly set, the pins
should extend in 2.3 seconds and retract in 1.9 seconds.

The proximity switches (06) on both the engage and disengage ends of the cylinders provide information to the
AC800 control system regarding the cylinder locked or unlocked status.
Pilot operated check valves (07) lock the cylinders in any position they are left in.
Engage
When the operator presses the mast anchor pin switch on the operators console to the ENGAGE position, the
AC800 control system causes the B solenoid MAPES (01) to energize. Oil flows from port P to port B on the direc-
tional valve, through the cylinder head end pilot-operated check valve (07) and out port B7of the valve bank. Oil
pressure in passage B also pilots the opposite pilot-operated check valve and forces it to open.
n t
Oil from port B7 enters the head end of both mast anchor pin cylinders to extend the cylinder rods to lock the
e
anchor pins. Oil from the rod side of the cylinder returns to tank through the VB2 port A7, the rod side pilot operated
Y m
check valve and solenoid ports A and T.
NL uip ion
Disengage
O q t
L f E ra
When the operator presses the mast anchor pin switch on the operators console to the DISENGAGE position, the
A
AC800 control system causes the A solenoid MAPDS (02) to energize. Oil flows from port P to port A on the direc-
I o e
tional valve, through the cylinder rod end pilot-operated check valve (07) and out port A7of the valve bank. Oil
p
R ce O
pressure in passage A also pilots the opposite pilot-operated check valve and forces it to open.
E t
AT nan en
Oil from port A7 enters the rod end of both mast anchor pin cylinders to retract the cylinder rods to unlock the
anchor pins. Oil from the head side of the cylinder returns to tank through the VB2 port B7, the head side pilot oper-
M te m
ated check valve and solenoid ports B and T.
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

When facing the valve banks, valve bank 3 (VB3) is mounted on the right side of the machinery house rear wall
(see Item 02, Figure 9-25).
Refer to Figure 9-38. Four hydraulic circuits are controlled by the valve assemblies mounted on VB3 (stations 5
and 6 are available for future valve assemblies).The following topics describe the functions of these circuits in
detail. Refer to the auxiliary hydraulic schematic in the LinkOne parts manual for your drill for reference.
06 05 04 03 02 01
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r r
f fo
07
E
F SE E
E
R U US
T T
O
N NO
O
D DO
320-VB3_01
LEGEND
01. Station 1: Unload Relief Circuit 05. Station 5: Available Circuit - Blank Cover
02. Station 2: Front Jacks Circuit 06. Station 6: Available Circuit - Blank Cover
03. Station 3: Left Rear Jack Circuit 07. VB3 Pressure Transducer
04. Station 4: Right Rear Jack Circuit

Station 1: Unloader Relief Circuit
LEGEND
01. Solenoid A
02. Adjustable 3000 PSI (207 Bar)
03. VB3PT Pressure Transducer
04. Pilot-Operated Relief Valve 01 02
n t 03
Y e
m
NL uip ion
04
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E n i p
BD1230a01
C a q i u
N
E r M E
r
R
E E fo f o
E F S E
Figure 9-39: Unloader Relief Circuit
R U U S
Refer to Figure 9-39. The unloader relief circuit is used to build pressure in VB3 when any of the valves on VB3 are
T T
activated. This circuit uses a four-position, four way, solenoid-actuated valve with a manual override. The valve is
O
spring centered and the center is open. Oil is supplied to this circuit from two sources:
N NO
• VB3 Port P1 - Oil flow is from the high volume section of the auxiliary pump.
O
D DO
• VB3 Port P2 - Oil flow is from the 1B1 port on VB1 when the unloader / diverter valve B solenoid VB1DS is
energized (refer to Subtopic: Station 1: Relief/Unload Oil Diverter Valve Circuit on page 9.48.)
When in the spring-centered open position, this valve allows oil at port P on the valve to bypass the relief valve,
flowing directly back to the tank without building pressure. This is an energy-saving provision for periods when the
auxiliary hydraulic circuits are at rest.
Whenever the operator initiates movement for any of the leveling jacks controlled by the valves on Valve Bank 3,
the AC800 control system causes the A solenoid VB3RS (01) to energize. This causes the valve to shift so that oil
from the P port of the valve flows to the A port, which is blocked. Oil flow backs up against the pressure relief valve
and VB3 pressure builds to 3000 psi (207 bar) which is the setting of the relief valve (02). This establishes the max-
imum pressure available to the equipment.

Station 2: Front Jacks Circuit
01
02
n t
Y e
03 N
L ip n m
O qu tio
L f E ra
LEGEND
I A e
01. Solenoid B
02. Solenoid A
03. Adjustable Flow Control Valve
R ce O o p
04. Regeneration Valve
T E n t
n
05. Dual Counterbalance Valves
A na e
06. Front Jack Limit Switches (2 total) 04
M te m
07. Front Jack Cylinders (2 total)
p
08. Front Jack Cylinder Base
Pressure Switch
E
C a q i n u i
E N M E
R o r o r
E08 E f f
F E
RE US US
05
T 07 T 06
O
N NO
O
D DO
BD1229a01

Figure 9-40: Front Jacks Circuits

Refer to Figure 9-40. The front jack valve controls the direction of oil flow to both front jacks. This is a four-position,
four way valve. It is solenoid actuated with a manual override. The valve is spring centered, and the center is
blocked at port P and open to tank at all other ports.
The jacks are hydraulically connected in parallel so that the pressure will tend to equalize between the cylinders
during the machinery leveling procedure, and also while drilling. The flow rate is determined by a preset flow con-
trol valve (refer to Test Point 35 in Table 9-7 for the flow valve setting). The circuit includes a regeneration valve
(04) and dual counterbalance valves (05) as described in the following paragraphs.
Regeneration Valve. The regeneration circuit is used to permit fast cylinder movement when the jacks are being
lowered. This circuit is actuated when the jack is being extended, but not yet lifting the weight of the drill. It func-
tions by circulating the oil being displaced from the rod end of the jack cylinder back into the head end of the cylin-
n t
der (hence “regeneration”). This causes the jack to extend at a faster rate than it would if the oil from the cylinder
e
rod end were directed back to the tank.
Y m
NL uip ion
Since the regeneration has only about one-half the force necessary to lift the drill, the regeneration circuit must turn
off once the jacks begin to lift the drill. A pressure switch detects when the jack pads have reached the ground, and
O q t
have started to pick up the weight of the drill. Once the pressure switch is actuated, the regeneration circuit is shut
L f E ra
off.
I A o e
Dual Counterbalance Valve. The dual counterbalance valve prevents the jack cylinder from drifting, either under
p
R ce O
load or from the retracted position, when the control valve is in the neutral position.
E t
AT nan en
M te m
p
Dual counterbalance valve pressures are pre-set at the factory. Changing the settings
E i n u i
incorrectly can cause severe equipment damage. Follow correct procedures.
C a q
N M E
Refer to Figure 9-40. When the operator places the FRONT, MANUAL JACKS levelling jack switch in the EXTEND
E
R o r o r
position (or during Auto Level operation), the AC800 control system causes the B solenoid FJES (01) to energize.
f f
The valve spool shifts so that oil from the P port of the valve flows to the B port of the valve and out the B2 port of
E E
the valve bank. Oil flows over the counterbalance valve check valve into the head end of the hydraulic cylinders. As
F
E S S E
pressure increases, pressure through the crossover ports on the head end counterbalance valve causes the valve
port on the rod side of the cylinder to open. Oil from the rod end of the cylinders is then able to flow through the
R U U
counterbalance valve, and either regenerates (if the jacks are not both on the ground) or returns to the A port to
tank.
T T
O
N NO
When the operator places the FRONT, MANUAL JACKS levelling jack switch in the RETRACT position (or during
Auto Level operation), the AC800 control system causes the A solenoid FJRS (02) to energize. The valve spool
O
D DO
shifts so that oil from the P port of the valve flows to the A port of the valve and out the A2 port of the valve bank.
Oil flows through the regeneration valve, over the counterbalance valve check valve, and into the rod end of the
hydraulic cylinders. As pressure increases, the crossover pressure through the ports on the rod side of the counter-
balance valve causes the valve ports on the head end to open. Oil from the head end of the cylinders is then able
to flow through the counterbalance valve and back to tank.
Front Jack Cylinder Base Pressure Switch. This pressure switch detects the front jack cylinder base pressure.
The switch has two functions:
• The first function is to signal when the jack pads reach the ground. For this, the switch must be set above
the pressure required to extend the cylinder with the regeneration solenoid energized before the jack pad
reaches the ground. This pressure is typically 400-700 psi (27.6-48.2 bar).

• The second function is to ensure the machine is supported on the jacks during maintenance mode propel.
Propel is disabled unless all three switches are tripped (this switch and one switch for each rear jack). For
this, the switches must be set below the normal cylinder base pressure while supporting the machine on the
jacks. This pressure is normally above 800 psi (55.2 bar).
Set the pressure switch differential setting to minimum. Set the pressure switch to trip at 700 to 800 psi (40 to 55.2
bar) with raising pressure. The switch must reset at a pressure greater than 600 psi (41.3 bar).
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

Stations 3 and 4: Rear Jack Circuits
01
02
n t
Y e 03
m
NL uip ion
O q t
A L f E04 ra
I o p e
ER ce O
A T an nt
08 M ten me 05
E i n i p
C a 07 q u
N
06
E r M E
R fo o r
FE E f
E S S E
R U U
T T BD1228a01
O
N NO
O
D DO
LEGEND
01. Solenoid B (1 for each circuit) 06. Rear Jack Limit Switches (1 for each circuit)
02. Solenoid A (1 for each circuit) 07. Rear Jack Cylinders (1 for each circuit)
03. Adjustable Flow Control Valve (1 for each circuit) 08. Rear Jack Cylinder Base Pressure Switches
04. Regeneration Valve (1 for each circuit) (1 for each circuit)
05. Dual Counterbalance Valves 1 for each circuit)
Figure 9-41: Rear Jacks Circuits

Refer to Figure 9-41. The rear jack valves control the direction of oil flow to the rear jacks. Each circuit has a four-
position, four-way valve. It is solenoid actuated with a manual override. The valve is spring centered, and the cen-
ter is blocked at port P and open to tank at all other ports.
Each rear jack is independently controlled except when in Auto-level mode. The flow rate for each circuit is deter-
mined by a preset flow control valve (refer to Test Point 34 in Table 9-7 for the flow valve setting). Each circuit also
includes a regeneration valve (04) and dual counterbalance valves (05) as described in the following paragraphs.
Regeneration Valve. The regeneration circuit is used to permit fast cylinder movement when the jack is being low-
ered. This circuit is actuated when the jack cylinder is being extended, but not yet lifting the weight of the drill. It
functions by circulating the oil being displaced from the rod end of the jack cylinder back into the head end of the
cylinder (hence “regeneration”). This causes the jack cylinder to extend at a faster rate than it would if the oil from
the cylinder rod end were directed back to the tank.
n t
Y e
m
Since the regeneration has only about one-half the force necessary to lift the drill, the regeneration circuit must turn
NL uip ion
off once the jacks begin to lift the drill. A pressure switch detects when the jack pad has reached the ground, and
has started to pick up the weight of the drill. Once the pressure switch is actuated, the regeneration circuit is shut
O q t
off.
A L f E ra
Dual Counterbalance Valve. The dual counterbalance valve prevents the jack cylinder from drifting, either under
I o e
load or from the retracted position, when the control valve is in the neutral position.
p
ER ce O
t
AT nan en
M te m
Dual counterbalance valve pressures are pre-set at the factory. Changing the settings
E p
incorrectly can cause severe equipment damage. Follow correct procedures.
C a q i n u i
E N M E
R o r o r
f f
Both rear leveling jack cylinder circuits operate the same. The following paragraphs refer to the
E E
left jack cylinder. The right jack is the same except for port and solenoid designations.
F
E S S E
R U U
Refer to Figure 9-41. When the operator places the LEFT REAR MANUAL JACKS levelling jack switch in the
EXTEND position (or during Auto Level operation), the AC800 control system causes the B solenoid LRJES (01) to
T T
energize. The valve spool shifts so that oil from the P port of the valve flows to the B port of the valve and out the
O
N NO
B3 port of the valve bank. Oil flows over the counterbalance valve check valve into the head end of the hydraulic
cylinders. As pressure increases, pressure through the crossover ports on the head end counterbalance valve
causes the valve port on the rod side of the cylinder to open. Oil from the rod end of the cylinders is then able to
O
D DO
flow through the counterbalance valve, and either regenerates (if the jacks are not both on the ground) or returns to
the A port to tank.
When the operator places the LEFT REAR MANUAL JACKS levelling jack switch in the RETRACT position (or dur-
ing Auto Level operation), the AC800 control system causes the A solenoid LRJRS (02) to energize. The valve
spool shifts so that oil from the P port of the valve flows to the A port of the valve and out the A3 port of the valve
bank. Oil flows through the regeneration valve, over the counterbalance valve check valve, and into the rod end of
the hydraulic cylinders. As pressure increases, the crossover pressure through the ports on the rod side of the
counterbalance valve causes the valve ports on the head end to open. Oil from the head end of the cylinders is
then able to flow through the counterbalance valve and back to tank.
Rear Jack Cylinder Base Pressure Switch. This pressure switch detects the rear jack cylinder base pressure.
The switch has two functions:

• The first function is to signal when the jack pads reach the ground. For this, the switch must be set above
the pressure required to extend the cylinder with the regeneration solenoid energized before the jack pad
reaches the ground. This pressure is typically 400-700 psi (27.6-48.2 bar).
• The second function is to ensure the machine is supported on the jacks during maintenance mode propel.
Propel is disabled unless all three switches are tripped (one switch for each rear jack and one for both front
jacks). For this, the switches must be set below the normal cylinder base pressure while supporting the
machine on the jacks. This pressure is normally above 1500 psi (103 bar).
Set the pressure switch differential setting to minimum. Set the pressure switch to trip at 1000 to 1100 psi (69 to 76
bar) with raising pressure. The switch must reset at a pressure greater than 800 psi (55 bar).
9.4.4 Auxiliary And Low Pressure Hydraulic Systems Data Sheet

n t
Y e
m
NL uip ion
Point*
O q t
1 Auxiliary Pump Two section vane pump, ccw rotation, 2.50 cu. in./rev (41 cc/rev)
and 4.29 cu. in./rev (70.3 cc/rev). No adjustment required.
A L f E ra
e
2 Low Pressure Pump Pressure compensated piston pump, cw rotation, 0-64 cu. in./rev
I o p
(10.5 cc/rev). Set compensator at 1500 psi (103.4 bar) as measured
R ce O
at T423.
E t
AT nan en
3 Pump Suction Strainer 90 micron cleanable inlet strainer with magnetic separator rod and
reservoir isolation (handwheel) valve to allow service without drain-
ing the reservoir. Main motor will not start if isolation valve is closed.
M te m Clean the element if the AC800 control system GUI indicates a fault.
E i n i p
No adjustments required.
4 HOTT
C a q u RTD type temperature transducer measures the hydraulic reservoir
N M E
Hydraulic Reservoir Oil
E
oil temperature. No adjustment required.
r r
Temperature Transducer
5 HTLS
R
E E fo f o Float type level switch detects unacceptably low hydraulic reservoir
F
Hydraulic Reservoir Oil oil level. Main motor will not start if oil level is too low. No adjust-
E S
Level Switch
S E ment required.
6
R U U
Reservoir Breather Filter/moisture removal type breather filters to 3 micron. Replace the
T T
breather if the red indicator on top is visible.
7
O
N NO
Main Return Filters 3 micron absolute filters for the auxiliary pump flow. Filters have a
condition gauge and electrical condition switch. Change elements
when the condition gauge is in the red or when the AC800 control
8
O
D DO
Low Pressure Return Fil-
system GUI shows a fault.
20 micron return filters for propel pump and propel motor case
ters drains. Mast, winch, and other miscellaneous returns requiring low
back pressure. Filters have an electrical condition switch. Change
elements when the AC800 control system GUI shows a fault.
9 Oil Cooler By-Pass Relief Limits the pressure drop across the oil cooler to 90 psid. No adjust-
Valve ment required.
10 Thermostatic Mixing The thermostatic valve blocks oil from going through the oil cooler
Valve until it reaches 130°F (55°C). Above this temperature, oil is forced
through the oil cooler. No adjustment required.
Table 9-7: Auxiliary and Low Pressure Hydraulic Systems Data Sheet


Point*
11 Onboard Oil Top Off Sys- Stores up to 80 gal (304 L) of hydraulic oil on the machine to top off
tem the hydraulic reservoir and main air t-tank as required. Oil is dis-
pensed through a 3 micron filter system. While operating the pump,
check the pressure gauge readings on the inlet and outlet of both fil-
ters. If the drop across either filter exceeds 20 psid (1.4 bar),
change both filter elements.
12 Pump Inlet Selector Selects the source of oil going into the top off system pump. With the
Valve valve handle vertical down, the pump draws oil from the storage
tank. With the handle horizontal, the pump will draw oil through a
n t
hose connected to the selector valve bottom port. This line can draw
oil from cans, barrels, or other sources of external oil.
Y e
m
13 Filter Outlet Selector Selects the destination of oil coming out of the filters. With the valve
NL uip ion
Valve handle vertical up, the oil is directed to the 2 solenoid valve inlets for
delivery to the desired location. With the handle horizontal, the fil-
O q t
tered oil will be directed to the on board storage tank.
14 VB1RS
L f E ra
When energized, this solenoid shifts the valve spool and blocks the
A
I e
small section auxiliary pump flow from tank to build up pressure in
o
VB1 Diverter Valve A
p
VB1 and VB2. This solenoid must be on when any function on VB1 or
R ce O
Solenoid
VB2 is activated.
E t
AT nan en
15 VB1DS When energized, this solenoid shifts the valve spool to divert the oil
VB1 Diverter Valve B flow from the small section of the auxiliary pump to the VB3 passage
M te m
Solenoid to allow more than 1 jack cylinder to be moved at the same time.
16
E
VB1 Diverter A Port
i n i p
Limits the P passage pressure to 3000 psi (207 bar) in VB1 and VB2
Relief
C a q u
when VB1RS is energized. Set and adjust as required.
17
N M E
VB1 Overload Relief
E
Limits the VB1 and VB2 P passage pressure in case of system fail-
R o r o r
ures. Factory set at 3600 psi (248 bar). Do not attempt to check or
f
adjust.
FE E f
E
18 Pressure Compensated Flow out of this valve is proportional to the electric current supplied
E S
Flow Control to the coil with 0 amps there is 0 flow. Maximum flow output of the
R U U S valve is 22.0 gpm (83.5L/min). This valve is used to control the

speed of the function. The associated directional valve must also be
T T on for the function to move.
19
O
N NO
Winch Pressure Reduc-
ing/Relieving Valve
Limits the winch operating pressure to 2000 psi (138 bar). To check:
Disconnect both winch solenoid valve electrical connectors to AWLS
O
D DO
and AWRS on VB1.
Measure pressure at T119 located on the wall side of this valve (see
Figure 9-29).
Operate the winch at full speed in either direction using the auxiliary
winch remote tether control.
This will energize both VB1RS and AWPV which both need to be on to
generate winch pressure.
Adjust the pressure reducing valve as required.
Reconnect the winch solenoid valve electrical connectors.
Table 9-7: Auxiliary and Low Pressure Hydraulic Systems Data Sheet (Continued)


Point*
20 Mast Raise Cylinder With the flow control full on, cylinder cycle time is about:
Raise: 139 sec
Lower: 93 sec
No adjustment required.
21 Pipe Rack Cylinder Cylinder cycle time:

To over hole: 8.2 sec
To stow: 7.0 sec
22 Winch
n t
With the flow control full on, winch speed is about:
Up: 15.8 rpm
Y e
m
NL uip ion
Down: 13.0-14.0 rpm
23 Mast Anchor Flow Con-

O q t
Limits the flow to the mast anchor pin cylinders. Adjust to give the
trol
L f E ra
correct cylinder cycle times:
A
I o e
Full in to full out: 2.3 sec
R ce O p
Full out to full in: 1.9 sec
E t
AT nan en
24 Mast Anchor Cylinder The check valves lock the cylinders in any position they are left in.
Pilot Operated Checks Energizing the control valve delivers oil to one side of the cylinder
opening the opposite check valve.
M te m
p
25 Back Brace Lock Cylin- Normal cycle times for the back brace lock cylinders are:
ders
E
C a q i n u i
Unlock to lock: 13.5 sec
N
Lock to unlock: 10.1 sec
E r M E
r
26 Deck Wrench Pressure Limits the pressure to the deck wrench cylinders to 2000 psi (138
R fo
Reducing Valve
E E f o
bar).
F
To adjust:
E S S E Disconnect both auxiliary winch solenoid valve electrical connectors
R U U
to AWLS and AWRS on VB1.
T T
Figure 9-33).
O
N NO
winch remote tether control. This will energize both VB1RS and
O
AWPV which both need to be on to generate pressure.
D DO


Point*
27 Breakout Wrench In/Out Limits the pressure to the breakout wrench in/out cylinders to 800
Pressure Reducing Valve psi (55.2 bar).
To adjust:
Disconnect both winch solenoid valve electrical connectors to AWLS
and AWRS on VB1.
Figure 9-33).
t
winch remote tether control. This will energize both VB1RS and
n
AWPV which both need to be on to generate winch pressure.
Y e
m
NL uip ion
28 Breakout Wrench In/Out Limits the flow to the breakout wrench swing cylinder. Adjust to give
Flow Control
O q t
the correct cylinder cycle times:
L f E ra
A
I o e
p
29 VB1PT
ER ce O
Pressure transducer measures the pressure to VB1 and VB2.
t
AT nan en
VB1 and VB2 Pressure
Transducer
M te m
30 Breakout Wrench Dual The dual sequence valve moves and applies force to the jaw cylinder
Sequence Valve first. After the jaw is tight it maintains force on the jaw cylinder while
E i n i p
moving the brake cylinder. For resetting the wrench, the jaw cylinder
C a q u
first releases and then the break cylinder resets.
E N M E
To set the sequence valve proceed as follows:
R o r o r
Remove the cap from the tee on the break cylinder base port.
E E f f
Remove the break cylinder rod hose and connect it to the tee.
F E
Install the cap on the break cylinder rod port fitting.
E
R U U S S
Connect a gauge to test port T222 (VA port).
Force on VB1RS and BOW2RPS.
T T Set the pressure to 2400 psi (166 bar) as required.
O
N NO
Connect a gauge to test Port T221 (VB port).
Force on VB1RS and BOW2BPS.
O
D DO
Set the pressure to 2400 psi (166 bar) as required.
Reconnect the rod side of the break cylinder.
31 Deck Wrench Dual Coun- The counterbalance valves lock the cylinders in any position they are
terbalance Valves left in. Energizing the control valve delivers oil to one side of the cyl-
inder opening the opposite counterbalance valve. The valve will also
receive excess pressure from the cylinder.
32 All Counterbalance Counterbalance valves are factory set. Do not attempt to adjust.
Valves Seals may be replaced but all other service should be by replacing
the valve cartridge.


Point*
33 Deck Wrench Cylinder Normal cycle times for the deck wrench cylinders are:
34 Rear Jack Flow Control Limits flow to each rear jack to:
Before SN BD320167: 15 GPM (57 LPM) to provide a retract rate of
1.27 in/sec (33.2 mm/sec) and an extend rate of 0.74 in/sec (18.8
mm/sec) without regeneration on.
t
After SN BD320166: 13.5 GPM (51.1 LPM) to provide a retract rate
n
of 1.16 in/sec (29.5 mm/sec) and an extend rate of 0.67 in/sec
e
(17.1 mm/sec) without regeneration on.
Y m
NL uip ion
35 Front Jack Flow Control Limits flow to each front jack to:
O q t
Before SN BD320167: 20 GPM (76 LPM) to provide a retract rate of
L f E ra
1.26 in/sec (32 mm/sec) and an extend rate of 0.77 in/sec (19.6
I A o p e
After SN BD320166: 27 GPM (102.2 LPM) to provide a retract rate of
ER ce O
1.16 in/sec (29.5 mm/sec) and an extend rate of 0.67 in/sec (17.1
t
AT nan en
M te m
36 VB3 Unloader Relief The valve is a pilot operated, vented relief. With the unloader relief
valve solenoid VB3RS de-energized, the relief is vented to tank.
E i n i p
Pressure at T311 will be 65-175 psi (4.5-12.1 bar). No adjustment
C a q urequired. With VB3RS energized, pressure at T311 should be 3000
N
psi (207 bar). Adjust the pilot relief as required.
E r M E
r
37 VB3PT Pressure transducer measures the pressure to VB3.
R fo f o
VB3 Pressure Transducer
E E
F E
38 Jack Regen Valve Each valve contains rod and base motion control/load holding valves.
E S S
Each valve also contains a 2-position, 3-way solenoid piloted valve to
R U U
control extend speed.
T T
With the solenoid off, the cylinder has normal extend and retract
speeds. The cylinder rod and base ports are connected directly to the
O
N NO
control valve work ports.
With the solenoid energized, the cylinder rod and base ports are con-
O
D DO
nected together. This regenerative extend increases the extend
speed by about 2.5 times. The cylinder force is also reduced by
about 2.5 times.


Point*
39 Jack Cylinder Base Pres- This pressure switch detects the jack cylinder base pressure. The
sure Switch switch has two functions:
The first function is to signal when the jack pads reach the ground.
For this, the switch must be set above the pressure required to
extend the cylinder with the regen solenoid energized before the jack
pad reaches the ground. This pressure is typically 400-900 psi (27.6-
62.0 bar).
The second function is to ensure the machine is supported on the
jacks during maintenance mode propel. Propel is disabled unless all
n t
three switches are tripped. For this, the switches must be set below
the normal cylinder base pressure while supporting the machine on
e
the jacks. This pressure is normally above 1500 psi (103 bar).
Y m
NL uip ion
Set the pressure switch differential setting to minimum. Set the
pressure switch to trip at 1000 to 1100 psi (69 to 76 bar) with rais-
ing pressure. The switch must reset at a pressure greater than 800
O q t
psi (55 bar).
40 Jack Limit Switch

A L f E ra
This switch is tripped with the jack cylinder fully retracted. Propel is
I o e
disabled unless all 4 switches are tripped.
p
41 VB4 P2 Overload Relief
ER ce O
Limits the VB4 P2 passage pressure to 2000 psi (138 bar) in case of
t
AT nan en
system failures. Do not attempt to check or adjust.
42 Pipe Rack Holdback Pres- Limits the pressure used to keep the pipe racks in the stowed posi-
M te m
sure Reducing Valve tion to 450 psi (31 bar). To set connect a gauge to T405. With the
p
low pressure pump running and PRHBS de-energized, adjust the
E
C a q i n i
valve as required.
u
N
43 Compressor Inlet Pres- Limits the pressure used control the GD compressor inlet control to
E M E
sure Reducing Valve
r
350 psi (24 bar). To set, connect a gauge to T407. With the low
R fo o r pressure pump running and CHUS de-energized, adjust the valve as
f
required.
FE E
E
44 Compressor Inlet Flow Limits the rate of flow to the GD compressor unload cylinders. Adjust
45
E
Control
R U U S S
View Hatch Flow Control
as required to obtain smooth unloading.
Limits the rate of flow to the view hatch cylinder. Normal cycle times:
T T Close to open 2.6 sec; open to close 3.5 sec. No adjustment
O
N NO
required.
46 View Hatch Double Pilot This check valves lock the cylinder in any position it is left in. Ener-
O
Operated Check Valves gizing the control valve delivers oil to one side of the cylinder open-
D DO
ing the opposite check valve.
47 LH Pipe Rack Gate Flow Limits the rate of flow to the LH pipe rack gate cylinder. Normal cycle
Control times: Close to open 2.5 sec; open to close 1.8 sec. No adjustment
required.
48 LH Pipe Rack Gate Dou- These check valves lock the cylinder in any position it is left in. Ener-
ble Pilot Operated Check gizing the control valve delivers oil to one side of the cylinder open-
Valves ing the opposite check valve.
49 RH Pipe Rack Gate Flow Limits the rate of flow to the RH pipe rack gate cylinder. Normal cycle
Control times: Close to open 2.5 sec; open to close 1.8 sec. No adjustment
required.


Point*
50 RH Pipe Rack Gate Dou- These check valves lock the cylinder in any position it is left in. Ener-
ble Pilot Operated Check gizing the control valve delivers oil to one side of the cylinder while
Valves opening the opposite check valve.
51 Propel Brake Manual With the main motor not running, this valve allows release of both
Release Valve propel brakes by applying pressure to the valve’s HP port. Applied
pressure must not exceed 700 psi (48 bar). Minimum brake release
pressure is 265 psi (18.3 bar).
52 HBPS Indicates if the pressure on the head brake is adequate to release it.
t
Head Brake Pressure Set at 1300 psi (90 bar).
n
Switch
53 Head Brake Pressure Tap

Y e
This pressure tap can be used to measure the pressure at the head
m
NL uip ion
(T425) brake.
It can also be used to bleed the brake and lines of air. Connect a
pressure gauge hose to the tap with the other end open. With the
O q t
low pressure pump running and HBES and HBS energized, the head
L f E ra
brake is released. Allow air and oil to flow into a suitable container
A
I e
until a steady stream of oil is observed.
54 View Hatch Pressure

R ce O o p
Limits the pressure to the view hatch cylinder to 300 psi (21 bar). To
Reducing Valve
E set, connect a gauge to T409. With the low pressure pump running
t
AT nan en
and either DHOS or DHCS energized, adjust the valve as required.
55 On Board Top Off Sys- Depending on the position of the two selector valves there are 3
M te m
tem Operating Modes modes of system operation:
E i n i p
Fill operation will pull oil out of the onboard tank and deliver it to
C a q ueither the hydraulic reservoir or main air t-tank. In this mode the
N
pump inlet selector valve is in the vertical down position and the fil-
E r M E ter outlet valve is in the vertical up position.
R fo o r In the recirculation mode the pump will pull oil out of the tank, run it
FE E f through the filters and return it to the tank. In this mode the pump
inlet selector valve is in the vertical down position and the filter out-
E S S E let valve is in the horizontal position.
R U U
The fill mode will deliver pre filtered oil from pails, drums, or other
external sources to the tank. In this mode the pump inlet selector
T T valve is in the horizontal position and the filter outlet valve is in the
O
N NO
horizontal position. Oil will be drawn in through a hose connected to
the bottom port of the pump inlet selector valve.
56
O
D DO
HRFSV
Hydraulic Reservoir Fill
Solenoid Valve
When the top off system pump is running and this valve is energized,
oil will be delivered to the hydraulic reservoir through the main
return filters. Note: This valve is only used with the single top off
system.
57 ACTTFSV When the top off system pump is running and this valve is energized,
Air Compressor T-Tank oil will be delivered to the main air compressor t-tank. Note: This
Fill Solenoid Valve valve is only used with the single top off system.
58 Cable Reel System The cable real hydraulics are self contained with no connection to the
other drill hydraulic systems. The cable reel is a constant tension
winch which applies pressure to try and retrieve cable. Cable is
payed out by forcing oil over the relief valve.


Point*
59 Anti-Cavitation Check During pay out, this valve supplies oil to the reel motor B port when
Valve the motor A port is pumping oil into the pump pressure passage.
60 Cable Reel Pump This pump is a pressure compensated piston pump with clockwise
rotation as viewed from the pump shaft end. The pump supplies flow
and pressure to retrieve cable. During pay out, the motor pumps oil
back to the pump forcing the pump to zero flow. The excess motor
flow returns to tank over the relief valve which is set above the pump
compensator. When the machine is stationary the pump pressure
applies tension to the cable at the pump compensator pressure.
61 Cable Reel Relief Valve

n t
Controls the cable tension pressure during cable pay out. Normally
e
set at 300 psi (20.7 bar) above the pump compensator setting.
Y m
NL uip ion
62 Pump Pressure Gauge Displays the P port pressure.
63 Flow Control Valve This valve is used to isolate the pump and relief valve during adjust-
O q t
ment. During normal operations, the valve must be fully open.
64 Solenoid Control Valve

L f E ra
The valve is a 3-position, 4-way, open center solenoid valve. In neu-
A
I o e
tral, all ports are common. Pump pressure is low so the pump is pro-
p
R ce O
ducing full flow. The CRTUS solenoid is energized during all normal
E
operations. The pump is connected to the motor retrieve port putting
t
AT nan en
the pump at compensator pressure. The CRPOS solenoid is energized
only to manually un-reel the cable.
65
M te m
Counterbalance Valve This valve prevents the cable from paying out when the cable reel is
E p
in neutral or off.
66
C a q
Pressure Adjustment
i n u i
The cable reel pump motor must be running. Turn the relief valve
N
adjustment full in. Completely close the flow control valve. If, during
E r M E closing, the pump pressure exceeds 950 psi (65.5 bar), stop and
R fo o r adjust the pump compensator to 950 psi (65.5 bar) first and then
E E f
finish closing the flow control valve.
F E
A. Adjust the pump pressure compensator to 950 psi (65.5 bar).
E
R U U S S
B. Adjust the relief valve setting to 900 psi (62 bar).
C. Adjust the pump compensator to 600 psi (41.4 bar).
T T D. Open the flow control completely. This is only a starting point.
O
N NO
Propel the machine into and away from the cable and evaluate it's
operation. If the cable tension is too high, repeat steps A through D
with 100 psi (6.9 bar) lower pressures. If the cable does not retrieve
O
D DO
properly, repeat steps A thru D with 100 psi (6.9 bar) higher pres-
sures. When satisfactory cable reel operation is achieved, record the
pressure and use these values for future adjustments.
67 Breakout Wrench Cylin- The total cycle time for both breakout wrench cylinders to go full
der Cycle Time stroke is as follows:
Full retract to full extend: 10.9 sec
Full extend to full retract: 9.6 sec
68 Cylinder Mounted Test Test ports at various cylinder ports are to be used primarily to bleed
Ports air from the lines connecting the cylinders to the control valves.


Point*
69 Wiggins Remote Fill Con- Allows remote filling of the hydraulic reservoir. Oil passes through
nection the 3 micron main return filters before entering the reservoir.
Located near the right hand rear bordering ladder.
70-75 Available
76 CIPS This switch monitors the hydraulic pressure to the main air compres-
Compressor Inlet Pres- sor inlet restriction valves on drills equipped with a GD compressor.
sure Switch Set the switch to 275 psi (19 bar).
t
77 Dust Curtain Double Pilot These check valves lock the cylinder in any position it is left in. Ener-
n
Operated Check Valves gizing the control valve delivers oil to one side of the cylinder while
e
opening the opposite check valve.
Y m
NL uip ion
78 Dust Curtain Flow COn- Limits the amount of flow going to the dust curtain cylinder to 1.5
trol Valve GPM (3.8 LPM). To adjust:
O q t
The main motor must be running.
L f E ra
Position the cylinder so it is fully retracted.
A e
Fully extend the cylinder. The time to extend should be 4.4 seconds.
I
R ce O o p
If necessary, adjust the flow control. Rotate the screw in for more
more flow (less time) or out for less flow (more time).
E t
AT nan en
Fully retract the cylinder. The cycle time should be 3.3 seconds.
If necessary, adjust the flow control and continue the above steps
M te m
until the cycle times are correct.
79
E
Dust Curtain Cylinder
i n i p
Limits the pressure to the dust curtain cylinder base to 350 psi (24.1
C a q u
Base End Port Relief bar). To adjust:
N M E
RE o r r
Install a pressure gauge on pressure tap T110.
E E f f o Have an assistant press the dust curtain switch in the cab to fully
lower (extend) the dust curtain cylinder and have the assistant con-
E F S E tinue to hold the switch activated while measuring the pressure at
S
T110.
R U U Adjust the relief as necessary to obtain 350 psi (24.1 bar).
80
T T
Dust Curtain Cylinder Limits the pressure to the dust curtain cylinder rod to 1000 psi (69
O
N NO
Rod End Port Relief bar). To adjust:
O
D DO
Install a pressure gauge on pressure tap T109.
Have an assistant press the dust curtain switch in the cab to fully
raise (retract) the dust curtain cylinder and have the assistant con-
tinue to hold the switch activated while measuring the pressure at
T109.
Adjust the relief as necessary to obtain 1000 psi (69 bar).


Point*
81 Front Jack Cylinder Base This pressure switch detects the jack cylinder base pressure. The
Pressure Switch switch has two functions:
The first function is to signal when the jack pads reach the ground.
For this, the switch must be set above the pressure required to
extend the cylinder with the regen solenoid energized before the jack
pad reaches the ground. This pressure is typically 400-700 psi (27.6-
48.2 bar).
The second function is to ensure the machine is supported on the
jacks during maintenance mode propel. Propel is disabled unless all
n t
three switches are tripped. For this, the switches must be set below
the normal cylinder base pressure while supporting the machine on
e
the jacks. This pressure is normally above 800 psi (55.2 bar).
Y m
NL uip ion
Set the pressure switch differential setting to minimum. Set the
pressure switch to trip at 700 to 800 psi (40 to 55.2 bar) with raising
pressure. The switch must reset at a pressure greater than 600 psi
(41.3 bar).
O q t
A L f E ra
* Test Point references are shown as numbers in triangles on the schematics
I o p e
R Pressure
e TapsO
E c t
AT nan en
9.4.5 Auxiliary And Low Pressure Hydraulic Systems
Tap No. Location

M te m Purpose Expected Reading
T1 Inlet Strainer 1 Out-

E i n i p
To measure auxiliary pump 0 - 6 in (0 - 152.4 mm) Hg vacuum
let
C a q u
inlet vacuum.
T2
E N
Inlet Strainer 2 Out-
M E
To measure auxiliary pump 0 - 6 in (0 - 152.4 mm) Hg vacuum
let
R o r r
inlet vacuum.
o
T101
E E
VB1 A8G Port
f f
To measure RH pipe rack With valve in neutral, should be tank
E F S E
cylinder extend pressure. pressure.
S
With valve actuated, pressure at RH pipe
R U U
rack cylinder extend port should be 3000
psi (207 bar) maximum.
T T
O
N NO
T102 VB1 B8G Port To measure RH pipe rack With valve in neutral and all pipe racks
cylinder retract pressure. stowed, should be 450 psi (31 bar).
With valve in neutral and a pipe rack over
D DOO
the hole, should be RH cylinder retract
pressure.
With valve actuated, pressure should be
RH cylinder retract pressure. Retract
pressure should be 3000 psi (207 bar)
maximum.
T103 VB1 A7G Port To measure LH pipe rack With valve in neutral, should be tank
cylinder extend pressure. pressure.
With valve actuated, pressure at LH pipe
rack cylinder extend port should be 3000
Table 9-8: Auxiliary and Low Pressure Hydraulic Systems Pressure Taps

T104 VB1 B7G Port To measure LH pipe rack With valve in neutral and all pipe racks
cylinder retract pressure. stowed, should be 450 psi (31 bar).
With valve in neutral and a pipe rack over
the hole, should be LH cylinder retract
pressure.
With valve actuated, pressure should be
LH cylinder retract pressure. Retract pres-
sure should be 3000 psi (207 bar) maxi-
mum.
T111 VB1 A3G Port To measure mast hoist cyl- With valve in neutral, should be tank
inder extend pressure.
n t pressure.
With valve actuated, pressure at mast
Y e hoist cylinder extend port should be 3000
m
NL uip ion
T112 VB1 B3G Port To measure mast hoist cyl- With valve in neutral, should be tank
O q t
inder retract pressure. pressure.
L f E ra
With valve actuated, pressure at mast
hoist cylinder retract port should be 3000
I A o p e psi (207 bar) maximum.
T113 VB1 A2G Port

R ce O
To measure winch up port
E
With valve in neutral, should be tank
t
pressure. pressure.
AT nan en
With valve actuated, pressure at winch up
port should be 2000 psi (138 bar) maxi-
M te m
mum.
T114 VB1 B2G Port

E i n i p
To measure winch down With valve in neutral, should be tank
C a q u
port pressure. pressure.
N
With valve actuated, pressure at winch
E r M E down port should be 2000 psi (138 bar)
R fo o r maximum.
T120
E E f
RH Pipe Rack Cylin-
F
The primary purpose of this
E
der Base Port pressure tap is to bleed air
E
R U U S S
from the plumbing from the
control valve to the cylinder.
T121
T T
RH Pipe Rack Cylin- The primary purpose of this
O
N NO
der Rod Port pressure tap is to bleed air
T203
O
D DO
VB2 A7G Port To measure the mast
anchor pin cylinder retract
With valve in neutral or actuated, should
have system pressure at the mast anchor
pressure. pin retract port.
T204 VB2 B7G Port To measure the mast With valve in neutral or actuated, should
anchor pin cylinder extend have system pressure at the mast anchor
pressure. pin extend port.
T207 VB2 A5G Port To measure the back brace With valve in neutral or actuated, should
lock cylinder extend pres- have system pressure at the back brace
sure. lock cylinder extend port.
Table 9-8: Auxiliary and Low Pressure Hydraulic Systems Pressure Taps (Continued)

T208 VB2 B5G Port To measure the back brace With valve in neutral or actuated, should
lock cylinder retract pres- have system pressure at the back brace
sure. lock cylinder retract port.
T211 VB2 A3G Port To measure the deck With valve in neutral, should be tank
wrench dual counterbal- pressure.
ance valve V1 port pres- With valve actuated, pressure at V1 port
sure. should be 2000 psi (138 bar) maximum.
T212 VB2 B3G Port To measure the deck With valve in neutral, should be tank
wrench dual counterbal- pressure.
t
ance valve V2 port pres- With valve actuated, pressure at V2 port
sure.
e n should be 2000 psi (138 bar) maximum.
Y
T213 VB2 A2G Port To measure the breakout With valve in neutral or actuated, should
m
NL uip ion
wrench swing cylinder have system pressure at the breakout
retract pressure. wrench swing cylinder retract port.
T214 VB2 B2G Port

O q t
To measure the breakout With valve in neutral or actuated, should
L f E ra
wrench swing cylinder have system pressure at the breakout
A e
extend pressure. wrench swing cylinder extend port.
T215 VB2 A1G Port I

R ce O o p
To measure the breakout With valve in neutral or actuated, should
E
wrench dual sequence valve have system pressure at the breakout
t
AT nan en
VA port pressure. wrench dual sequence valve VA port.
T216 VB2 B1G Port To measure the breakout With valve in neutral or actuated, should
M te mwrench dual sequence valve have system pressure at the breakout
E p
VB port pressure. wrench dual sequence valve VB port.
T217
C a q
VB2 GP Port i n u i
To measure VB1 and VB2 P With all valves off, should have 250 psi
N M E
passage pressure. (17.2 bar) maximum.
E r
With any valve on, should have 3000 psi
R fo o r (207 bar) maximum.
T218
E E
VB2 GT Port
F f To measure VB1, VB2 and 150 psi (10.3 bar) maximum.
E S S E VB3 T (tank) passage pres-

sure.
T221
R U U
Dual Sequence Valve To measure the breakout With valve in neutral or actuated, should
T T
VB Port wrench dual sequence valve have system pressure at the breakout
T222
O
N NO
Dual Sequence Valve
VB port pressure.
To measure the breakout

wrench dual sequence valve VB port.
With valve in neutral or actuated, should
O
D DO
VA Port wrench dual sequence valve have system pressure at the breakout
VA port pressure. wrench dual sequence valve VA port.
T223 LH Back Brace Cylin- The primary purpose of this

ders Rod Port pressure tap is to bleed air
T224 LH Back Brace Cylin- The primary purpose of this

ders Base Port pressure tap is to bleed air

T225 RH Back Brace Cylin- The primary purpose of this

T226 RH Back Brace Cylin- The primary purpose of this

T227 LH Deck Wrench Cyl- The primary purpose of this
t
inder Base Port pressure tap is to bleed air
e n
Y m
NL uip ion
T228 LH Deck Wrench Cyl- The primary purpose of this
inder Rod Port pressure tap is to bleed air
O q t
A L f E ra
e
T229 RH Deck Wrench The primary purpose of this
Cylinder Base Port
I o p
pressure tap is to bleed air
R ce O
E
t
AT nan en
T230 RH Deck Wrench The primary purpose of this
Cylinder Rod Port pressure tap is to bleed air
M te m from the plumbing from the
E i n i p
T231
C a q
Breakout Wrench
u
The primary purpose of this
N M E
Swing Cylinder Rod
E
pressure tap is to bleed air
r r
Port from the plumbing from the
R o o
E E f f
F
T223 Breakout Wrench The primary purpose of this
E
Port
S S E
Swing Cylinder Base pressure tap is to bleed air
R U U control valve to the cylinder.
T305
T T
VB3 A3G Port To measure the pressure to With valve in neutral, should be tank
O
N NO
the right rear regen valve
B1 port.
pressure.
With valve actuated, pressure at right
rear regen valve B1 port. 3000 psi (207
T306
O
D DO
VB3 B3G Port To measure the pressure to
bar) maximum.
With valve in neutral, should be tank

the right rear regen valve pressure.
A1 port. With valve actuated, pressure at right
rear regen valve A1 port. 3000 psi (207
bar) maximum.
T307 VB3 A2G Port To measure the pressure to With valve in neutral, should be tank
the left rear regen valve B1 pressure.
port. With valve actuated, pressure at left rear
regen valve B1 port. 3000 psi (207 bar)
maximum.

T308 VB3 B2G Port To measure the pressure to With valve in neutral, should be tank
the left rear regen valve A1 pressure.
port. With valve actuated, pressure at left rear
regen valve A1 port. 3000 psi (207 bar)
maximum.
T309 VB3 A1G Port To measure the pressure to With valve in neutral, should be tank
the front regen valve B1 pressure.
port. With valve actuated, pressure at front
regen valve B1 port. 3000 psi (207 bar)
maximum.
T310 VB3 B1G Port

n t
To measure the pressure to With valve in neutral, should be tank
Y e
the front regen valve A1 pressure.
m
port. With valve actuated, pressure at front
NL uip ion
regen valve A1 port. 3000 psi (207 bar)
maximum.
T311 VB3 GP Port

O q t
To measure the pressure in With all VB3 valves off, 250 psi (17.3 bar)
A L f E ra
the VB3 P passage. maximum.
I e
With any VB3 valve on, 3000 psi (207
R ce O o p
bar) maximum.
T313 Right Rear Regen

E
To measure the pressure in
t
Right rear jack cylinder base pressure.
AT nan en
Valve GA2 Port. the right rear jack cylinder 4000 psi (276 bar) maximum.
base.
T314 Right Rear Regen

M te mTo measure the pressure in Right rear jack cylinder base pressure.
E
Valve GB2 Port.
i n i p
the right rear jack cylinder 4000 psi (276 bar) maximum.
C a q u
rod.
T315
N
Left Rear Regen
E M E
To measure the pressure in Left rear jack cylinder base pressure.
r r
Valve GA2 Port. the left rear jack cylinder 4000 psi (276 bar) maximum.
R o o
base.
E E f f
F
T316 Left Rear Regen To measure the pressure in Left rear jack cylinder rod pressure. 4000
E S
Valve GB2 Port.
S E the left rear jack cylinder

rod.
R U U
T T
T317 Front Rear Regen To measure the pressure in Front jack cylinder base pressure. 4000
Valve GA2 Port. the front jack cylinder base. psi (276 bar) maximum.
T318 O
N NO
Front Rear Regen
Valve GB2 Port.
To measure the pressure in
the front jack cylinder rod.
Front jack cylinder rod pressure. 4000 psi
(276 bar) maximum.
T404 O
D DO
VB4 B9G Port To monitor pressure to the
carriage head brake valve.
With solenoid valve off, 0 psi (0 bar).
With solenoid valve on, 1500 psi (103
bar).
T405 VB4 A8G Port To monitor pipe rack hold- With solenoid valve off, 450 psi (31 bar).
back pressure reducing With solenoid valve on, 0 psi (0 bar).
valve with control valve off.
T406 VB4 B8G Port To monitor pipe rack hold- With solenoid valve off, 0 psi (0 bar).
back pressure to VB1. With solenoid valve on, 450 psi (31 bar).

T407 VB4 A7G Port To monitor GD compressor With solenoid valve off, 350 psi (24 bar).
inlet control pressure reduc- With solenoid valve on, 0 psi (0 bar).
ing valve with control valve
off.
T408 VB4 B7G Port To monitor GD compressor With solenoid valve off, 350 psi (24 bar).
inlet control unload pres- With solenoid valve on, 0 psi (0 bar).
sure.
T409 VB4 A6G Port To measure pressure in the View hatch cylinder base pressure - 300
view hatch cylinder base psi (21 bar) maximum.
t
port.
T410 VB4 B6G Port

e n
To measure pressure in the View hatch cylinder rod pressure - 300 psi
Y
view hatch cylinder rod (21 bar) maximum.
m
NL uip ion
port.
T411 VB4 A5G Port To measure pressure in the LH pipe rack upper gate cylinder base
O q t
LH pipe rack upper gate cyl- pressure - 1500 psi (103 bar) maximum.
L f E ra
inder base port.
T412 VB4 B5G Port

I A o e
To measure pressure in the
p
LH pipe rack upper gate cylinder rod
R ce O
LH pipe rack upper gate cyl- pressure - 1500 psi (103 bar) maximum.
E
inder rod port.
t
AT nan en
T413 VB4 A4G Port To measure pressure in the RH pipe rack upper gate cylinder base
RH pipe rack upper gate cyl- pressure - 1500 psi (103 bar) maximum.
M te m inder base port.
T414 VB4 B4G Port

E i n i p
To measure pressure in the RH pipe rack upper gate cylinder rod
C a q u
RH pipe rack upper gate cyl- pressure - 1500 psi (103 bar) maximum.
N M E
inder rod port.
T416
E
VB4 B3G Port
R o r r
To monitor the propel speed With solenoid valve PSS off, 0 psi (0 bar).
E E f f o control signal. With solenoid valve PSS on, 660 psi (46
bar) maximum.
E F S E
S
T418 VB4 B2G Port To monitor the RH propel With solenoid valve off, 0 psi (0 bar).
R U U
brake pressure. With solenoid valve on, 660 psi (46 bar)
maximum.
T T
O
N NO
T420 VB4 B1G Port To monitor the LH propel With solenoid valve off, 0 psi (0 bar).
brake pressure. With solenoid valve on, 660 psi (46 bar)
maximum.
T421
O
D DO
VB4 GT Port To monitor VB4 T passage
pressure.
15 psi (1 bar) maximum.
T422 VB4 P1G Port To monitor VB4 P1 passage With the main motor running, 660 psi (46
pressure. bar) maximum.
T423 VB4 P2G Port To monitor VB4 P2 passage With the low pressure pump running,
pressure. 1500 psi (103 bar) maximum.
T425 Carriage Head Brake To monitor head brake With the head brake control valve off, less
Top Pressure Port. pressure. Also used for than 5 psi (0.3 bar).
bleeding air from the brake. With the head brake control valve on,
1500 psi (103 bar).

T430 View Hatch Cylinder The primary purpose of this

Base Port pressure tap is to bleed air
T431 View Hatch Cylinder The primary purpose of this

Rod Port pressure tap is to bleed air
T434 RH Pipe Rack Upper The primary purpose of this
t
Gate Cylinder Base pressure tap is to bleed air
Port
n
e
Y m
NL uip ion
T435 RH Pipe Rack Upper The primary purpose of this
Gate Cylinder Rod pressure tap is to bleed air
O q t
Port from the plumbing from the
A L f E ra
e
T501 Hydraulic Mixing To measure pressure into 150 psi (10.3 bar) maximum.
Valve B Port
I o p
the hydraulic oil cooler.
R ce O
E
T502 Hydraulic Mixing To measure hydraulic oil 60 psi (4.1 bar) maximum.
t
AT nan en
Valve A Port cooler outlet pressure.
T601 VB6 Station 1 near To measure pressure in the 500 psi (34.5 bar) maximum.
the wall
M te m right front boarding stair
E p
cylinder base port.
T602
C a q
VB6 Station 1 away i n u i
To measure pressure in the With RFLRS on or both solenoids off,
N M E
from the wall right front boarding stair same as T2 pressure from T421.
E r
cylinder rod port. With RFLLS on, 600 psi (41.3 bar) maxi-
R fo o r mum.
T603
E E
VB6 Station 2 near
F f To measure pressure in the 500 psi (34.5 bar) maximum.

the wall
E S S E right rear boarding stair cyl-

inder base port.
T604
R U U
VB6 Station 2 away To measure pressure in the With RRLRS on or both solenoids off,
T T
from the wall right rear boarding stair cyl- same as T2 pressure from T421.
O
N NO
inder rod port. With RRLLS on, 600 psi (41.3 bar) maxi-
mum.
O
D DO
T605 Right Front Stair Cyl- The primary purpose of this
T606 Right Front Stair Cyl- The primary purpose of this

T607 Right Rear Stair Cyl- The primary purpose of this


T608 Right Rear Stair Cyl- The primary purpose of this

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

9.5 Low Pressure Hydraulic System Components

Low Pressure Hydraulic System Subtopic 9.5.1
Flow Diagram
Low Pressure Hydraulic Pump Subtopic 9.5.2
Valve Bank 4 (VB4)

n t Subtopic 9.5.3
Y e
Stations 4 and 5: RH and LH Pipe Rack Upper Gate Circuits
m
NL uip ion
Station 6: Deck Hatch Circuit
O q t
Station 7: GD Compressor Inlet Valve Control Circuit
L f E ra
Station 8: Pipe Rack Holdback Circuit
A
I o p e
Station 9: Head Brake Enable Circuit
ER ce O
t
Table 9-9: Low Pressure Hydraulic System Components
AT nan en
9.5.1 Low Pressure Hydraulic System Flow Diagram
M te m
E i n i p
Figure 9-42 is a block diagram that shows the oil flow between the low pressure hydraulic system components.
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

VB4
320XPC Low Pressure Head Brake Enable
Hydraulic Flow
Pipe Rack Holdback
GD Main Air
Low Pressure Compressor Inlet
Suction
Return to Tank Deck Hatch

P2
n t RH Pipe Rack Gate
Y e
m
NL uip ion
LH Pipe Rack Gate
O q t
Spare
L f E ra
Propel Speed
I A o p e
R ce O
RH Propel Brake
E t
AT nan en
LH Propel Brake
M te m
T1
E i n i p
C a q u
Low
Pressure
Case
N
Pump
Drain
E r M E
R fo o r
FE E f
E S S E
R U U
Low Pressure
Hydraulic Tank
Return Filter P1
T T
VB6
O
N NO
Boarding Stairs
RH Suction
Cylinder(s)
Strainer
(Option)
O
D DO
T1
From Winch, Mast,

To Propel
and Right and Left
Pumps
Rear Jack Regen 320xpc low press hyd flow
Valve Drains
Figure 9-42: Low Pressure Hydraulic System Block Diagram
The low pressure hydraulic system consists of a hydraulic tank, electric motor driven low pressure hydraulic pump
and a portion of valve bank 4 (VB4). Stations 4 through 7 on VB4 are used to provide hydraulic power to operate
the pipe rack gates, viewing hatch, Gardner Denver air compressor inlet hydraulic loading control, pipe rack hold-
back and hoist brake circuits. On drills equipped with an optional hydraulic boarding stairs, the low pressure pump
also provides oil flow to valve bank 6 (VB6), as shown in Figure 9-42.

Refer to the Auxiliary Hydraulics Schematic Diagram in your LinkOne Parts manual for the low pressure system
hydraulic schematic.
9.5.2 Low Pressure Hydraulic Pump
01 02 03 04 05
n t 06
Y e
m
NL u07ip ion
O q t
A L f E ra
I o p e
08
ER ce O
t
320xpc lp pump
AT nan en
M te m
LEGEND
E i n i p
01. Electric Motor
C a q u 06. Pressure Compensator Adjustment Knob
N M E
02. Adapter and Coupling 07. Suction Hose - From Right Hand Suction
E r
03. Hydraulic Pump Strainer
R o r
04. Case Drain Hose - To Tee at Port T1 on VB4
f o
08. Flange-Head Locking Screw (4)
E E f
05. Pressure Hose - To Port P2 on VB4
E F S E
R U U S Figure 9-43: Low Pressure Pump
T T
Refer to Figure 9-43. The low pressure hydraulic pump and motor assembly is mounted on the machinery house
O
N NO
deck behind the hydraulic tank (also see Item 07, Figure 9-25). The motor becomes energized when the DC Sys-
tem switch on the operator’s console is switched to the ON position. This pump supplies oil to valve bank 4 and the
optional valve bank 6.
O
D DO
This system shares the same hydraulic tank as the propel and auxiliary hydraulic systems. Hydraulic oil is drawn
from the tank through the suction hose (07, Figure 9-43) from the open, left hand strainer handwheel valve by the
pressure compensated, low pressure hydraulic pump. The pump compensator is set at 1500 psi (103 bar). Refer to
Subtopic: Low Pressure Pump Compensator Adjustment on page 9.98. for pump compensator adjustment proce-
dure.
9.5.2.1 Low Pressure Hydraulic Pump and Motor Maintenance
Pump and Motor Package Removal/Installation
Remove the hydraulic pump-motor assembly as follows:

! WARNING
Inadvertent machine movement during service can cause serious injury, or death. Do not
perform maintenance work on a machine without first disabling the operator controls.
Lock out and tag the operator controls to prevent inadvertent machine startup during
maintenance work.
2. Tag and disconnect the wiring from the pump motor electrical junction box.
n t
e
! WARNING
Y m
NL uip ion
Hot hydraulic oil can spray with extreme force and volume, causing injury or death. Use
O q t
L f E ra
A
I o e
R ce O
p
E t
AT nan en
3. Be sure that no pressure exists in any of the low pressure hydraulic system circuits.
M te m
E i n i p
C a q u
Clean dirt from the pump-motor assembly and hydraulic hose fittings before loosening
N M E
any of the hydraulic components.
E
R o r o r
f
4. Turn the handwheel valve off (fully counterclockwise).
FE E f
E S S E
R U U
T T
Failure to execute step 4 will enable oil to siphon from the hydraulic oil tank during removal of
O
the pump-motor assembly.
N NO
5. Tag and disconnect the pump case drain, pressure and suction hose assemblies (04, 05 and 07) and fittings
O
D DO
from the pump. Cap and/or plug the hose fittings and pump ports to prevent contamination of the hydraulic sys-
tem.
6. Remove the four capscrews (08) from the pump-motor mounting feet, and remove the pump-motor assembly
from the deck.
7. Clean dirt and oil from the pump mounting surfaces. Follow the cleaning procedures in Appendix A.
8. Position the replacement pump-motor assembly on the mounting pads and secure with capscrews (08).
9. If removed, install the fittings in the suction and pressure ports of the pump-motor assembly.
10. Install the suction, pressure and case drain hose assemblies.

11. Open the handwheel valve.
12. Connect the electrical wiring to the pump motor as tagged.
13. Jog the pump-motor until the system is fully primed. Check for proper pump rotation: clockwise as viewed from
the pump shaft end.
Pump and Motor Package Disassembly
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
LEGEND
O
D DO
01. Hydraulic Pump, Key and Mounting Hardware 05. Coupler Half - Motor
02. Adapter and Mounting Hardware 06. Electric Motor and Key
03. Coupler Half - Pump 07. Flange-Head Locking Screw (4)
04. Coupler Insert
Figure 9-44: Low Pressure Pump and Motor Repair
1. Refer to Figure 9-44. Remove the capscrews, nuts and lockwashers (01) and slide the pump away from the
adapter (02). The pump coupler half (03) will be removed with the pump. Remove the coupler insert (04). If
necessary, remove the adapter (02).
2. The pump is not repairable. If repairs are necessary, replace the pump.

3. Inspect the coupler parts for wear. Replace parts as necessary.
4. Clean the adapter and coupler parts. Follow the cleaning procedures in Appendix A.
5. Install the pump coupler half on the replacement pump. Do not tighten the set screw at this time.
6. Install the coupler insert (04) into the motor coupler half (05).
7. Install the replacement pump on the adapter (02).
8. Through the slotted opening in the adapter, slide and align the pump coupler half with the coupler insert. Make
sure the insert teeth are properly engaged with the coupler halves and that the pump coupler half is tight
n t
against the insert. Tighten the setscrew on the pump coupler half (03). Make sure the setscrew in the motor
e
coupler half is also tight.
Y m
NL uip ion
Low Pressure Pump Compensator Adjustment
O q t
1. Install a 0-3000 psi (0-207 bar) pressure gauge on VB4, port T423 (see reference 12 on Figure 9-45).
2. Start the main motor.

A L f E ra
I o p e
ER ce O
t
AT nan en
Do not back out the compensator adjustment knob more than 1.12 inches (28.45 mm) as
M te m
shown in Figure 9-45 while the pump is running.-
E i n i p
C a q u
3. The pressure reading should be 1500 psi (103.5 bar). If necessary, turn the adjustment knob (02, Figure 9-45)
N
until the desired pressure is read on the gauge.
E r M E
R fo o r
FE E f
E S S E
R U U
LEGEND
01. 1.12 inch (28.45 mm) Maximum
T T
02. Pump Compensator Adjustment Knob 01
O
N NO
O
D DO 02
R3490_01ap
Figure 9-45: Pump Compensator Adjustment

9.5.3 Valve Bank 4 (VB4)
Valve bank 4 (VB4) is mounted toward the rear on the machinery house left wall (see Item 04, Figure 9-25).
Refer to Figure 9-46. Although a total of nine hydraulic circuits are controlled by the valve assemblies mounted on
the 10-station, VB4 (station 10 is available for a future valve assembly), only stations 4 through 10 are supplied
with oil from the low pressure pump. Stations 1 through 3 are supplied with oil from port H on the left hand main
hydraulic pump and are discussed in the propel system (see Subtopic 9.3.2.1).The following topics describe the
functions of the low pressure circuits on VB4 in detail. For reference, refer to the auxiliary hydraulic schematic in
the LinkOne parts manual for your drill.
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

10 09 08 07 06 05 04 03 02 01
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
11
12
R o r o r
E E f f
E F S E
R U U S 320-VB4_01
T T
LEGEND
O
01. Station 1: Left Propel Brake Circuit (Ref.) 08. Station 8: Pipe Rack Holdback Circuit
N NO
02. Station 2: Right Propel Brake Circuit (Ref.) 09. Station 9: Head Brake Enable Circuit
03. Station 3: Propel High Speed Circuit (Ref.) 10. Station 10: Available Circuit - Blank Cover
O
04. Station 4: Right Pipe Rack Upper Gate Circuit 11. Pressure Gauge (Not included - shown for typi-
D DO
05. Station 5: Left Pipe Rack Upper Gate Circuit cal mounting purposes only)
06. Station 6: Viewing Hatch Circuit 12. Pressure Tap T423
07. Station 7: Air Compressor Inlet Hydraulic
Unloading Control Circuit (Drills with Gardner
Denver compressor only)

Stations 4 and 5: RH and LH Pipe Rack Upper Gate Circuits
01
02
03
n t
Y e
m
NL uip ion
O04 q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
05
BD1235a01
R U U 06 S
T T
O
N NO
O
LEGEND
01. Solenoid B 04. Dual Pilot-Operated Check Valve
02. Solenoid A 05. Upper Gate Cylinder
03. Flow Control Valve 06. Proximity Switch
Figure 9-47: Pipe Rack Upper Gate Circuits

! WARNING
When short pipe sections are used in the drill string, they may not reach up to the point
where the pipe rack gate will hold them in the rack. The short pipe could fall out and
cause severe personal injury or death. Always be sure that the length of pipe in the pipe
rack is sufficient to allow the pipe rack gate to hold the pipe in the rack.
The pipe rack gate is located at the top of the pipe rack. It consists of a curved rod, or gate arm, that rotates down
and in front of the drill pipe when it is stored in the pipe rack, protecting the drill pipe from falling out of the pipe
rack. When a loaded pipe rack is moved into the OVER HOLE position and the pipe is lifted from the rack by the
t
rotary carriage machinery, the pipe rack gate arm rotates up and out of the way. This permits rack to return to the
n
STORE position. When the pipe rack is back in the STORE position, the gate arm rotates back down.
Y e
m
When the empty pipe rack moves out of the STORE position, the gate arm rotates up, allowing the rack to be
NL uip ion
placed in position to receive the pipe. When the pipe is placed into the pipe rack, the gate arm rotates back down
and prevents the pipe from falling out.
O q t
A L f E ra
I o p e
R ce O
The following paragraphs refer to the RH pipe rack gate circuit. The LH circuit is identical as
E t
AT nan en
shown in Figure 9-47. Both pipe rack gate circuits are plumbed into the drill, even though on
most drills, only one circuit is used. The additional circuit is capped and available if the need
arises to add an additional pipe rack assembly.
M te m
E i n i p
Refer to Figure 9-47. The pipe rack gate valve is a three-position, four-way valve. The valve is solenoid actuated
C a q u
with manual override and spring return. Oil to operate the pipe rack gate is provided by the low pressure hydraulic
N M E
pump.
RE o r r
o
The proximity switch (06) on the head end of the cylinder provides information to the AC800 control system regard-
E E f f
ing the gate open or closed status.
E F S E
S
Pilot operated check valves (04) lock the cylinders in any position they are left in.
R U U
T T
When the operator presses the pipe rack switch on the operators console to the OVER HOLE position, the AC800
control system causes the A solenoid PRG2OS (02) to energize. Oil flows from port P to port A on the directional
O
N NO
valve, through the cylinder head end pilot-operated check valve (06) and out port A4of the valve bank. Oil pressure
in passage A also pilots the opposite pilot-operated check valve and forces it to open.
O
D DO
Oil from port A4 enters the head end of the RH pipe rack upper gate cylinder to extend the cylinder rod which will
open the gate arm. Oil from the rod side of the cylinder returns to tank through the VB2 port B4, the rod side pilot
operated check valve and solenoid ports B and T.
When the operator presses the pipe rack switch on the operators console to the STORE position, the AC800 con-
trol system causes the B solenoid PRG2CS (01) to energize. Oil flows from port P to port B on the directional valve,
through the cylinder rod end pilot-operated check valve (06) and out port B4of the valve bank. Oil pressure in pas-
sage B also pilots the opposite pilot-operated check valve and forces it to open.
Oil from port B4 enters the rod end of the RH pipe rack upper gate cylinder to retract the cylinder rod which will
close the gate arm. Oil from the head side of the cylinder returns to tank through the VB2 port A4, the head side
pilot operated check valve and solenoid ports A and T.

Station 6: Deck Hatch Circuit
01
02
03
n t
e
04
Y m
NL uip ion
07
O q t
A L f E ra
I o p e
ER ce O
t
AT n05an en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F 06 S E
R U U S
T T
O
N NO
BD1234a01
O
LEGEND
01. Solenoid B 05. Dual Pilot-Operated Check Valve
02. Solenoid A 06. Viewing Hatch Cylinder
03. Pressure Relief Valve 07. VB4 Pressure Transducer
Figure 9-48: Deck Hatch Circuit

Refer to Figure 9-48. The deck hatch valve is a three-position, four-way valve. The valve is solenoid actuated with
manual override and spring return. Oil to operate the deck hatch circuit is provided by the low pressure hydraulic
pump.
The pressure transducer (07) provides information to the AC800 control system regarding the VB4 working pres-
sure.
Pilot operated check valves (05) locks the cylinder in any position it is left in.
When the operator presses the deck hatch switch on the operators console to the CLOSE position, the AC800 con-
trol system causes the A solenoid DHCS (02) to energize. Oil flows from port P to port A on the directional valve,
through the cylinder head end pilot-operated check valve (05) and out port A6 of the valve bank. Oil pressure in
n t
passage A also pilots the opposite pilot-operated check valve and forces it to open.
Y e
m
Oil from port A6 enters the head end of the deck hatch cylinder to extend the cylinder rod which will close the deck
NL uip ion
hatch. Oil from the rod side of the cylinder returns to tank through the VB2 port B6, the rod side pilot operated
check valve and solenoid ports B and T.
O q t
L f E ra
When the operator presses the deck hatch switch on the operators console to the OPEN position, the AC800 con-
A
trol system causes the B solenoid DHOS (01) to energize. Oil flows from port P to port B on the directional valve,
I o e
through the cylinder rod end pilot-operated check valve (05) and out port B6 of the valve bank. Oil pressure in pas-
p
R ce O
sage B also pilots the opposite pilot-operated check valve and forces it to open.
E t
AT nan en
Oil from port B6 enters the rod end of the deck hatch cylinder to retract the cylinder rod which will open the deck
hatch. Oil from the head side of the cylinder returns to tank through the VB2 port A6, the head side pilot operated
M te m
check valve and solenoid ports A and T.
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

Station 7: GD Compressor Inlet Valve Control Circuit
01
02
n t 03
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NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
LEGEND
E i n i p
C a q u
01. Solenoid B
N
02. Pressure Relief Valve
E
r M E
r
04. GD Compressor Inlet Restrictor
Valves
R
E E fo f
05. Compressor Inlet Pressure o 04
F
Switch (CIPS)
E S E
R U 05U S
T T
O
N NO
O
D DO BD1233a01

Figure 9-49: GD Compressor Inlet Valve Control Circuit
Refer to Figure 9-49. The compressor inlet hydraulic unloading valve is a two-position, four-way valve. The valve is
solenoid actuated with manual override and spring return. Oil to operate this circuit is provided by the low pressure
hydraulic pump.

When the operator presses the DC Systems switch on the operators console to the ON position, the AC800 control
system causes the B solenoid CIHUS (01) to energize. Oil flows from port P to port B on the directional valve and
out port B7 of the valve bank. Oil from port B7 enters the inlet restrictor valves (04) to fully close the air compressor
inlet valves. Solenoid B will remain energized for 10 seconds after the main motor contactor is closed. Solenoid B
is also energized for 20 seconds after the main motor contactor is opened.
The pressure switch CIPS (05) provides information to the AC800 control system regarding the compressor inlet
hydraulic unloading control working pressure while solenoid B is energized. THe switch should be set to close at
275 psi (19 bar).
The compressor inlet flow control valve (03) is initially set to a rate of 1 gpm (3.8 lpm), but should be adjusted to
provide smooth inlet valve unloading.
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e
This circuit operates at 350 psi (24 bar) as determined by the pressure reducing valve (02). To check or adjust this
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pressure, refer to Breakout Wrench IN/OUT Pressure Reducing Valve (03) Adjustment.
NL uip ion
Compressor Inlet Control Pressure Reducing Valve (03) Adjustment. Limits the compressor inlet operating
O q t
pressure to 350 psi (24 bar). To check or adjust:
A L f E ra
I o p e
R ce O
2. Disconnect the solenoid valve electrical connector to CIHUS on VB4.
E t
AT nan en
3. Place the DC Systems switch in the ON position to start the low pressure pump.
M te m
4. Measure the pressure at T407. The pressure should be 350 psi (24 bar). If the pressure is too low or too high,
E p
proceed with step 5, below.
C a q i n u i
N M E
E
R o r o r
f f
6. Reconnect the solenoid valve electrical connector.
FE E
E S S E
R U U
T T
O
N NO
O
D DO

Station 8: Pipe Rack Holdback Circuit
LEGEND
01. Solenoid B
01 02. Pressure Reducing Valve
03. To Ports B71 and B81 on VB1
n t
Y e 02
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E 03 in i p
C a q u
N
BD1232a01
E r M E
R o r
f o
E E f
E F E
S
R U U S
T T
O
N NO
Figure 9-50: Pipe Rack Holdback Circuit
O
D DO
Refer to Figure 9-50.
When the pipe rack is in the stowed position, the pipe rack limit switch sends a signal to the AC800 control system
indicating that the pipe rack is stowed. The AC800 control system then actuates the pipe rack holdback solenoid
PRHBS (01). Oil from the low pressure pump is ported to Port B8 and on to the pipe rack circuits (ports B71 and
B81 on VB1) to maintain pressure on the rod end of the pipe rack cylinders which will prevent the pipe rack from
drifting.
The pipe rack holdback valve is a two-position, four-way valve. The valve is solenoid actuated with manual over-
ride and spring return. Oil to operate the pipe rack holdback circuit is provided by the low pressure hydraulic pump.
This circuit operates at 450 psi (31 bar) as determined by the pressure reducing valve (02). To check or adjust this
pressure, refer to Pipe Rack Holdback Pressure Reducing Valve Adjustment.

Pipe Rack Holdback Pressure Reducing Valve Adjustment. Limits the compressor inlet operating pressure to
450 psi (31 bar). To check or adjust:
2. Disconnect the solenoid valve electrical connector to PRHBS on VB4.
3. Place the DC Systems switch in the ON position to start the low pressure pump.
4. Measure the pressure at T405. The pressure should be 450 psi (31 bar). If the pressure is too low or too high,
proceed with step 5, below.
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e
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NL uip ion
6. Reconnect the solenoid valve electrical connector.
O q t
Inlet Restriction Valves on the main air compressor must be closed during the compressor start up. This will insure
L f E ra
the main air compressor load is minimal providing for easy start up of the main motor. Auxiliary Hydraulic System
A
provides the pilot pressure for keeping the inlet valves closed because, in the beginning of main air system opera-
I o e
tion, the air pressure needed for regulation is none existent.
p
ER ce O
t
AT nan en
Low Pressure pump keeps part of the VB4 rails pressurized at 1500 PSI.
M te m
E i n i p
C a q u
The 1 GPM (3.8 L/MIN) pressure compensated, adjustable flow control valve provides the oil flow rate for con-
N M E
trolled rate of the Compressor Inlet Restriction Valve movement.
E
R o r o r
E E f f
F E
The 350PSI (24 BAR) pressure reducing valve maintains the maximum safe pressure for proper Compressor Inlet
E S S
Restriction Valve operation.
R U U
T T
O
N NO
Compressor Inlet Hydraulic Unloading Control Solenoid (CIHUS) is kept energized for 10 seconds after the main
motor contactor is closed. With the CIHUS energized the oil coming out of the VB4 port B7 is keeping the Com-
O
D DO
pressor Inlet Restriction Valves closed.
When the CIHUS de-energizes the Compressor Inlet restriction Valves are controlled by the air pilot pressure com-
ing from the Subtractive Pilot valve.
Also, the CIHUS is kept energized for 20 seconds after the main motor contactor opens. This will allow the main
motor to slow down without being loaded by the compressor.

Station 9: Head Brake Enable Circuit
01
02
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NL uip ion
O q t
03
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
LEGEND
01. Solenoid B
N M04 E
02. VB4 Overload Relief Valve
E r r
03. Head Brake Control Valve
R fo fo
(located on rotary carriage) 05
E
04. Pressure Switch (HBPS)
F SE E
05. Head Brake (located on
E
R U US
rotary carriage)
T T
O
N NO
BD1231a01
O
D DO
Figure 9-51: Head Brake Enable Circuit
A disc-type pulldown brake provides braking for the rotary carriage assembly if the hoisting or pulldown systems
lose control or power, and when the machine is not in operation. The brake is mounted on the end of the pulldown
gearcase intermediate shaft. The brake is spring set and hydraulic pressure released.
Refer to Figure 9-51. The head brake circuit provides the hydraulic pressure required to release the head brake. Oil
to operate the head brake enable circuit is provided by the low pressure hydraulic pump. The low pressure pump
keeps stations 4 through 10 on VB4 pressurized at 1500 psi (103 bar). The head brake enable valve is a two-posi-

tion, four-way valve. The valve is solenoid actuated with manual override and spring returned. The head brake con-
trol valve (06) is a two-position, three-way valve. The valve is solenoid actuated and spring returned.
When the operator presses the hoist brake switch on the operators console to the RELEASE position, the AC800
control system causes the solenoid HBES (01) on VB4 and the head brake control valve (03) solenoid HBS on the
rotary carriage to energize. Oil flows from port P to port B on the directional valve to port B9 on the VB4 manifold.
From the B9 port, oil flows to the head brake control valve inlet port (port 3) and out of port 2 to the brake (05)
where it will build pressure. The pressure in the brake will quickly reach the VB4 passage pressure of 1500 psi (103
bar) which is sufficient to fully overcome the brake spring tension and release the brake.
The hoist brake pressure switch HBPS (04) will close at 1300 psi (90 bar) to indicate to the AC800 control system
that a sufficient amount of hydraulic pressure is present at the brake for it to release.
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e
The overload relief valve (02) protects VB4 from excessive pressure if a system failure occurs. This relief valve is
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factory preset to 2000 psi (138 bar) and must not be adjusted or pressure tested.
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

320XPC-UDC Mechanical Systems Manual Propel System
Section 10
Propel System
10.1 General
t
The drill is propelled by left and right hand crawler tracks mounted on crawler side frames. The crawler assemblies
n
are identical to each other except that they are configured as left- and right-hand units.
e
Y m
NL uip ion
LEGEND
O q t
01. Drive Tumbler
L f E ra
02. Transmission
03. Track
I A o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
Figure 10-1: Propel Drive Components
N O O
N
O
D DO
Each crawler track is driven by a reversible hydrostatic drive system. Pressurized hydraulic oil is supplied to each
hydraulic motor by individual pumps in the main hydraulic system. The direction of crawler travel is reversed by
reversing the direction of fluid flow through the motors. This is accomplished when the operator moves the propel
control levers on the operator console.
Propel speed is controlled by modulating the volumetric rate of hydraulic fluid passed through the motors. Each
propel drive transmission is flange-mounted at the front end of the crawler frame. The transmission consists of a
three stage planetary gear reducer with an integrated spring-set, hydraulically released, disc brake. The propel
motor is flange-mounted to the input shaft end of the transmission, as an integral part of the transmission unit.
Each transmission has a manually operated mechanical coupling, which is used to disconnect the propel motor
from the transmission when towing the drill.

Sec10Propel.fm -10.1- Section 10, Version 00 - 07/12
Propel System 320XPC-UDC Mechanical Systems Manual
The propel brakes are automatically released when hydraulic pressure is applied to the propel motors. When
hydraulic pressure is removed or lost, the brakes automatically apply, thus preventing uncontrolled machine travel.
The propel brakes must be hydraulically released before attempting to tow the drill. This is accomplished by using
a hand pump which is included with the optional tow package.
Towing the drill requires an optional towing package to be installed. This drill does NOT
have this option. Do not attempt to tow a drill that does not have the towing package
installed.
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The crawler transmissions multiply the torque received from the hydraulic motors and produce output torque to
e
rotate the drive tumblers, which are bolted to the transmission hub. The drive tumblers engage and drive the
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crawler tracks. The crawler side frames are connected to the main frame at the rear of the machine by a rigidly
NL uip ion
mounted main axle. A compensating equalizer axle at the front of the crawlers is designed to maintain the machine
in a stable condition while traversing uneven terrain.
O q t
A L f E ra
I o p e
R ce O
Power for the propel system is provided by the main hydraulic system. Because of its complex-
E
T an nt
ity, the main hydraulic system is covered as a separate section in this manual. Refer to Section
9, Hydraulic System.
A
10.2.1 Propel Motor
M ten me
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
Figure 10-2: Propel Motor

Section 10, Version 00 - 07/12 -10.2- Sec10Propel.fm
The propel transmissions (02, Figure 10-1) are driven by variable-displacement, plug-in type, axial piston hydraulic
motors (Figure 10-2) of bent axis design. The propel motor is an integral component of the propel transmission
assembly, but it can be removed independently.
When the operator places the drill in PROPEL mode, the AC800 Controller allows the joystick to control the propel
pump servos. As the joystick is moved, hydraulic pressure is ported to the propel motor, and the propel motor
causes the propel transmission to turn.
The propel brakes are an integral part of the propel transmission. When the operator’s BRAKE RELEASE button is
in the RELEASE position and when the joystick is moved off its neutral position, oil is ported from the main pumps
to special brake ports in the motor (not the same pressure lines as those that drive the motor) to cause the brakes
to release. When the joystick is in the neutral position, the brakes are not released.
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e
The piston displacement is hydraulically actuated, and can be controlled by the drill operator. When the operator
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places the DRILL SPEED switch to LOW speed setting, the motor’s maximum displacement provides high torque,
NL uip ion
low speed propelling. When the switch is in the HIGH speed setting, the motor’s minimum displacement provides
low torque, high speed propelling.
O q t
L f E ra
The high speed/low torque setting provides for a specific minimum motor displacement. The motor’s swash plate is
A
in its destroked configuration. The amount the swash plate can move in the destroked direction is limited by a phys-
I o e
ical stop that can be adjusted by turning the stop in or out, adjusting the degree to which the plate can be
p
destroked.
ER ce O
t
AT nan en
The low speed/high torque setting provides for a specific maximum motor displacement. The motor’s swash plate
is in its fully stroked configuration. The amount the swash plate can move in the stroked direction is limited by a
M te m
physical stop that can be adjusted by turning the stop in or out, adjusting the degree to which the plate can be
E p
stroked.
C a q i n u i
N
10.2.2 Propel Transmission
E r M E
R fo o r
FE E f
E S S E
R U U
T T
O
N NO
O
D DO
Figure 10-3: Propel Transmission
The propel transmission (Figure 10-3) is a three-stage planetary gear reducer with an integral hydraulically-
released, multiple-disc brake. The transmission and motor can be removed or installed as a unit, without need for
disassembly or subassembly of its components.

The drive tumbler, R54640D2, meshes with lugs on the crawler track shoes, causing them to move. The crawler
track shoes are supported by rollers at the top of the crawler frames and provide a continuous track on which the
drill propels.
10.2.3 Crawler Final Assembly
03
02
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e
01
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NL uip ion
O q t
A L f E ra
I o p e
ER ce O 06 05
t
AT nan en
04
09
M te m 07
E i n i p
C a q u 08 BD177b01
N
05
E r M E
r
LEGEND
R fo o
01. Propel Transmission (1 per side) 06. Main Axle
FE E
02. Equalizer (Pivot) Axle
f 07. Crawler Track (2)
E
03. Propel Motor (1 per side) 08. Lower Rollers (10 per side)
E S S
04. Idler Roller (1 per side) 09. Upper Rollers ( 3 per side - not visible - hidden by
R U U
05. Crawler Frame (2) crawler track)
T T
O
Figure 10-4: Crawler Final Assembly
N NO
Refer to Figure 10-4. The final crawler assembly consists of two crawler assemblies which are connected to the
O
D DO
drill’s main frame with two axles:
10.2.3.1 Equalizer Axle
The equalizer axle (02) is mounted to the forward end of the main frame by a large pin and clevis at the center bot-
tom of the frame. It attaches to the two crawler frames by means of pins. This arrangement permits some side-to-
side flexibility as the drill propels over uneven terrain.
10.2.3.2 Main Axle
The main axle (06) is mounted to the underside of the main frame by two split collars. To attach the crawler frames,
the axle extends through an unbushed bore at the rear of each crawler frame. The connection is secured by a
retainer plate bolted into the end of the shaft. This arrangement permits some front-to-back flexibility as the drill
propels over uneven terrain.

10.2.4 Crawler Frames
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NL uip ion
Figure 10-5: Crawler Frame
The crawler frames (Figure 10-5) support and distribute the weight of the drill to the ground. In addition to the pro-
O q t
pel transmission assembly, the crawler frames contain three upper rollers, ten lower rollers, and an idler roller.
A L f E ra
I o e
10.2.4.1 Upper and Lower Rollers
R ce O p
E t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
f f
Figure 10-6: Upper Roller
FE E
E S E
On each crawler frame, thirteen rollers support the track as it moves around the crawler frame. Three upper rollers
S
support the weight of the track as it moves across the top of the crawler frame. Ten lower rollers support and dis-
R U U
tribute the weight of the drill to the crawler track.
T T
O
N NO
O
D DO

10.2.4.2 Idler Roller
n t
Y e
m
NL uip ion
O q t
A L f E ra
Figure 10-7: Idler Roller
I o p e
R ce O
At the rear of each crawler frame, an idler roller is used to maintain alignment of the track shoes as they move
E
around the crawler frame. The idler roller is mounted in sliding bearing blocks, which enable it to move fore and aft
t
AT nan en
in the crawler frames. This provides a means of adjusting track tension.
M te m
10.2.4.3 Crawler Track
E i n i p
The crawler track provides a surface on which the drill propels. It consists of a series of shoes pinned together to
C a q u
form a continuous track. The shoes are 36" wide. The original set includes 19 cleated shoes and 39 non-cleated
shoes.
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

10.3 Propel System Maintenance
LEGEND
01. Motor
02. Transmission
n t
Y e
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NL uip ion
02
01
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
r r
BD0053c01
R
E E fo f o
E F S E
S
Figure 10-8: Propel Motor and Transmission
R U U
10.3.1 Propel Motor
T T
O
N NO
Refer to Figure 10-8. The propel transmissions (02) are driven by variable-displacement, plug-in type, axial piston
hydraulic motors (01) of bent axis design.
O
D DO
The piston displacement control is hydraulically actuated, and can be positioned by the drill operator to either the
maximum displacement for high-torque/low-speed propelling, or to the minimum displacement for low-torque/high-
speed propelling. The minimum and maximum displacement adjustments are factory set.
The motor is an integral part of the propel transmission. However, it can be removed from the transmission for
replacement without having to remove the transmission from the crawler frame.
10.3.1.1 Removal
To remove either propel motor proceed as follows:
1. Position the machine on level ground. Block the machine to prevent movement in either direction.

! WARNING
work.
3. Clean all dirt away from the hydraulic motor and hose assemblies.
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e
! WARNING
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NL uip ion
O q t
L f E ra
A
I o e
R ce O
p
E t
AT nan en
sure circuits.
5. Close the Handwheel valves.

M te m
E i n i p
C a q u
6. Tag and remove the hydraulic hoses from the motor. Cap or plug all hose fittings and motor ports.
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

LEGEND
UP 01. High Pressure Input (Port B - see Note,
below)
02. High Pressure Input (Port A - see Note,
below)
03. Return/Drain
04. Speed Control
05. Brake Release
t
01 02
e n Note: Ports A and B are the opposite on the
Y
LH crawler.
m
03
NL uip ion
O q t 04
A L f E ra
I o p e
ER ce O 05
t
AT nan en
M te m
E i n i p
C a q u
E N M E
r
F7827G_01a
R fo o r
FE E f
Figure 10-9: Propel Motor Hose Connections (RH Shown)
E S S E
R U U
T T
O
N NO
O
D DO
hoisting equipment to stabilize and lift heavy objects. The propel motor weighs approxi-
7. Attach a suitable hoist to the motor to prevent an overhung load on the shaft when the mounting bolts are loos-
ened.
8. Mark the mounting position of the motor on the transmission so that the hose connection ports will be correctly
located when the motor is reinstalled. Identify the motor, if more than one is being removed, to assure that it is
remounted on the same transmission.
9. Refer to Figure 10-12. Remove the four capscrews (55) from the motor mounting flange and pull the motor (56)
away from the transmission. Use care to prevent binding of the shaft or damage to the spline teeth when with-
drawing the motor.

10. Remove and discard the O-ring (57) from the pilot diameter on the motor.
11. If the motor is being replaced with a new or rebuilt motor, remove the bolt (50), locating ring (51) and splined
coupler input sleeve (52) from the end of the motor shaft. Save the coupler input sleeve to use on the new
motor because it is not included with the new motor.
10.3.1.2 Cleaning, Inspection, And Repair
Clean and inspect the propel motor and motor mounting area in accordance with the general cleaning and inspec-
tion procedures described in Appendix A of this manual. Inspect the drive splines for wear or tooth damage.
Inspect the hydraulic hoses and fittings for damage or signs of leaking. The motor shaft seal can be replaced, but
t
the propel motors are not field repairable, and must be replaced if they become worn or damaged. Replace O-ring
n
whenever the motor is removed from the transmission. Refer to the LinkOne electronic parts manual for compo-
e
nent identification.
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NL uip ion
O q t
Refer to Figure 10-12. Install the hydraulic motor on the propel transmission as follows:
A L f E ra
I e
1. If the motor being replaced is a new or rebuilt motor, install the splined coupler input sleeve (52) and locating
o p
ring (51) on the end of the motor shaft and secure with the bolt (50).
R ce O
E t
AT nan en
2. Lubricate the O-ring (57) with oil, and install it on the hydraulic motor pilot diameter.
3. Grease the motor output shaft spline with lithium grease.
M te m
E i n i p
C a q u
E N M E
Assembling heavy components with inadequate hoisting apparatus can injure personnel
R o r r
and/or damage equipment. Use suitable slings and hoisting equipment to stabilize and
o
E E f f
lift heavy objects. The propel motor weighs approximately 200 lbs (91 kg).
E F S E
S
4. Using a suitable lifting device, lift the hydraulic motor and insert the splined coupler input sleeve (52) into the
R U U
gearshift hub (48). Note the identification markings to ensure correct location of the motor. The motor case
T T
drain fitting should be positioned at the top. Be careful to avoid side loading and/or binding of the shaft as the
motor is moved into position against the transmission.
O
N NO
5. Fasten the motor to the transmission with hex head capscrews, M20X45-8.8.
O
D DO
6. Fill the motor case with clean oil, then install the hydraulic hose assemblies in accordance with the identifica-
tion tags placed during motor removal.
7. Open the Handwell valves.
8. Start the hydraulic pumps, and bleed air from the control and high-pressure circuits.

10.3.1.4 Adjustment
Technician Tip
Propel motors are preset and should only need adjustment in rare instances. Consider that the
motors receive their flow from the main pumps, and the main pump minimum and maximum
displacement settings affect the propel speed as much as the motor displacement. Before
adjusting any motor settings, be certain that all pump settings are as specified and that the
other components of the propel system are working properly.
t
The propel motor features variable displacement, and provides either high speed and low torque, or low speed and
n
high torque. This feature is activated by a switch on the operator’s console.
Y e
m
NL uip ion
The motors are adjusted at the factory for both high speed and low speed, and in most instances do not require re-
adjustment once the drill is in production. In the event that the drill does not propel evenly, however, the capability
to adjust the high speed and low speed settings is provided. Confirm that the pumps are properly adjusted prior to
adjusting the propel motors.
O q t
A L f E ra
I e
Refer to Figure 10-9 and adjust the propel motor settings as follows:
R ce O o p
E t
AT nan en
01
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO BD0523a01
02
LEGEND
01. Maximum Displacement Adjustment
02. Minimum Displacement Adjustment
Figure 10-10: Propel Motor Adjustments

The motor displacement adjustments are not capable of modulating the servo settings to inter-
mediate positions. Their function is limited to establishing the maximum and minimum setpoints
for motor piston displacement. At the maximum displacement position, the motor has the lowest
output speed and highest torque capability. At minimum displacement, the motor has the high-
est speed and lowest torque capability.
1. Start the main drive, and raise the drill with the jacks until the crawler tracks are completely clear of the ground.
n t
Y e
m
Operation of the propel system with the drill partially supported on the jacks can cause
NL uip ion
injury to personnel and damage to the equipment. Check visually to be certain that the
crawler tracks are raised completely off the ground before operating the propel drive.
O q t
L f E ra
2. Place the PROPEL MODE - MAINTENANCE switch, located on the operator console, in the MAINTENANCE
A
I o e
position to enable operation of the propel drive while the drill is supported on the jacks.
R ce O p
E
3. Refer to Figure 10-11. Remove the motor displacement caps.
t
AT nan en
+
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
Figure 10-11: Motor Displacement Cap
O
D DO
Motor displacement caps are part of the sealing system designed to prevent oil from leaking
around the adjusting screw. Always re-install the cap after adjustments have been made.
4. Adjust the maximum displacement stop (01, Figure 10-10) on each propel motor to obtain drive tumbler speed
of 4.0 rpm at maximum pump output. Turn the adjusting screw inward (clockwise) to increase tumbler speed.
5. Adjust the minimum displacement stop (02, Figure 10-10) to obtain drive tumbler speed of 8.0 rpm at maximum
pump output. Turn the adjusting screw outward (counterclockwise) to increase tumbler speed.
6. Lower the drill from the jacks, and test the propel mode for straightness of tracking.

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
Figure 10-12: Propel Transmission Assembly

LEGEND
01. Bolt 20. Shaft Nut 39. Outer Disk
02. Cap 21. Snap RIng 40. Brake Seal Kit
03. Spacer 22. Ball Bearing 41. Back-Up Ring
04. Bolt 23. Retaining Collar 42. O-ring
05. Shift Ring 24. Locating Ring 43. O-ring
06. Locking Nut 25. Third Stage Planetary 44. Back-Up Ring
07. Bearing 26. Second Stage Planetary 45. Piston
08. Snap Ring 27. Sun Gear Shaft 46. Back-Up Plate
09. Bolt 28. Snap Ring 47. Snap Ring
10. O-ring 29. Not Used
n t 48. Gearshift Hub
e
11. Snap Ring 30. Plug 49. Snap Ring
Y
12. Locating Ring 31. Snap Ring 50. Hex Head Bolt
m
NL uip ion
13. First Stage Planetary 32. Snap Ring 51. Locating Ring
14. Snap Ring 33. Shifter Shaft 52. Input Sleeve
15. Sun Gear 34. Input Shaft 53. Not used
16. O-ring 35.
O q t
Coupler 54. Not used
L f E ra
17. Thrust Washer 36. Back-Up Plate 55. Hex Head Bolt
A e
18. Face Seal 37. Brake Disk Kit 56. Hydraulic Motor
19. Roller Bearing 38.
I o
Inner Disk
R ce O p
57. O-ring
T E n t
n
Figure 10-13: Legend for Figure 10-12
A a
10.3.2 Propel Transmission
M ten me
E i n i p
C a q u
The transmission and motor can be removed or installed as a unit, without need for disassembly or subassembly of
N
its components.
E r M E
10.3.2.1 Removal
R fo o r
FE E f
E
Refer to Figure 10-12 and remove the propel transmission from the crawler frame assembly as follows:
E
R U U S S
1. Position the drill on firm even ground, and rotate the crawler drive so that the transmission oil drain plug is at
the six o'clock position.
T T
O
N NO
2. Raise the drill with the jacks to relieve the weight from drive tumbler, and place blocking under the machine
frame for support.
O
D DO ! WARNING
work.
4. Separate two track links (08), and remove the crawler track from the top of the drive tumbler (Refer To Subtopic
10.3.5.1).

5. Clean all dirt away from the hydraulic motor and hose assemblies.
! WARNING
n t
sure circuits.
Y e
m
NL uip ion
7. Turn Handwell valves off.
O q t
8. Tag and remove the hydraulic hoses from the motor. Cap or plug all hose fittings and motor ports.
A L f E ra
I e
9. Tag and remove the hydraulic hose assembly from the brake pressure supply fitting on the transmission. Cap
R ce O o p
or plug the hose fitting and brake hydraulic supply port.
E
T an nt
10. Remove thirty capscrews from drive tumbler.
A
M ten me
! WARNING
E i n i p
C a q u
N
E r M E
hoisting equipment to stabilize and lift heavy objects. The drive tumbler weighs approx-
R o
imately 1000 lbs (455 kg).
f o r
FE E f
E
11. Attach suitable lifting equipment to drive tumbler, and remove it from transmission.
E
R U U S S
12. Remove the transmission lubricant fill and drain plugs, and drain the oil into a suitable disposal container.
T T
Install the plugs again, when all of the lubricant has been drained.
O
N NO ! WARNING
O
D DO
drop, resulting in personal injury or death. Use suitable slings and hoisting equipment to
stabilize and lift heavy objects. The transmission and motor assembly weighs approxi-
13. Support the propel transmission with adequate lifting/moving equipment. Be sure it is positioned straight and
level in relation to the crawler frame bore.
14. Remove thirty capscrews that fasten transmission to crawler frame.
15. Slide the transmission out of the pilot bore in the crawler frame, being careful to move straight out to prevent
cocking of the spindle in the frame bore. Protect the motor from contacting the frame as it is being withdrawn
through the frame.

16. Transport the transmission to a suitable, clean work area for disassembly.
10.3.2.2 Disassembly
Disassemble the propel transmission as follows:
1. Place the transmission on blocks with the hydraulic motor located at the top.
2. Remove the hydraulic motor from the input end of the transmission, as described under the Subtopic 10.3.1.1,
Steps 6 through 8, inclusive.
t
3. Remove bolt, retaining plate and coupler.
e n
4. Remove hydraulic hose adapter and ring seal from the spindle.
Y m
NL uip ion
5. Attach a spring cage fixture and protective buffer (Figure 10-14) to the spindle, and apply enough axial force
against coupler to enable removal of snap ring.
O q t
A L f E ra
I o p e
R ce O
01
E t
AT nan en
M te m
02
E i n i p
C a q u
E N M E
r r
03
R
E E fo f o
LEGEND
01. Spring Cage Fixture
E F S E
02. Buffer
S
03. Adjusting Screw
R U U
04 04. 20MM Screw
T T
O
N NO BD0524a01
O
D DO Figure 10-14: Spring Cage Fixture
6. Back out the adjustment screw slowly to allow concentric compression springs to completely relax while they
push back-up plate and coupler away from piston.
7. Remove the spring cage fixture from the spindle, then pull coupler and back-up plate out of the spindle coun-
terbore.
8. Remove compression springs from the spring pockets in piston. Discard the springs.

9. Place a large, clean, protective rag into the counterbore of the spindle, then apply very-low-pressure com-
pressed air through the brake hydraulic pressure supply port. Increase the air pressure slowly until piston is
forced out of the bore and onto the rag. Remove the piston and rag from the spindle.
10. Remove and discard the O-ring and back-up ring from piston. Notice the relative positions of the O-ring and
back-up ring for reassembly.
11. Remove snap ring from the inside end of shifter shaft, then remove coupler from the shifter shaft.
12. Remove and discard the O-ring and back-up ring from the spindle bore. Notice the relative positions of the O-
ring and back-up ring for reassembly.
n t
13. Remove and discard the eleven inner and five outer brake disks.
Y e
m
NL uip ion
01
O q t
02
A L f E ra
I o p e
ER ce O LEGEND
t
AT nan en
01. Piston
02. Outer disk (5 ea.)
03. Inner disk (11 ea)
M te m
03
BD0525a01
E i n i p
Figure 10-15: Brake Disk Arrangement
C a q u
N M E
14. Remove brake back-up plate from the assembly.
E
R o r o r
f
15. Remove snap ring from the counterbore of the spindle.
FE E f
E
16. Remove snap ring from bearing carrier.
E
R U U S S
T T
O
N NO
O
D DO
hoisting equipment to stabilize and lift heavy objects
17. Attach suitable hoisting equipment, and reposition the transmission assembly so that the motor-mounting face
of the spindle is down, and well supported on wooden blocking.
18. Remove bolts from spacer, then remove spacer and cap from the end cover.
19. Remove the twenty-four bolts, and remove the end cover.

hoisting equipment to stabilize and lift heavy objects
20. Place lifting eyes in the threaded screw holes in the end cover, support the cover with adequate lifting/moving
equipment, then lift the end cover and entire shifter shaft assembly away from the transmission.
n t
e
To avoid damage to the shifter shaft, be sure to lift the end cover straight up to enable
Y
the shifter shaft to be withdrawn without binding.
m
NL uip ion
21. Loosen the thrust washer from the pilot diameter in the end cover, then remove the thrust washer from shifter
shaft.
O q t
A L f E ra
I e
22. Remove snap ring from shift ring.
R ce O o p
23. Remove bolts from shift ring, then remove the shift ring, with shifter shaft and ball bearing intact, from the end
E t
AT nan en
cover.
24. Remove snap ring from shift ring, and remove shifter shaft and ball bearing from shift ring.
M te m
E n i p
25. Remove and discard O-ring from shift ring bore.
C a q i u
N
26. Remove locking nut, then press the ball bearing from the shifter shaft.
E r M E
R o r
27. Carefully lift the third stage planetary out of the ring gear, and away from input shaft.
f o
FE E f
28. Loosen ring gear A from the pilot diameter in ring gear B, and remove ring gear A from the assembly.
E S S E
R U U
29. Remove and discard the two O-rings from ring gear A.
T T
30. Remove input shaft and thrust washer. Be careful to prevent the thrust washer from dropping off the end of the
O
N NO
input shaft.
O
31. Remove thrust washer from input shaft.
D DO
32. Lift sun gear shaft, including snap ring, out of the assembly. Then, remove snap ring from the sun gear shaft.
33. Carefully lift the second planetary stage gear assembly out of ring gear B.
34. Lift sun gear shaft out of engagement with the first stage planetary.
35. Remove locating ring from bearing carrier.
36. Carefully lift the first stage planetary, bearing carrier, ball bearing, and coupler as a unit out of ring gear B.
37. Remove coupler and ball bearing from bearing carrier by removing snap ring.

38. Remove ball bearing from coupler by removing snap ring.
39. Remove the crimping on the eight locations of shaft nut, then loosen and remove the shaft nut from the spindle.
hoisting equipment to stabilize and lift heavy objects.
t
40. Attach a suitable lifting device to ring gear B, and lift the ring gear away from the spindle. The cups and one
n
cone of the two tapered roller bearings, and one half of face seal, will remain with the ring gear.
Y e
m
41. Remove tapered roller bearing cone from inside ring gear B.
NL uip ion
42. Remove the other tapered roller bearing cone from the hub of the spindle.
O q t
L f E ra
43. If bearings are going to be replaced, remove the two bearing cups from ring gear B.
I A o p e
44. Remove each half of face seal from ring gear B and the spindle.
ER ce O
t
AT nan en
Clean and inspect the propel transmission components in accordance with the general cleaning and inspection
M te m
procedures described in Appendix A of this manual. None of the components are repairable, and, therefore must
E n i p
be replaced if worn or damaged. If a component in any one of the three planetary gear assemblies needs replace-
C a q i u
ment, that entire planetary unit must be replaced. It is recommended that all O-rings be replaced whenever the
N
transmission is disassembled for repair. Refer to the LinkOne electronic parts manual for component identification.
E r M E
10.3.2.4 Assembly
R fo o r
FE E f
E
Refer to Figure 10-12 and assemble the propel transmission as follows:
E
R U U S S
1. Position the spindle with the motor mounting side down on clean wooden blocking.
T T
2. Install the two cups from tapered roller bearings (19) in the bearing seats of ring gear (B). Be certain that the
O
N NO
cups remain seated firmly against the shoulder in the counterbore.
O
D DO
Dry ice may be used to freeze the cups, so they may be installed. If the cups are pressed into
the housing, extreme care should be taken so they are not damaged.
3. Install one half of face seal (18) on the spindle.
4. Install one cone of tapered roller bearing (19) on the spindle.
5. Pack the half of face seal (18) and bearing cone (19) with an excess of clean grease.
6. Install the other half of face seal (18) in ring gear (B).

7. Attach suitable hoisting equipment to ring gear (B), and position the ring gear on the spindle so bearing (19)
and face seal (18) halves are correctly mated.
8. Pack bearing (19) seat area with an excess of clean grease.
n t
9. Install remaining tapered bearing cone (19) with shaft nut (20). Tighten the nut finger tight. Be sure that the
e
bearing cone seats correctly in the cup.
Y m
NL uip ion
10. Measure the axial position of ring gear (B) relative to the spindle, then torque shaft nut (20) until the bearing is
preloaded 0.3mm (0.012"). Crimp the torque nut flange in eight equally spaced locations.
O q t
A L f E ra
I o p e
R ce O
Ring gear (B) may be rotated in only one direction during preloading of the tapered roller bear-
E t
ings.
AT nan en
11. Install ball bearing (22) on coupler (39), and retain it with snap ring (11).
M te m
E n i p
12. Install coupler (35) and mounted bearing (22) in the bore of bearing carrier (23), and fasten with snap ring (21).
C a q i u
E N M E
R o r o r
E E f f
The bearing retainer should already be assembled as a factory-installed component of the third
F
stage planetary (25).
E S S E
R U U
13. Install the third stage planetary (25) in ring gear (B). Mesh the planetary gear/ring gear teeth and the planetary
gear carrier/spindle splines with care to avoid causing nicks and burrs. Lubricate the teeth with gearcase oil
T T
before assembly.
O
N NO
O
D DO
14. Attach a suitable hoisting apparatus to ring gear assembly (B), and position the unit on its side.
15. Install snap ring (31) on bearing carrier (23). Access can be gained through the input shaft opening in the spin-
dle.
16. Reposition the transmission assembly so the unit is resting securely on wooden blocking with the motor mount-
ing face of the spindle down.

17. Install locating ring (24) in pilot counterbore of bearing carrier (23).
18. Install sun gear shaft (27) in the third stage planetary (25). Be sure the relieved face of the sun gear is inserted
first, and that it seats against locating ring (24).
19. Install the second stage planetary (26) into ring gear (B) and over the end of sun gear shaft (27). Retain the
planetary gear assembly with snap ring (28).
20. Install the sun gear (15) in the second stage planetary (27). Be sure that the counterbored end of the gear is
positioned at the top after installation.
21. Slide thrust washer (15) over end of the input shaft (34), then insert the splined-end of the input shaft through
n t
the center of the sun gear shafts, and mesh the splines with those in coupler (35). The thrust washer bottom
e
face should be seated on the bottom of the counterbore in sun gear (15).
Y m
NL uip ion
22. Lubricate two O-rings (16) with oil, and install them in O-ring grooves of ring gear (A).
O q t
23. Line up the through-bolt holes in ring gear (A) with the tapped holes in ring gear (B), then insert ring gear (A)
L f E ra
pilot diameter into the counterbore of ring gear (B). Be sure that the matching faces of the two ring gears are
A
tight together, when installed. Do not install the mounting bolts at this time.
I o p e
R ce O
24. Carefully install the first stage planetary (13) in ring gear (A) and over input shaft (34).
E t
AT nan en
25. Install ball bearing (07) on shifter shaft (33), and retain the bearing securely with lock nut (06).
M te m
E i n i p
C a q u
Apply Loctite compound to the threads of the lock nut before assembling to the shifter shaft.
E N M E
R o r o r
26. Install shifter shaft (33) and mounted bearing (07) into the counterbore of shift ring (05), and fasten in place
f f
with snap ring (08).
FE E
E S S E
27. Lubricate and install O-ring (10) in the bore of the end cover.
R U U
28. Assemble shift ring (05) with mounted shifter shaft to the end cover, and fasten with bolts (04). Torque the bolts
T T
to 38 ft lbs (51 N.m).
O
N NO
O
D DO
Apply molybdenum-based protectant/sealant to sealing surfaces and threads. AVOID contact
with sealant and O-ring (10). Assemble the parts only after sealant has cured (dried).
29. Install snap ring (11) on shift ring (05).
30. Slide thrust washer (12) over shift shaft (33) and position in the pilot counterbore of the end cover.

31. Attach suitable hoisting equipment to the end cover assembly and lift it into position above the ring gear. Lower
the end cover so that the shift shaft feeds through the center of input shaft (34), and the cover closes com-
pletely over the pilot diameter of ring gear (A). Install twenty-four bolts (09) and torque in a crisscross pattern
evenly, and uniformly to 85 N.m (63 ft-lbs).
n t
Y e
m
NL uip ion
Input shaft (34) should have 0.039-0.079" (1-2 mm) end play after the end cover is installed.
O q t
32. Apply molybdenum-based protectant/sealant to the sealing surfaces of the cap (02) and spacer (03), and to the
L f E ra
threads of bolts (01). Allow to dry before assembling to the end cover. Torque the bolts to 38 ft-lbs (51 N.m).
I A o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
33. Attach suitable hoisting apparatus to the propel transmission and position it so that the end cover is on the bot-
N
tom and the input shaft side is exposed on top for assembly.
E r M E
R o r
34. Install snap ring (32) in the brake disk area of the spindle.
f o
FE E f
E
35. Install back-up plate (36) against snap ring (32).
E
R U U S S
36. Install inner and outer brake disks (38 and 39), and be sure that they are correctly engaged with the spindle
and coupler (35). Refer to Figure 10-15 for the arrangement of the inner and outer brake disks.
T T
O
N NO
37. Lubricate back-up ring (41) and O-ring (42) with gear oil, and install in the spindle. The back-up ring must be
installed before the O-ring.
O
D DO
38. Install coupler (48) on shifter shaft (33), and retain it with snap ring (49). Lubricate splines with gear oil before
inserting coupler (48) into coupler (35).
39. Lubricate back-up ring (44) and O-ring (43) with gear oil, and install on the outside diameter of piston (45). The
back-up ring must be installed before the O-ring.
40. Install piston (45) in the counterbore of the spindle, and push it in as far as it will go against the brake disks.
Lubricate the counterbore with gear oil before installing the piston.
41. Position back-up plate (46) subassembly in the counterbore of the spindle until it contacts the brake springs.

42. Attach the spring cage fixture and protective buffer to the spindle, and apply enough axial force against coupler
(48) to enable compression of the brake springs. Press the shaft in only to the point where back-up plate (46)
seats firmly against the bottom of the counterbore in the spindle. Over-tightening can cause damage.
43. Install snap ring (47) in the spindle to retain back-up plate (46).
44. Remove the spring cage fixture from the spindle.
45. Install seal ring (29) and adapter (30) in the brake hydraulic pressure port, and tighten securely.
46. Install coupler (52) on the motor spindle with retaining plate (51) and bolt (50).
n t
47. Install the hydraulic motor on the propel transmission as described above under Subtopic 10.3.1.3, Step 1
e
through Step 4.
Y m
NL uip ion
48. Open Handwell valves.
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
LEGEND
O
N NO
O
D DO
01. Roller Shaft Tube 11. Capscrew 21. Lower Shim Pin
02. Cotter Pin 12. Washer 22. Idler Shim
03. Roller Shaft Pin 13. Shoe Guide 23. Idler Shim
04. Lower Roller Shaft 14. Shim Shoe Guide 24. Cotter Pin
05. Upper Roller Shaft 15. Screw 25. Idler Bearing
06. Thrust Washer 16. Transmission 26. Idler Shaft Pin
07. Roller Assembly 17. Drive Tumbler 27. Idler Thrust Washer
08. Bushing 18. Capscrew 28. Idler Roller Assembly
09. Link Assembly 19. Crawler Frame 29. Idler Bushing
10. Roller Shaft tube 20. Upper Shim Pin 30. Idler Shaft
Figure 10-16: Crawler Frame Assembly

Refer to Figure 10-16 and install the propel transmission on the crawler frame as follows:
hoisting equipment to stabilize and lift heavy objects. The transmission and motor
assembly weighs approximately 2800 lbs (1270 kg).
1. Attach suitable hoisting apparatus to propel transmission (15) and position it so that the hydraulic motor end is
t
aligned with the pilot bore in crawler frame (18). Be sure that the lube drain plug is located at the six o'clock
n
position, then insert the transmission into the frame.
Y e
m
2. Align the screw holes in the transmission with those in the frame, then install the thirty capscrews (14). Torque
NL uip ion
the capscrews to 1526-1873 ft-lbs (2070-2540 N.m).
O q t
A L f E ra
I o p e
R ce O
E t
AT nan en
3. Attach suitable lifting equipment to drive tumbler (16), and install it on transmission (15) with thirty capscrews
M te m
(17). Torque the capscrews to 1526-1873 ft-lbs (2070-2540 N.m).
E i n i p
C a q u
4. Install crawler track (08) on drive tumbler (16). Refer to Subtopic 10.3.5.3 for installation procedures.
E N M E
r
5. Install the hydraulic pressure hose assembly for the brake to the fitting on the transmission spindle.
R fo o r
E E f
6. Install the high-pressure and control pressure hoses to the motor.
E F S E
S
7. Remove the transmission lubrication fill/level plug and fill the transmission with approximately 9.5 gallons (36
R U U
liters) of gear oil (refer to Subtopic 12.2.5). Check and replace the fill plug seal if damaged, then install the plug
securely.
T T
N NO
10.3.3 Idler Roller
O
O
D DO
The idler roller keeps the crawler track aligned. The idler roller is mounted in sliding bearing blocks, which enable it
to move fore and aft in the crawler frames. This provides a means of adjusting track tension.
10.3.3.1 Removal
Remove the idler roller assembly as follows:
1. Position the machine on level ground.
! WARNING

work.
3. Separate the crawler track as described under Subtopic 10.3.5.1 and remove it from the idler roller.
4. Remove two cotter pins (02) from each upper shim pin (20) on the inside and outside frame locations, then
remove both upper shim pins from the crawler frame.
5. Note the locations of shims (22 and 23) ahead of and behind inner and outer idler bearings (25), then remove
t
all shims (refer to Subtopic 10.3.5.4 for shim removal procedure).
e n
6. Remove the lubrication hose assembly from idler shaft (30).
Y m
NL uip ion
7. Remove cotter pins (24) from each idler shaft pin (26), and remove the idler shaft pins from two idler bearings
(25).
O q t
A L f E ra
I o p e
R ce O
E t
AT nan en
M te m
8. Attach suitable lifting equipment to the idler roller, and lift the weight of the idler from idler shaft (30).
E i n i p
C a q u
9. Remove two idler bearings (25) and idler thrust washers (27) from each end of idler shaft (30).
E N M E
10. Remove idler shaft (30) from idler roller (28), then lift the idler away from the crawler frame.
R o r o r
E E f f
E F S E
S
Clean and inspect the idler roller components in accordance with the general cleaning and inspection procedures
R U U
described in Appendix A of this manual. None of the components are repairable, therefore, replace any that are
T T
damaged or worn. Refer to the LinkOne electronic parts manual for component identification.
O
N NO
O
D DO
Refer to Figure 10-16 and install the idler roller assembly as follows:
1. Using suitable lifting equipment, position idler roller (28) in the pocket of crawler frame (19).
2. Lubricate idler shaft (30) with oil and install it in the bore of idler roller (28). Position the shaft so that the grease
hole is horizontal, and is pointed toward the tumbler end of the crawler.

3. Install thrust washer (27) on idler shaft 30) at each side of the idler roller.
4. Install idler bearing (25) on each end of idler shaft (30), and fasten it with idler shaft pin (26) and two cotter pins
(24).
5. Install shims (22 and 23) in the same positions on each side of inner and outer idler bearings (25) as before
removal.
6. Lock the shims in place with upper shim pins (20) and two cotter pins (03).
7. Install the lubrication hose assembly to idler shaft (30).
n t
8. Refer to Subtopic 10.3.5.3 and reassemble the crawler track.
Y e
m
9. Adjust the crawler track tension as described under Subtopic 10.3.5.4.
NL uip ion
O q t LEGEND
L f E ra
01. Crawler Track Link
I A e
02. Upper Roller Shaft
R ce O o p
03. Upper Roller
04. Lower Roller
E t
05. Lower Roller Shaft
AT nan en
06. Roller Shaft Pin
07. Cotter Pin
02
M te m
03
E i n i p
C a q u 06
N M E
01 07
RE 04
o r r
E E
05
f f o
E F S E
R U U S
T T
O
N NO
BD0526a01
O
D DO Figure 10-17: Upper and Lower Rollers
10.3.4 Upper and Lower Rollers
Refer to Figure 10-17. On each crawler frame, thirteen rollers support the track as it moves around the crawler
frame. Three upper rollers support the weight of the track as it moves across the top of the crawler frame. Ten
lower rollers support and distribute the weight of the drill to the crawler track.
Each roller is supported by a shaft mounted in a bushing along the side frame. The rollers are lubricated by the
auto-lube system.

10.3.4.1 Removal
To remove the upper or lower rollers, proceed as follows:
1. Position the machine on level ground.
! WARNING
Inadequate blocking of a raised drill can enable the machine to drop causing severe
injury, death, and/or equipment damage. Do not perform maintenance work under the
t
drill until it is securely blocked.
e n
2. Raise the machine and position secure blocking beneath the frame.
Y m
! WARNING
NL uip ion
O q t
L f E ra
A e
I o p
R ce O
E
work.
t
AT nan en
M te m
4. Separate the crawler track as described under Subtopic 10.3.5.1. Remove the lubrication hose assembly from
the roller shaft.
E i n i p
C a q u
N M E
5. Remove the cotter pins from the roller shaft pin.
RE o r r
6. Remove the roller shaft pin from lower or upper roller shaft.
E E f f o
F E
7. Place blocking below the roller to prevent the roller from dropping when the roller shaft is removed.
E
R U U S S
8. Remove the lower or upper roller shaft from the roller, then remove the roller and thrust washers from the
T T
frame.
O
N NO
10.3.4.2 Cleaning, Inspection, and Repair
O
D DO
Clean and inspect the track support roller components in accordance with the general cleaning and inspection pro-
cedures described in Appendix A of this manual. None of the components are repairable; therefore, replace any
that are damaged or worn. Refer to the LinkOne electronic parts manual for component identification.
Install the roller as follows:
9. Block the support roller with shim thrust washers in position within the crawler frame.
10. Lubricate the roller shaft with grease, and install the shaft through the frame supports and roller.
11. Install roller shaft pin in the roller shaft, and fasten it with two cotter pins.

12. Install the grease lubrication hose to roller shaft.
13. Manually operate the lubrication system and bleed the lines to the crawlers as required. Refer to Subtopic
12.7.4.7 in Section 12.
10.3.5 Crawler Track Assembly
NOTE: Nut is tack welded to pin

retainer. Nut must be tight prior
t
to welding. Torque nut to 75 ft
n
lbs (102 Nm) and tack weld.
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en LEGEND
M te m 01. Track Link
E n i p
02. Cleated Link
C a q i u
03. Link Pin
04. Pin Retainer
E N M E
05. Nut
R o r o r
E E f f Figure 10-18: Crawler Links
E F S E
S
The crawler track assembly consists of a series of individual links (shoes), which are connected with link pins to
R U U
form the continuous track upon which the drill is propelled. The links are available in various widths and configura-
T T
tions to accommodate differing soil conditions. The links on this drill are 36” wide, all cleated.
O
N NO
10.3.5.1 Track Link Removal
O
D DO
Remove track links as follows:
1. Propel the drill so the link to be removed is located behind the idler roller, and as near to ground level as possi-
ble, but with sufficient clearance to drive out the link pins.
2. Place temporary blocking between the under-side of the track links and the top of the crawler frame to support
the track when the link pins are removed.

! WARNING
work.
4. Remove the link pin retaining capscrew and hex nut from the track link (refer to Figure 10-18). The hex nut is
t
tack welded to the capscrew to prevent it from vibrating loose during operation. Cut off the weld, or break the
n
capscrew to remove it from the track link.
Y e
m
5. Remove the link pins at the place where the track is to be separated using one of the following two methods:
NL uip ion
O q t
! WARNING
A L f E ra
e
The weight of a falling track can cause serious injury or death. Do not stand in the path
I o p
of a crawler track when the link pin is being removed.
R ce O
E t
AT nan en
Slide Hammer Method
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO Figure 10-19: Slide Hammer Method
Sparks or flying metal chips can injure eyes or face. Wear eye and face protection when
using hammers.
A. Obtain a rod with one end threaded for a nut.
B. Grind a 3/4" (19mm) x 45 degree chamfer on the other end of the rod.

C. Weld the ground end to the link pin (refer to Figure 10-19). Use sufficient weld to prevent the rod separating
from the pin.
D. Slide the slap hammer onto the rod, and install the hex nut on the rod end.
E. Remove the rod by slapping the hammer against the rod nut (refer to Figure 10-20).
Drive Rod Method
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
N
Figure 10-20: Drive Rod Method
E r M E
R o r
A. Obtain a smooth threaded rod of sufficient length and strength, with a mating hex nut on one end. The
f o
E E f
threaded rod must be less than 1.5 inches (38 mm) diameter to fit into the bore of the track link.
E F S E
B. Thread the hex nut on the striking end of the threaded rod.
R U U S
C. Insert the rod into the bore of the track link, and drive the link pin out. The rod will need to be bent slightly at
T T
the pin end to clear the link.
O
N NO
O
D DO
D. Attach suitable lifting equipment to stabilize the link being removed, then disassemble the remaining link
pins that fasten the link to the track. Link weight is approximately 450 Ibs (200 kg).
E. Remove the uncoupled link from the crawler track.

Clean and inspect the idler roller components in accordance with the general cleaning and inspection procedures
described in Appendix A of this manual. Repair of the crawler track is limited to replacement of defective link pins
and welding of the damaged track links.
Repair a damaged link as follows:
! WARNING
n t
e
work.
Y m
NL uip ion
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities, if
O q t
the track link is being repaired while mounted to the drill.
A L f E ra
I e
2. Check suspected cracks with liquid dye penetrant or Magnaflux.
R ce O o p
3. Clean the area to be welded. Remove all surface grease, oil, etc.
E t
AT nan en
4. Grind or air-gouge the crack completely.
M te m
5. Pre-heat the weld zone to 600-700°F (315-370°C) and maintain this temperature during welding, checking with
E n i p
a temperature indicating crayon.
C a q i u
N
6. Weld the track link with 10018-M electrodes. Pre-heat the electrodes in an oven at 350°F (175°C). Remove
E M E
only two electrodes from the oven at a time for use.
r
R fo o r
E E f
7. Slowly cool the track link after welding by wrapping the weld area with an insulating blanket.
E F S E
S
10.3.5.3 Track Link Installation
R U U
T T !
Refer to Figure 10-18 and install track links as follows:
O
N N O WARNING
O
D DO
tenance work on a machine without first disabling the operator - controls. Lock out and
work.

2. Using a lifting device of sufficient capacity, align the open track ends. Use a drift pin to help align the link pin
bores.
3. Install the link pins in the bores in the track links. There should be a slip-fit between the pin and the bore.
4. Install the link pin retaining capscrew and hex nut. Tighten the nut to 75 ft-lbs (102 Nm) maximum.
5. Tack weld the hex nuts to the capscrews to prevent loosening.
6. Repeat Step 2 through Step 5 to install addition track links and pins.
t
10.3.5.4 Track Tension Adjustment
e n
Y m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
TC0706
R o r o r
f
Figure 10-21: Track Tension Adjustment
FE E f
E
Adjustment of crawler track tension is accomplished by adding or removing shims to the track adjustment mecha-
E S S
nism. A manually-operated hydraulic pump and two hydraulic rams with the required connecting hoses are fur-
R U U
nished with the machine, and are used to assist with track adjustment. To adjust track tension, proceed as follows:
T T
O
1. Position the machine on level ground, then use the drill jacks to raise the drill enough to lift the crawler tracks
N NO
clear of the ground.
O
D D O ! WARNING
work.
3. Remove two cotter pins from each upper shim pin on the inside and outside frame locations, then remove both
upper shim pins from the crawler frame.
4. Remove loose shims from behind inner and outer idler roller bearings (24).

5. Install one ram on the inboard side of the crawler frame between the ram support bracket on the crawler frame
and the idler bearing. Position the other cylinder similarly on the outboard side of the frame.
6. Connect the hydraulic hand pump to the two rams.
7. Operate the hand pump to pressurize the rams. This action moves the idler bearings to the rear, and removes
slack from the crawler track. Continue operating the pump until the crawler track sag is approximately 12" - 14"
(300 - 350 mm), as measured at the track midpoint, between the top of the crawler link and the underside of
the crawler frame. Refer to Figure 10-22
n t
Y e
m
NL uip ion
O q t
L f E ra
C
I A o p e
ER ce O
t
AT nan en
M te m
BD0530b01
E i n i p
C a q u
Figure 10-22: Track Tension Measurement
E N M E
r
8. Add shims as required on the ram side of the idler bearings to maintain the new position and ensure that the
R o o r
track sag will remain as set. Use the shims which were removed from behind the idler bearings to fill the
f
E E f
required gap. The number and sizes of shims used should be identical at both idler bearing locations.
F
E S S E
R U U
T T
Shims are furnished in two thicknesses, 0.5 and 0.75 inch (12.7 and 19 mm).
O
N NO
9. Relieve the pressure on the rams, then remove them from the crawler frame brackets.
O
D DO
10. Lower the machine to the ground.

320XPC-UDC Mechanical Systems Manual Leveling System
Section 11
Leveling System
11.1 General
t
This section provides descriptive and maintenance information for the leveling jacks and jack hydraulic cylinders.
e n
The four leveling jacks, attached to the corners of the main frame, are hydraulically actuated units that establish
Y m
NL uip ion
and maintain a level and stable position for the drill during drilling operations. Hydraulic pressure is supplied from
the auxiliary hydraulic system. Refer to Section 9, Hydraulic System.
O q t
Operation of the jacks is controlled from the operator cab. The rear jacks (nearest the mast) are independently
L f E ra
adjustable. The front jacks cylinders are connected in parallel so that they raise or lower as a self-equalizing pair.
A
I o e
The jacks can also be placed in the automatic mode, which automatically raises the drill deck to the lowest level
R ce O p
elevation for good drill stability.
E t
AT nan en
M te m
During maintenance procedures, apply standard torque to fasteners, unless otherwise speci-
E i n i p
fied. Refer to Appendix A for general mechanical maintenance procedures, and to Appendix B
C a q u
for general hydraulic component maintenance procedures. It is advisable to replace all seals
N M E
and O-rings whenever hydraulic components are disassembled. Refer to the LinkOne Parts
E r r
Manual for identification of components and service kits.
R
E E fo f o
11.2 Rear Jacks F E
E
R U U S S
T T
Refer to Figure 11-1. The rear jack cylinder housings (02 and 04) are an integral part of the rear deck module (01).
O
N NO
The rod end of the cylinder is pinned to the jack cap (05) on top of the jack housing. The cylinder barrel is pinned to
the spud (03); the spud, in turn, is pinned to the shoe.
O
D DO
Refer to Figure 11-2. Each of the two rear jacks consists of a hydraulic cylinder, spud, and shoe along with hydrau-
lic hoses, a pressure switch, regeneration / counterbalance valve, limit switch and mounting hardware as shown in.

Sec11Level.fm -11.1- Section 11, Version 00 - 07/12
Leveling System 320XPC-UDC Mechanical Systems Manual
01
02
05
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en 03
M te m
E i n i p
C a q u
N M E
FRONT
RE o r r
E E f f o BD1240a01
F
04
E S S E
R U U
T T
O
LEGEND
N NO
01. Rear Deck Module - shown detached from Main Frame Module for clarity
02. Left Rear Jack Housing
O
D DO
03. Spud (Typical) - shown with shoe removed
04. Right Rear Jack Housing
05. Jack Cap (Typical)
Figure 11-1: Rear Jack Locations

Section 11, Version 00 - 07/12 -11.2- Sec11Level.fm
01 01
11
02
02
10 03
10 03
12
n t
e 09 04
Y m
NL uip ion
O q t 05
A L f E ra
I o p e 06
R ce O
06 08
E
05
t
07
AT nan en
07
08
M te m
E i n i p
C a q u
Jack-LR Jack-RR
LEGEND$
E N M E
r r
01. Jack Cap 07. Regen/C’Bal Valve (Retract) Hose
R fo o
02. RH Jack Cylinder Base (Extend) Hose 08. Regeneration / Counterbalance Valve
E E f
03. RH Jack Cylinder Rod (Retract) Hose 09. RH Hydraulic Cylinder Housing
F E
04. Electrical Junction Box (JB401) 10. Jack Limit Switch
E S S
05. Pressure Switch 11. LH Hydraulic Cylinder Housing
R U U
06. Regen/C’Bal Valve (Extend) Hose 12. Mast / Drill Deck I/O Cabinet
T T
O
N NO
Figure 11-2: Rear Jacks
O
D DO

11.2.1 Rear Jack Hydraulic Cylinder Repair
11.2.1.1 Cylinder Removal
The removal of either rear jack cylinder for repair is the same. It is advisable to service one jack at a time, as fol-
lows:
1. Lower the drill and jacks until the jack shoes rest on the ground, but without weight bearing on the shoes.
! WARNING
n t
Inadvertent operation of the blasthole drill during maintenance could cause severe
e
injury and/or death. Lock out and tag out the drill operating controls to prevent acciden-
Y m
NL uip ion
tal operation.
2. Lock out and tag out the drill operating controls to prevent inadvertent start-up or movement of the drill during
maintenance activities.
O q t
A L f E ra
I o e
3. Refer to Figure 11-3. If installed, remove the plumbing protection covers (01, 02 and 03).
R ce O p
E t
AT nan en
M te m
E n i p
LEGEND
i
01
C a q u
02 01. Top Cover (LH Only)
02. Upper Cover
E N M E
03. Lower Cover
r r
03
R
E E fo f o
E F S E
R U U S
T T
O
N NO
O
D DO
F8345a
Figure 11-3: Rear Jack Plumbing Covers (Optional)
4. Remove the jack pad (refer to Subtopic 11.2.3).
5. Close the handwheel valve on the left hand suction strainer.

01 04 02
02
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e 03
R ce O
03
E t
AT nan en
F8050Aa
M te m
p
LEGEND
E i n i
01. LH Jack Cylinder Regeneration Valve
C a q u
02. Cylinder Rod Pressure Test Port
N M E
03. Cylinder Base Pressure Test Port (on
E r
bottom of valve)
R o r
F8050Ba
04. RH Jack Cylinder Regeneration Valve
E E f f o
E F S E
Figure 11-4: Rear Jack Cylinder Regeneration Valves
R U U S
T T ! WARNING
O
N NO
O
D DO
Hot hydraulic oil under pressure can spray and burn with extreme force and volume,
causing injury or death. Use lockout and tagout procedures to guard against inadvertent
hydraulic system or machine start-up during service or maintenance. Allow the hydrau-
lic system to cool prior to any maintenance or repair. Slowly release pressure or vent cir-
cuits before disconnecting hydraulic lines. Wear appropriate face and body protective
devices while carefully loosening any connection or fitting.
6. Install a pressure gauge onto the test ports (02 and 03, Figure 11-4) on the regeneration valve (01 or 04).
Check the pressure on both the head end and the rod end of the cylinder. If any pressure remains, take action
to remove the pressure before beginning any disassembly.
7. Tag and disconnect the hydraulic hoses from the fittings at the top of the jack cylinder. Allow oil to drain into a
catch basin. Cap and/or plug all hoses and fittings to prevent contamination of the hydraulic system.

8. Remove the mounting hardware that attaches the jack cap (01, Figure 11-2).
! WARNING
parts can cause severe injury or death, and damage to the equipment. Always support
heavy components using a suitable hoist or other means for removal, disassembly,
assembly and installation. Provide appropriate support for any components that are not
supported by the machinery during maintenance. The jack cap, cylinder and spud
assembly weighs approximately 4300 lbs (1955 kgs).
n t
Note: The jack cap weighs approximately 267 lbs (121 kgs), the cylinder weighs approxi-
Y e
mately 1000 lbs (455 kgs) and the spud weighs approximately 855 lbs (389 kgs).
m
NL uip ion
9. Support and lift the jack cap with a suitable hoist to withdraw the cap, cylinder, and spud as a unit.
O q t
10. Remove the cotter pins, flat washers, and upper cylinder pin. Remove the jack cap.
A L f E ra
I o e
11. Refer to Figure 11-5. Through the access holes (05) in the jack spud (04), remove the two pipe plugs (07).
R ce O p
Drive out the pin (06) to separate the lower end the cylinder from the jack spud.
E t
AT nan en
M te m
p
LEGEND
E
C a q i n u i 04
01. Top Cover (LH Only)
02. Upper Cover
N
01
M E
02 03. Lower Cover
E r
04. Jack Spud
R fo o r 03 05. Access Hole (each
E E f
side)
F
06. Pin
E
05
E S
07. Pipe Plug (2)
R U U S
T T
O
07
N NO
O
R57579F1b
D DO
06
F8345a
Figure 11-5: Rear Jack Cylinder Removal
Refer to Figure 11-6 and remove parts from the rod and barrel to access the seals and other parts of the service kit.

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
r r
LEGEND
R fo o
01. Wear Ring 06. Backup Ring
FE E
02. Backup Ring
f 07. Wear Ring
E
03. Seal 08. Dual-Seal U-Cup
E S S
04. O-ring 11. Backup Ring
R U U
05. O-ring 12. Wiper
T T
O
N NO
Figure 11-6: Hydraulic Cylinder Serviceable Components
O
D DO
11.2.1.3 Repair
Clean and inspect the cylinder components in accordance with the general cleaning and inspection procedures
provided in Appendix B of this manual. Repair consists of the replacement of all service kit components. If other
parts are worn or damaged, the entire cylinder must be replaced. See the LinkOne electronic parts manual for com-
ponent identification.
11.2.1.4 Assembly
Refer to Figure 11-6 and install and assemble parts in the reverse order of removal.
Refer to Figure 11-2 or 11-5 and proceed as follows:

! WARNING
supported by the machinery during maintenance. The jack cap, cylinder and spud
assembly weighs approximately 4300 lbs (1955 kgs).
Note: The jack cap weighs approximately 267 lbs (121 kgs), the cylinder weighs approxi-
t
mately 1000 lbs (455 kgs) and the spud weighs approximately 855 lbs (389 kgs).
n
Y e
1. Align the cylinder and spud. Drive in the lower cylinder pin and install he pipe plugs.
m
NL uip ion
2. Align the cylinder and jack cap. Be sure that the cylinder ports are aligned correctly to mate with the hydraulic
O q t
hose assemblies. Install the upper cylinder pin, flat washers, and cotter pins.
L f E ra
3. Support and position the jack cap, cylinder, and spud with a suitable hoist. Lower the unit into the housing.
A
I o p e
R ce O
4. Install the mounting hardware to attach the jack cap.
E t
AT nan en
5. Align the shoe and spud. Push in the retainer pin. Install the capscrew and lockwasher to attach the retainer
pin to the spud.
M te m
6. Install the hydraulic hose assemblies in accordance with their identification tags.
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

11.2.2 Front Jacks
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
F E
FRONT
E
R U U S S BD1244a01
T T
O
N NO Figure 11-7: Front Jack
O
D DO
Refer to Figure 11-7. Each of the two front jacks consists of a hydraulic cylinder, spud, and shoe with housing and
mounting hardware. The rod end of the cylinder is pinned to the jack cap on top of the jack housing. The cylinder
barrel is pinned to the spud; the spud, in turn, is pinned to the shoe. The operator actuates both jacks simultane-
ously through a single switch on the operator’s console. Hydraulic pressure is applied to both cylinder pistons
through internal passages in the rods, causing the spuds and shoes to extend or retract.
11.2.2.1 Cylinder Removal
1. Lower the drill so that the shoes rest on the ground, but without weight bearing on the shoes.

! WARNING
injury and/or death. Lock out and tag out the drill operating controls to prevent acciden-
tal operation.
2. Lock out and tag out the drill operating controls to prevent inadvertent start-up or movement of the drill during
3. Remove the cotter pins that attach the retainer pin to the spud. Drive out the retainer pin.
n t
4. Close the handwheel valve on the left hand suction strainer.
Y e
m
NL uip ion
! WARNING
O q t
Hot hydraulic oil under pressure can spray and burn with extreme force and volume,
L f E ra
I A e
hydraulic system or machine start-up during service or maintenance. Allow the hydrau-
R ce O o p
lic system to cool prior to any maintenance or repair. Slowly release pressure or vent cir-
E
t
AT nan en
M te m
5. Install a pressure gauge into the test port on the regeneration valve. Check pressure on both the head end and
the rod end of the cylinder. If any pressure remains, take action to remove the pressure before beginning any
disassembly.
E i n i p
C a q u
N M E
6. Tag and disconnect the hydraulic hoses to the jack cylinder. Allow oil to drain into a catch basin. Cap and/or
E r
plug all hoses and fittings to prevent contamination of the hydraulic system.
R fo o r
E E f
7. Remove the mast rest assembly.
F
E S S E
8. Remove the mounting hardware that attaches the jack cap to the jack casing.
R U U! WARNING
T T
O
N NO
O
D DO
supported by the machinery during maintenance. For 8 inch front jacks, the jack cap,
cylinder and spud assembly weighs approximately 1780 lbs (810 kg). For 10 inch front
jacks, the jack cap, cylinder and spud assembly weighs approximately 2783 lbs (1038
kg).
9. Support and lift on the jack cap with a suitable hoist to withdraw the cap, cylinder, and spud as a unit.
10. Remove the cotter pins, flat washers, and upper cylinder pin. Remove the jack cap. Note: the jack cap for an 8
inch jack weighs 405 lbs (184 kg); the jack cap for a 10 inch jack weighs 428 lbs (195 kg).

11. Remove the pipe plugs and drive out the lower cylinder pin. Remove the spud. Note: the jack spud for an 8
inch jack weighs approximately 736 lbs (335 kg); the jack spud for a 10 inch jack weighs approximately 855 lbs
(389 kg).
11.2.2.2 Cylinder Repair
Clean and inspect the jack components in accordance with the general cleaning and inspection procedures pro-
vided in Appendix A of this manual. Repair consists of the replacement of all worn or damaged components. Refer
to the LinkOne electronic parts manual for your machine for component identification.
n t
e
The 10 inch front jack cylinder is the same as the 10 inch rear jack cylinder.
Y m
NL uip ion

O q t
A L f E ra
I e
1. Align the cylinder and spud. Drive in the lower cylinder pin and install he pipe plugs.
R ce O o p
2. Align the cylinder and jack cap. Be sure that the cylinder ports are aligned correctly to mate with the hydraulic
E t
AT nan en
hose assemblies. Install the upper cylinder pin, flat washers, and cotter pins.
3. Support and position the jack cap, cylinder, and spud with a suitable hoist. Lower the unit into the jack casing.
M te m
E n i p
4. Install the mounting hardware to attach the jack cap. Torque the jack cap to casing mounting bolts to 1820 ft-
C a q i u
lbs (2468 Nm) dry or 1365 ft-lbs (1851 Nm) lubed.
E N M E
5. Align the shoe and spud. Push in the retainer pin. Install the capscrew and lockwasher to attach the retainer
pin to the spud.
R o r o r
E E f f
F
6. Install the hydraulic hose assemblies in accordance with their identification tags.
E S S E
R U U
7. Bleed the hydraulic circuits.
T T
8. Install the mast rest assembly and back braces.
O
N NO
O
D DO

11.2.3 Leveling Jack Shoes
03 03
03
n t
Y e
m
NL uip ion
O q t
A L f E ra
BD1240a01
I o p e
ER ce O Figure 11-8: Jack shoe
t
AT nan en
Refer to Figure 11-8. On the lower end of each jack is the jack shoe. Jack shoes provide a wide area of support by
distributing the drill’s weight over a larger surface area. Jack shoes are available in several sizes and styles as
listed in Table 11-1.
M te m
E i n i p
C a q u
E N M E
r
Style Diameter Weight
R fo o r
f
30 in. (762 mm) 475 lbs (216 kg)
FE E
E
42 in. (1067 mm) 618 lbs (281 kg)
E
R U U S S 50 in. (1270 mm) 920 lbs (418 kg)
T T
O
N NO
O
D DO
50 in. (1270 mm) - used for rear
jacks
838 lbs (380 kg)
Table 11-1: Jack Shoe Styles and Weights

11.3 Troubleshooting
Problems with the leveling system will almost always be caused by hydraulic system malfunc-
tion or an electrical control circuit malfunction.
n t
Control valve does not shift cor-
e
Replace the Relief/unload/oil diverter valve.
rectly
Y m
NL uip ion
System oil level is low Replenish tank supply.
Tighten components and bleed air from
O q t
External leak in system
system.
dirty filters
A L f E ra Replace the filters.
I o p e
R ce O
clogged inlet line Clean the inlet line.
System fails to build
pressure
E t
clogged tank breather Clean or replace the breather.
AT nan en
fluid is too cold Heat the fluid.
M te m
main drive motor is not operating Repair or replace the main drive motor.
E i n i p
pump drive coupling failed Repair or replace the coupling.
C a q u
N
relief or unloading valve set too
E r M E
low
Adjust the valve to the correct setting.
R fo o r
f
pump is damaged Repair or replace the pump.
FE E
E
pump is cavitating Refer to “System fails to build pressure”.
pump noise E
R U U S
Excessive hydraulic
S air in the fluid
Leak in the inlet line to the pump.
Tighten the fittings.
T T Faulty pump shaft seal. Replace the seal.
O
N NO pump is cavitating Refer to “System fails to build pressure”.
O
D DO
Excessive system heat air in the fluid
Leak in the inlet line to the pump.
Tighten the fittings.
Faulty pump shaft seal. Replace the seal.
contaminated fluid Change filters and replace the fluid.
Adjust the needle valve for correct operat-

Drill pipe racks operate the needle valve is out of adjust-
ing speed. If unable to adjust, replace the
too slow or too fast ment or faulty
needle valve.
Table 11-2: Auxiliary Hydraulic System Troubleshooting

Adjust the needle valve for correct operat-

the needle valve is out of adjust-
ing speed. If unable to adjust, replace the
ment or faulty
Leveling jacks and needle valve.
winch move slowly Adjust the unloading relief valve to operate
The unloading relief valve is faulty at 1100 psig (75.9 bar). If unable to
adjust, repair or replace valve.
Breakout Wrench moves

faulty flow control valves Adjust or replace the flow control valves.
too fast or too slow
t
Table 11-2: Auxiliary Hydraulic System Troubleshooting (Continued)
e n
Y m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

BD320176 Mechanical Systems Manual Lubrication
Section 12
Lubrication
12.1 General
12.1.1 P&H Lubricant Specifications

n t
Y e
m
NL uip ion
O q t
Without reference to specific lubricant manufacturers’ products, this manual makes reference
L f E ra
only to the appropriate P&H Mining Equipment lubricant specifications. Each P&H material
A
specification pertaining to lubricants provides the equipment owner with the minimum require-
I o e
ments for the lubricant. Conformance to these requirements does not constitute the only basis
p
R ce O
of acceptance. Lubricants must be judged further on their satisfactory field performance.
E t
AT nan en
M te m
E n p
Contact your MinePro representative to make sure you have the latest version for lubricant
specifications.
C a q i u i
E N M E
In order for equipment to perform properly, the lubricant supplier and the equipment owner must work together to
R o r r
determine if the type of lubricant being considered will meet P&H Mining Equipment lubricant requirements (that is,
o
E E f f
specifications and performance). The lubricant supplier must confirm that the lubricant meets specifications; the
F
equipment owner must confirm that the lubricant is suitable for and performs in the operating environment.
E S S E
R U U
12.1.2 Operating in Cold Conditions
T T
O
12.1.2.1 Possible Effects Of Excessively Cold Lubricant
N NO
• Improper venting after the cycle may prevent the injectors from reloading. If pressure is not vented back to
O
D DO
the tank, the injector springs stay compressed and can not reload. The next cycle the injectors will not out-
put any lube if they have not recharged. As a result, the lube points may not receive proper lubrication.
• Cold grease can make it difficult to pump the lubricant. A restriction to flow in one area can cause a local
pressure drop to some components. The pressure switch on the lubrication control panel may reach the set
point pressure before it is high enough to cycle all the injectors. The lube pump turns off prematurely before
the lube points get the needed lubricant.
If cold weather problems occur, contact your P&H MinePro Services representative to assist in choosing which of
the following solutions should be selected.

Sec12Lube.fm -12.1- Section 12, Version 01 - 07/12
Lubrication BD320176 Mechanical Systems Manual
12.1.2.2 Possible Solutions
• Use a grease more appropriate for colder temperatures. Refer to the lubrication specifications in this section
of this manual for details.
• Slow the lubrication pump to allow more time for the cold grease to move through the lube piping. Refer to
Topic 12.7 in this section for more details.
12.1.3 Viscosity
The viscosity is a critical parameter in determining film thickness under operating conditions. Too low viscosity will
t
allow tooth surfaces to contact each other. Viscosity varies exponentially with operating temperature.
e n
Y
The viscosity grade selection is dependent on the maximum and minimum operating temperatures. If the extreme
m
NL uip ion
or peak operating sump temperatures are not known, measure the sump oil temperature during a period of
extreme or peak ambient temperature, after working the machine continuously for at least ½ shift.
O q t
Maximum oil viscosity (and, therefore, its suitability for application in cold weather) is also temperature-dependent
L f E ra
and is primarily determined by the pour point of the oil.
A
I o p e
R ce O
The channel point of an oil is about 8-14°F below the pour point. If the ambient temperature drops below the pour
E
point, the oil will not flow through a pump. This condition is unacceptable, even though some lubrication of gearing
t
AT nan en
might be possible if the gearing dips into oil in a sump. If the ambient temperature falls below the channel point, no
lubrication is possible as the oil will become semi-solid and will be displaced (channeled) as the gearing dips into
M te m
the sump. This condition will result in destruction of the gearing.
E i n i p
If it is desired to use a single grade of oil year round, users must be certain that at no time will either the maximum
C a q u
or minimum operating sump temperature be exceeded for the grade of oil being used.
E N M E
r
The minimum operating sump temperature represents the pour point of the oil, but it is still possible to operate the
R o o r
machine if the ambient temperature drops below the pour point. Temperature below the pour point is mainly a con-
f
E E f
cern if the machine is not operating. If a machine has been shut down for an extended period of time, and the ambi-
F E
ent temperature drops below the pour point during this time, observe carefully while the motions are run slowly
E S S
under no load. Warm up the oil to the point where it will flow before putting the gearing under load. This task is crit-
R U U
ical to avoid serious damage to gearing. If the sump temperature is still below the pour point, a lighter grade of oil
T T
should be used.
O
N NO
Oil selection will affect filter performance. When selecting filter elements, the viscosity, grade, and operating tem-
perature must be considered. The viscosity of the oil will change with temperature. Normally, a 10 psi pressure
O
drop is permitted across filters. To ensure that the filter element type and mesh is appropriate for the oil viscosity at
D DO
the highest and lowest temperature, the oil temperature, oil viscosity at that temperature, and the flow through the
filter must be known. Generally, the curves for filter elements are available from filter suppliers.

Section 12, Version 01 - 07/12 -12.2- Sec12Lube.fm
12.2 Oil Bath Lubrication

All gear drives, including the pump drive transmission, and some of the other rotating equipment on the blasthole
drill, are lubricated through self-contained oil bath reservoirs. Most of the equipment units that have self-contained
lubricant reservoirs lubricate their internal components by immersion in the oil bath, or by splashing lubricant from
the surface of the oil bath. The equipment within this category includes the following:
12.2.1 Pulldown Gearcase
LEGEND
n t
01. Inspection Cover with Breather:
Y e 01
m
NL uip ion
Fill gearcase through this port.
Oil should appear to fill the lower
O q t
glass; the upper glass should 02
L f E ra
appear half full.
I A o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
BD0870b01
E N M E
R o r o r
E E f f
F E
BD0870b01
E
R U U S S
T T
O
N NO
Figure 12-1: Pulldown Gearcase Lubrication
The pulldown gearcase uses oil, Material Specification P&H 496. Viscosity is indicated by the letter A, B or C, and
O
D DO
should be selected according to expected extreme ambient temperatures. Refer to Table 12-1
>-40°F >-15°F >10°F Capacity

(>-40°C) (>-26°C) (>-12°C)
496A 496B 496C 70 Gallons

(SAE 75W) (SAE 80W-90) (SAE 85W-140) (265 liters)
Table 12-1: Pulldown Gearcase Recommended Lubricants
Refer to Figure 12-1. Check oil level at the sight glass daily and add oil as required. Change oil as specified in
Table 12-8 or as indicated by oil analysis.

12.2.2 Hydraulic Pump Drive Transmission
LEGEND
01. Vent and Fill Cap
02. Dipstick
03. Drain Valve and Pipe (drains
out below deck)
01
n t 02
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
03
AT nan en
M te m
E i n i p
u
R59401F1_02a
NC a q
E r M E
Figure 12-2: Hydraulic Pump Drive Transmission Lubrication
R fo o r
E E f
The hydraulic pump drive transmission uses gear oil, Material Specification P&H 496C. Refer to Table 12-2
E F S E
S
All Seasons Capacity
R U U 496C 2 Gallons
T T (7.6 liters)
O
N NO
Table 12-2: Hydraulic Pump Drive Transmission Recommended Lubricants
O
D DO
Check the oil level on the dipstick every month and add oil as required. Change oil as specified in Table 12-8 or as
indicated by oil analysis.

12.2.3 Auxiliary Winch Gear Reducer
LEGEND
01. Relief Breather
02. Fill Plug
03. Drain Plug
01
02
n t
Y e
m
NL uip ion
03
O q t
A L f E ra
I e
BD0554a01
R ce O o p
E
Figure 12-3: Auxiliary Winch Gear Reducer Lubrication
t
AT nan en
The auxiliary winch gear reducer uses gear oil, Material Specification P&H 496. Viscosity is indicated by a letter,
M te m
and should be selected according to expected extreme ambient temperatures. Refer to Table 12-3.
E i n i p
C a q u
N
All Seasons Capacity
E r M E
r
496C 1 Quart
R
E E fo f o
(0.95 liter)
F E
Table 12-3: Auxiliary Winch Recommended Lubricants
E
R U U S S
T T
O
Check oil level in the auxiliary winch gear reducer every month and add oil as required. Change oil as specified in
N NO
Table 12-8 or as indicated by oil analysis.
O
D DO
Lubricate the auxiliary winch wire rope as required using Wire Rope Lubricant, Material Specification P&H 459.

12.2.4 Cable Reel Gear Reducers
LEGEND
01. Right Angle Gearcase
01 02. Drum Bearing Grease Fitting (both sides)
n t
Y e
m
02
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
BD0555a01
E N M E
r r
Figure 12-4: Cable Reel Gear Reducer Lubrication
R
E E fo f o
F E
should be selected according the expected extreme ambient temperatures. Refer to Table 12-4.
E S
R U U S Gear Reducer
T T
O
>-40°F >-15°F >10°F Capacity
N NO
(>-40°C) (>-26°C) (>-12°C)
496A 496B 496C 1.5 Pints
O
D DO
(SAE 75W) (SAE 80W-90) (SAE 85W-140)
Bearings
(0.7 liter)
472A (all seasons) Two places
Table 12-4: Cable Reel Recommended Lubricants
Check oil level at the level plug every week and add oil as required. Change oil as specified in Table 12-8 or as
On either side of the frame, lubricate drum bearing grease fittings using multi-purpose grease, Material Specifica-
tion P&H 472, as specified in Table 12-8.

12.2.5 Propel Transmissions
LEGEND
03
01. Drain Plug
02. Fill/Level Plug
02
03. Housing
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
01 BD195a01
E i n i p
C a q u
Figure 12-5: Propel Transmission Lubrication
N M E
The propel transmissions use gear oil, Material Specification P&H 496. Viscosity is indicated by a letter, and should
E
R r r
be selected according to the expected extreme ambient temperatures. Refer to Table 12-5
o o
E E f f
F E
>-40°F >-15°F >10°F Capacity
E S
(>-40°C) (>-26°C) (>-12°C)
R U U
496A S 496B 496C 5.25 Gallons
T T
(SAE 75W) (SAE 80W-90) (SAE 85W-140) (20 liters) each
O
N NO
Table 12-5: Propel Transmission Recommended Lubricants
O
Check oil level at the level plugs every week and add oil as required.Change oil as specified in Table 12-8 or as
D DO

12.3 Oil Pressure Lubrication

The rotary gearcase and the air compressor have enclosed, dedicated oil lubrication systems.
12.3.1 Rotary Gearcase
01
n t
Y e
m
NL uip ion
02
O q t
A L f E ra
I o p e F
ER ce O
t
AT nan en
M te m
L
E
BD0556c01
i n i p 03
C a q u
LEGEND
E N M E
01. Breather
R o r o r
03. Drain Valve
f f
02. Dipstick
FE E
E S S E
R U U Figure 12-6: Rotary Gearcase Lubrication
T T
O
The rotary gearcase is a sealed unit with a self-contained oil bath sump and gear-driven pump that circulates lubri-
N NO
cating oil, under pressure, to the bearings and gears.
O
D DO
The rotary gearcase uses gear oil, Material Specification P&H 496. Viscosity is indicated by a letter, and should be
selected according the expected extreme ambient temperatures. Refer to Table 12-6.
>-40°F >-15°F >10°F Capacity

(>-40°C) (>-26°C) (>-12°C)
496A 496B 496C 40 Gallons

(SAE 75W) (SAE 80W-90) (SAE 85W-140) (151.5 liters)
Table 12-6: Rotary Gearcase Recommended Lubricants
Check the oil level every week by removing the dipstick (02). Add oil as required. Change oil as specified in Table
12-8 or as indicated by oil analysis.

12.3.2 Air Compressor
12.3.2.1 T-Tank
n t
Y e
m
NL uip ion
01
O q t
A L f E ra
I o p e
02
ER ce O
t
AT nan en
M te m
BD0557b01
03
E i n i p
C a q u
LEGEND
N
01. Fill Plug 03. Manual Drain Valve
02. Sight Gauge
E r M E
R fo o r
FE E f
E
Figure 12-7: Air Compressor T-Tank Lubrication
E
R U U S S
The air compressor uses Dexron III® / Mercon ATF in all ambient temperatures. The oil capacity is 150 US Gallons
T T
(570 liters) which includes 128 USG (484.5 L) in the T-tank and 22 USG (83 L) for the remainder of the air system.
O
Check the oil level at the T-Tank sight gauge (02, Figure 12-7) each shift or after each 8 hours of operation. Change
N NO
the oil as specified in Table 12-8 or as indicated by oil analysis.
O
D DO
Dexron III® ATF is per GM specification 6297M and Mercon ATF is per Ford specification
M2C185A.

12.3.2.2 Main Air System Oil Filters - Sullair
LEGEND
01. Main Compressor Oil Filter (on compressor)
02. Oil Separator Filters (T-Tank)
03. Scavenger Oil Filter (on air control bracket)
04. Filter Condition Indicator
n t
Y e BD0729c01
m
NL uip ion
02
04
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
BD1085c01
C a q u
E N M E
R o r o r
E E f f
01
E F S E
R U U S
T T
03
O
N NO Figure 12-8: Main Air System Oil Filter Locations (Sullair)
O
D DO
Refer to Figure 12-8. Oil filters associated with the main air compressor are:
• The two main compressor oil filters (01), mounted on the compressor, are replaceable-element filters that fil-
ter the majority of the oil returning to the compressor from the T-Tank. Refer to Subtopic 3.8.11 in Section 3
to check or replace the filter elements.
• The two oil separator filters (02) are an integral part of the T-Tank. They remove the oil vapor from the outgo-
ing pressurized air for return to the compressor.
• The scavenger oil filter (03), mounted on the air control bracket, is a spin-on filter that filters the oil returning
through the scavenger lines. Refer to Subtopic 3.11.5 in Section 3 to replace the oil scavenger filter.

12.4 Hydraulic Tank

Hydraulic oil is used by the hydraulic systems to provide power and lubrication. The oil is stored in the hydraulic
tank which is located on the left wall in the machinery house.
The hydraulic system uses Dexron III® / Mercon ATF in all ambient temperatures or an equivalent hydraulic oil as
specified by the mine. Check the sight gauge at the beginning of each shift or after 8 hours of operation and add oil
as necessary.
n t
e
01 01 03 04
Y m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
08
M te m 05
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
07
T T
O
N NO
O
D DO06
R57523D1
LEGEND
01. Hydraulic Tank 05. OIl Level Nameplate
02. Breather 06. Oil Temperature Gauge
03. Low Pressure Return Filter (2) 07. Suction Strainers (2)
04. Main Return Filter (2) 08. Oil Level Sight Glass
Figure 12-9: Hydraulic Tank Components

Refer to Topic 3.6 in Section 3 for inspection intervals and service procedures for the return filters (03 and 04, Fig-
ure 12-9) and breather (02). Change the filters and the breathers when indicated.
Drain, flush and refill the hydraulic system as specified in Table 12-8 or as indicated by oil analysis.
The stated capacity of the hydraulic tank is 125 US Gallons (482 liters); however, the placard
next to the sight gauge is the final determiner of maximum and minimum oil levels, depending
on the physical condition of the drill (mast up or down, jacks extended or retracted). Refer to
t
Figure 12-10.
e n
Y m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
MAXIMUM MAST UP AND JACKS FULLY RETRACTED
M te m
MAXIMUM MAST DOWN AND JACKS FULLY EXTENDED
E i n i p
C a q u
E N M E
R o r o r
MAXIMUM MAST UP AND JACKS FULLY EXTENDED
E E f f
E F S E
R U U S
T T
O
N NO
MINIMUM
| | | | | |
| | | |
| |
|
| |
| |
BD0560a01
| | | | | | |
| | | | |
|
O
D DO Figure 12-10: Hydraulic Tank Level Sight Gauge and Temperature Gauge
P&H Mining Equipment recommends that a sample of oil be drawn from the hydraulic tank
annually. This sample should be about two quarts (two liters) and should be taken when the oil
is warmed through normal operation. The sample should be analyzed by a qualified lubrication
specialist to determine whether it is suitable for continued use. The interval between oil
changes may be extended based upon the operating conditions and on the care used in han-
dling oils and in keeping them clean during the handling process.

12.5 Manual Lubrication Points
! WARNING
operator controls to prevent inadvertent machine operation while performing manual
lubrication tasks.
12.5.1 Lube Points Without Fittings
n t
e
Miscellaneous pins, levers and linkages that move but are not considered wear surfaces should be lubricated
Y m
weekly or as required by administering a few drops of motor oil as indicated in Table 12-7.
< 20°F
NL uip ion
+20 to 110°F >110°F
O q t
(< -7°C) (-7 to 43°C) (>43°C)
SAE 10W
L f E ra
SAE 15W40
A
SAE 30
I o p e
Table 12-7: Miscellaneous Pins, Levers and Linkages Lubricants
ER ce O
t
AT nan en
12.5.2 Lube Points with Grease Fittings
M te m
Lubrication points that are provided with grease fittings use extreme pressure lithium grease. The preferred grade
is a synthetic grade NLGI #1. A non-synthetic grade NLGI #2 is a suitable alternative. A non-synthetic NLGI #1 or
E i n i p
#0 may be required for proper dispensing at low temperatures or by centralized lubrication systems.
C a q u
12.5.3 Mast Back Braces
E N M E
R o r o r
E E f f
E F S E
S
LEGEND
R U U
01. Pin (10 pins)
T T
02. Slide Area (6 slide areas)
O
N NO
01
O
D DO
02
BD1217a01
Figure 12-11: Mast Back Brace Manual Lubrication Points
Refer to Figure 12-11. Every month of operation on each back brace, lubricate the pins (01) and slide areas (02)
with motor oil (refer to Subtopic 12.5.1).

12.6 Lubrication Schedule
12.6.1 Reference Numbers
Figure 12-12 provides reference numbers for the Lubrication Schedule shown in Table 12-8.
04
01 03
n t 04
Y e
m
NL uip ion
12
O q t
L f E ra
08
07
I A o p e
R ce O
14
E
09
t
AT nan en
10
M te m 15
E n i p
02
i
11
C a q u
E N M E 04
r
13
R fo o r
FE E f
E S S E
R U U
T T
O
N NO
05 320_100502_02 BD1130d01
O
D DO Figure 12-12: Manual Lubricant Point Reference Diagram

12.6.2 Lubrication Schedule
Time Interval Ref Number Component Description Required References

from Service
Diagram (see
Figure 12-12)
Weekly or As 02 Miscellaneous Pins, Levers and Link- Lubricate Table 12-7

Required ages without grease fittings Figure 12-11
01 Auxiliary Winch Wire Rope Lubricate Table 12-3
Daily or 16 Hydraulic Oil Reservoir Check Level Figure 12-9
t
Every 8-12
n
Hours 14 Air Compressor Oil Reservoir Check Level Figure 12-7
e
(T-Tank)
Y m
NL uip ion
07 Rotary Gearcase Check Level Figure 12-6
05 Propel Transmission Check Level Figure 12-5
08
O q t
Pulldown Gearcase Check Level Table 12-1
A L f E ra Figure 12-1
Weekly or 08
I o p e
Pulldown Gearcase Check Level Table 12-1
Every 75-100
Hours
ER ce O Figure 12-1
t
AT nan en
10 Hydraulic Suction Filters Check Figure 12-9
Indicators
17
M te m Hydraulic Return Line Filters Check Figure 12-9
E n p
Indicators
C a q12 i u i
Air Compressor Oil Filters Check Figure 12-8
E N M E
Indicator
R o r14
o r Air Compressor Oil Separator Check Gauge Figure 12-7
E E f 09
f Auto-Lube Grease Reservoir Check Figure 12-14
E F S E
Dipstick
Monthly or
R U U
Every 250-300 S 03 Cable Reel Right Angle Gear Reducer Check Level Figure 12-4
T T
Hours 04 Cable Reel Drum Bearings Lubricate Figure 12-4
O
N NO
13
15
Auxiliary Winch Gear Case
Pump Drive Transmission

Check Level
Check
Figure 12-3
Figure 12-2
O
D DO Table 12-8: Lubrication Schedule
Dipstick

Time Interval Ref Number Component Description Required References

from Service
Diagram (see
Figure 12-12)
Semi-Annu- 07 Rotary Gearcase Change Oil Figure 12-6

ally or
Every 1800- 05 Propel Transmission Change Oil Figure 12-5
2000 Hours
14 Main Compressor Oil Change Oil Figure 12-7
15 Pump Drive Transmission Change Oil Figure 12-2
Annually or 03 Cable Reel Right Angle Drive Reducer Change Oil Figure 12-4
Every 3600-
4000 Hours 13
n t
Auxiliary Winch Gear Case Change Oil Figure 12-3
08
Y
Pulldown Gearcase
e Change Oil Figure 12-1
m
NL uip ion
10 Hydraulic Tank Change Oil Figure 12-9
O q t
Table 12-8: Lubrication Schedule (Continued)
A L f E ra
I o p e
12.7 Automatic Lubrication System
ER ce O
t
AT nan en
The automatic lubrication system supplies measured amounts of lubricant to specified lube points on the mast,
crawlers, and leveling jacks. The NLGI grade of the grease must be appropriate for the prevailing ambient temper-
M te m
ature range. P&H 472C is the preferred grade for all temperature ranges; however, at lower ambient temperature
E n i p
ranges, P&H 472A or 472B may be recommended by the lubrication supplier. Check the lubricant level in the
C a q i u
grease tank weekly. Refill the reservoir as necessary. Refer to Figure 12-14.
E N M E
The lubrication tank, pumps and controls are located in the machinery house. The grease pump is driven by an
electric motor.
R o r o r
E E f f
F
Figure 12-13 displays the schematic diagram for the complete automatic lubrication system.
E S S E
R U U
T T
O
N NO
O
D DO

01 02 03 04 05 06
25 26
07
24
n t
17 08
Y e
m
NL uip ion
09
16 10
23
O q t
L f E ra
18
I A o p e
R ce O
15
22
E t
AT nan en
M te m
p
21 20 19
E i n i
11
C a q u 14 13
N
12
M E
R60075_02a
LEGEND
RE o r r
f f o
01. Grease Pump Assy (Includes Items 25 and 26) 16. Upper Grease Solenoid (UGS)
FE E
02. 4000 PSI Pressure Relief Valve 17. Grease Strainer
E
03. Grease Strainer Condition Indicator 18. Grease Vent Solenoid (GVS)
E
R U U S S
04. Grease System Pressure Switch (GSPS)
05. 4000 PSI Pressure Relief Valve
19.
20.
Wiggins Quick Fill Connector (Optional)
Wiggins Quick Fill Strainer (Optional)
T T
06. Pressure Gauge 21. Grease Tank Drain Plug
07. Pressure Tap T22 22. Grease Tank
O
N NO
08. To Injectors (E through H)*
09. Upper Grease Pressure Switch (UGPS)
23.
24.
Pump Inlet Strainer
TanK Breather
O
10. To Injectors (D)* 25. Inlet Check Valve
D DO
11. Injector C1* 26. Outlet Check Valve
12. To Injectors (A and B)*
13. Pressure Tap T20 * Refer to Figure 12-16 for the injector schematic
14. Lower Grease Solenoid (LGS) and Table 12-9 for injector descriptions.
15. Lower Grease Pressure Switch (LGPS)
Figure 12-13: Automatic Lubrication System Schematic (Typical)
12.7.1 Pump Operation
The automatic lubrication system is activated by signals from timers in the AC800 Controller. Typically, the AC800
Controller will start an automatic lubrication cycle every 60 minutes when the drill is in one of the drilling modes,

and every five minutes when it is in the propel mode. The system can also be operated manually through the oper-
ator’s touch screen.
Refer to Figure 12-14. When the cycle starts, the electric motor (01) drives the grease pump (02). On the suction
stroke, the pump draws grease from the tank (07), through the pump inlet filter, located on the bottom of the pump
pickup tube, and pump internal inlet check valve to fill the pump cavity. On the discharge stroke, grease in the
pump cavity is sent through the internal pump outlet check valve, outlet hose (13) and on to the grease filter (12).
The pump has a dual output. The opposite side discharges to the pressure relief valve (04). If there is a problem in
the lube system and the pump pressure reaches 4000 psi (276 bar), the relief valve will open and grease will vent
to atmosphere.
n t
Y e
m
NL uip ion
01 02 03 04 05 LEGEND
01. Electric Motor
O q t
02. Grease Pump
L f E ra
03. Hose From Grease Filter Outlet
04. 4000 PSI Pressure Relief Valve
13
I A o p e
05. Grease Vent Solenoid Valve
R ce O
06 (GVS)
E
06. Return To Tank Hose
t
AT nan en
07. Grease Tank
07 08. Grease Tank Dipstick
09. Breather
M te m 10. Control Panel (See Figure 12-15
E n i p
for components)
12
C a q i u
08 11. 0-5000 PSI (0-350 Bar) Pressure
Gauge
E N M E
12. Grease Filter
r r
09 13. Hose From Pump Outlet
R
E E fo f o
E F S E
10
R U U S
T T
O
N NO
O
D DO
BD1216a01
11
Figure 12-14: Grease Tank Assembly

During any lube cycle, the solenoid-operated grease vent valve (05) is closed which prevents grease from flowing
from the grease filter through the vent valve and back to the tank. This forces the grease into the manifold and
grease lines to build up pressure as indicated on the pressure gauge (11).
12.7.2 Grease System Control
When the drill is in any drill mode and a lubrication cycle is started by the AC800 Controller (or manually), the upper
grease solenoid (10, Figure 12-15) energizes. This opens the line to the upper machinery lubrication points D
through H (01 through 05, Figure 12-16). As lubricant flows to the upper machinery lubrication points, pressure
builds in the system. When the pressure reaches 1500 psi (103 bar), the upper grease pressure switch (UGPS)
(18, Figure 12-15) closes. This indicates to the AC800 Controller that the UGS energized as required.
n t
Pressure continues to build. When the grease system pressure switch (06, Figure 12-15) senses 2400 psi (165
e
bar), it closes which causes the grease pump to stop pumping. At the same time, the vent valve (05, Figure 12-14)
Y m
solenoid de-energizes, allowing the vent valve to open the return line (06, Figure 12-14) back to the tank. The UGS
NL uip ion
remains energized until the pressure at the UGPS drops below 600 psi (41.4 bar). This delay ensures that all of the
injectors have time to reload for the next cycle. After that, the pressure that has built up in the upper and lower
O q t
machinery lubrication lines relieves back to the grease tank.
A L f E ra
I e
After the two minutes for depressurization, the UGS de-energizes and the cycle is complete.
R ce O o p
Operation of the lower grease system is the same as the upper except that when the drill is in propel mode, only
E t
AT nan en
the propel machinery requires lubrication and therefore, the upper grease solenoid (UGS) does not energize.
Instead, the lower grease solenoid (LGS) is energized to allow the grease to flow to the propel machinery lubrica-
tion points.
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

01 02 03 04 05
06
07
t
20
e n 08
Y m
NL uip ion
O q t
L f E ra
19
09
I A o p e
ER ce O
t
AT nan en
18
10
M te m
p
17
E n i
11
16
C a q i u
E N M E
r r
15
R
E E fo f o
F E
14
E S
12
R U U S
T T 13
O
N NO BD1216a01
LEGEND O
D DO
01. Hose From Pump Outlet 11. Lower Grease Solenoid (LGS)
02. 140 Micron Grease Filter 12. Hose To Upper Grease Injectors (D-H)
03. Hose To Grease Vent Valve Inlet 13. Hose To Lower Grease Injectors (A-C)
04. 0-5000 PSI (0-350 Bar) Pressure Gauge 14. Electrical Junction Box
05. Pressure Tap T22 15. Pressure Tap T20
06. Grease System Pressure Switch (GSPS) 16. Pressure Tap T21
07. Grease Manifold 17. Lower Grease Pressure Switch (LGPS)
08. Hose To Grease Solenoid Valves 18. Upper Grease Pressure Switch (UGPS)
09. Control Panel 19. Grease Filter Condition Indicator
10. Upper Grease Solenoid (UGS) 20. Grease Tank
Figure 12-15: Grease Control Panel Components

01
02
03
n t
Y e
m
04
NL uip ion
O q t
A L f E ra
I o p e
R ce O
05
E t
AT nan en
M te m
06
E p
07
i n i
08
C a q u
E N M E
09
R o r o r
E E f f
E F S E
10
R U U S
T T
O
N NO
O
R60983_02
LEGEND
D DO
01. Rotary Carriage Lube Points H1 - H12*
02. Mast Lube Points: G1 - G16* - w/Two Pipe Racks
08. From Lower Grease Solenoid Valve (LGS)**
09. Right Hand Crawler Lube Points B1 - B15*
G1 - G9* - w/One Pipe Rack 10. Left Hand Crawler Lube Points A1 - A15*
03. A-Frame Lube Points F1 - F8*
04. Rear Deck Lube Points E1 - E8* * Refer to Table 12-9 for descriptions of the Auto-
05. Main Frame Lube Points D1 - D4* matic Lubrication System Lube Points.
06. From Upper Grease Solenoid Valve (UGS)** ** Refer to Figure 12-13 for the complete grease
07. A-Frame Lube Points C1* schematic.
Figure 12-16: Automatic Lubrication System Injector Schematic (Typical)

12.7.2.1 Lubrication Points
Table 12-9 provides information for lube points lubricated by the automatic lubrication system.
Injector Lube Point Location of Injector
A1 Front Idler Left Crawler
A2 Front Lower Roller
A3-A10 Lower Rollers
A11 Rear Lower Roller
A12 Front Upper Roller

n t
A13 Middle Upper Roller
Y e
m
NL uip ion
A14 Rear Upper Roller
O q t
A15 Crawler Axle Pivot Bore
B1 Front Idler
A L f E ra Right Crawler
B2 Front Lower Roller

I o p e
B3-B10 Lower Rollers
ER ce O
t
AT nan en
B11 Rear Lower Roller
M te m
B12 Front Upper Roller
B13
E n
Middle Upper Roller
i i p
B14
C a q
Rear Upper Roller
u
E N M E
r
B15 Crawler Axle Pivot Bore
R fo o r
f
C1 Equalizer Axle Frame Pivot Pin Main Frame, below deck
FE E
E
D1-D2 Right Front Jack Casing Main Frame
D3-D4
E
R U U S S
Left Front Jack Casing
T T
E1-E2 Right Rear Jack Casing Rear Deck
E3-E4
F1
O
N NO
Left Rear Jack Casing
Left Hand Inner Mast Lock Bore A-Frame
F2 O
D DO
Left Hand Outer Mast Lock Bore
F3 Left Hand Mast Pivot Pin
F4 Left Hand Mast Raise Cylinder Base Pin
F5 Right Hand Inner Mast Lock Bore
F6 Right Hand Outer Mast Lock Bore
F7 Right Hand Mast Pivot Pin
F8 Right Hand Mast Raise Cylinder Base Pin
Table 12-9: Automatic Lubrication System Lube Points

Mast Lube Points with Dual Pipe Rack Arrangement
G1 Left Hand Deck Wrench Slide Mast
G2 Left Hand Pipe Rack Cylinder Pin - Rod End
G3 Left Hand Lower Swing Arm To Deck Pin
G4 Left Hand Lower Swing Arm To Pipe Rack Pin
G5 Left Hand Pipe Rack Cylinder Pin - Base End
t
G6 Right Hand Pipe Rack Cylinder Pin - Base End
G7
e n
Right Hand Lower Swing Arm To Pipe Rack Pin
Y m
NL uip ion
G8 Right Hand Lower Swing Arm To Deck Pin
G9 Right Hand Pipe Rack Cylinder Pin - Rod End
G10 Right Hand Deck Wrench Slide

O q t
A L f E ra
I e
G11 Left Hand Pipe Rack Upper Gate Lock Pivot Pin
G12
R ce O o p
Left Hand Pipe Rack Upper Swing Arm To Pipe Rack Pin
E t
AT nan en
G13 Left Hand Pipe Rack Upper Swing Arm To Mast Pin
G14 Right Hand Pipe Rack Upper Swing Arm To Mast Pin
G15
M te m
Right Hand Pipe Rack Upper Swing Arm To Pipe Rack Pin
E i n i p
C a q u
G16 Right Hand Pipe Rack Upper Gate Lock Pivot Pin
E N M E
Mast Lube Points with Single Pipe Rack Arrangement
G1
R o r r
Spare Port - Plugged
o
Mast
G2
E E f f
Spare Port - Plugged
E F S E
S
G3 Left Hand Deck Wrench Slide
G4
R U U
Right Hand Deck Wrench Slide
T T
O
G5 Right Hand Pipe Rack Cylinder Pin - Base End
G6
N NORight Hand Pipe Rack Cylinder Pin - Rod End
G7
G8
O
D DO
Right Hand Pipe Rack Lower Swing Arm To Deck Pin
Right Hand Pipe Rack Lower Swing Arm To Pipe Rack Pin
G9 Right Hand Pipe Rack Upper Swing Arm To Mast Pin
G10 Right Hand Pipe Rack Upper Swing Arm To Pipe Rack Pin
G11 Right Hand Pipe Rack Upper Gate Lock Pivot Pin
Table 12-9: Automatic Lubrication System Lube Points (Continued)

H1 Right Hand Drive Pinion Drip Rotary Carriage
H2 Right Hand Drive Pinion Bearing
H3 Upper Right Hand Back-up Roller Eccentric Bushing
H4 Lower Right Hand Back-up Roller Eccentric Bushing
H5 Right Hand Idler Pinion Bearing
H6 Lower Shaft Seal
t
H7 Left Hand Idler Pinion Bearing
H8 Air Swivel Seal

e n
Y m
NL uip ion
H9 Lower Left Hand Back-up Roller Eccentric Bushing
H10 Upper Left Hand Back-up Roller Eccentric Bushing
H11
O q t
Left Hand Drive Pinion Bearing
A L f E ra
I e
H12 Left Hand Drive Pinion Drip
R ce O o p
Table 12-9: Automatic Lubrication System Lube Points (Continued)
E t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

12.7.3 Automatic Lubrication System Components
12.7.3.1 Grease Pump with Electric Motor
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
F
BD1212a01
E S S E
R U U Figure 12-17: Grease Pump
T T
O
N NO
Refer to Figure 12-17. The grease pump is a Lincoln reciprocating-type unit driven by an AC electric motor.
O
REMOVAL
D DO ! WARNING
High-pressure oil or grease can spray and penetrate skin or eyes causing severe injury
or death. Use extreme caution when working around operating lubrication system and
wear appropriate face and body protective devices. Shut down, lock out, and tag the
machine before performing inspection, service, and maintenance of the lubrication sys-
tem. Obtain medical aid immediately for lube spray into eyes or penetration into the skin.
Be sure that the hydraulic and air systems are not pressurized before loosening or
removing any connections or parts for maintenance.

1. Shut down the machine, and lock out and tag the controls.
2. Turn off the main AC800 Controller.
3. Tag and disconnect the electrical wiring to the electric motor.
4. Tag and disconnect the discharge hose from the grease pump.
5. Remove four electric motor and four pump mounting bolts from the cover plate and remove the pump and
motor as an assembly.
t
e n
Refer to Appendix A for general mechanical maintenance procedures, and to Appendix B for general hydraulic
component maintenance procedures.
Y m
NL uip ion
Disassembly and repair of this pump requires special tools and methods. If the pump malfunctions, replace it and
O q t
send the old unit to a qualified repair facility.
A L f E ra
I o p e
ER ce O
t
Refer to your LinkOne parts manual for an illustration showing the pump breakdown and for
AT nan en
replacement parts information.
INSTALLATION
M te m
!E WARNING
i n i p
C a q u
E N M E
R o r r
High-pressure oil or grease can spray and penetrate skin or eyes causing severe injury
o
E E f f
or death. Use extreme caution when working around operating lubrication system and
F E
wear appropriate face and body protective devices. Shut down, lock out, and tag the
E S S
machine before performing inspection, service, and maintenance of the lubrication sys-
R U U
tem. Obtain medical aid immediately for lube spray into eyes or penetration into the skin.
T T
Be sure that the hydraulic and air systems are not pressurized before loosening or
O
removing any connections or parts for maintenance.
N NO
1. Position the pump and motor assembly on the tank.
O
D DO
2. Secure the pump and motor with the hardware removed during removal.
3. Connect the grease discharge hose to the pump.
4. Connect the electrical leads to the motor.
5. Turn on the main AC800 Controller.
6. Bleed the system. Refer to the topic. Bleeding Grease System.

12.7.3.2 RELIEF VALVE
The relief valve (04, Figure 12-14) is not adjustable, and cannot be repaired by the user. To replace the valve, pro-
ceed as follows.
! WARNING
Inadvertent machine movement during service can cause serious injury, or death. Do not
perform maintenance work on a machine without first disabling the operator controls.
Lock out and tag the operator controls to prevent inadvertent machine startup during
t
maintenance work.
e n
Y m
! WARNING
NL uip ion
O q t
L f E ra
I A e
R ce O o p
E
t
AT nan en
M te m
2. Be sure that no pressure exists in any of the grease system circuits.
E i n i p
C a q u
3. Unscrew the valve from the pump outlet.
E N M E
r r
4. Install a new valve. Be sure that the connection is tight.
R
E E fo
12.7.3.3 Pressure Switches
f o
E F S E
S
Refer to Figure 12-15. The grease system uses three pressure switches: GSPS (06), LGPS (17) and UGPS (18)
R U U
which are SPDT snap-action type switches with automatic reset. The range is adjustable between 235 and 3200
T T
psi (16 to 218 bar) on decreasing pressure, and between 295 and 3400 psi (20 to 231 bar) on increasing pressure.
O
The switches are connected normally open.
REMOVAL N NO
O
D DO ! WARNING
Hazardous voltage can cause burns, injury, or even death. Disconnect, lock out, and tag
inspection and repairs are being performed. Before beginning repairs, try the operational
controls to verify that the intended power source is disconnected.

! WARNING
1. Disconnect, lock out, and tag the power source that feeds the system to prevent power from being applied
t
e n
2. Disconnect and tag the wiring to the switch to be removed.
Y m
NL uip ion
3. Remove the pressure switch from the hydraulic fitting.
REPAIR
O q t
A L f E ra
I o e
R ce O p
component maintenance procedures. Replace the pressure switch if faulty.
E t
AT nan en
Installation
M te m
1. Install the pressure switch onto the fitting.
E i
2. Connect the wiring to the switch.
n i p
C a q u
N M E
3. Connect the power source after service is being performed.
E
R o r o r
f
4. Bleed the grease system. Refer to Subtopic 12.7.4.7.
FE E f
Adjustment
E S S E
R U U
To adjust the pressure switches the main AC800 Controller must be on. Refer to Figure 12-18 and proceed as fol-
T T
lows:
O
N NO
O
D DO

LEGEND
02 01. Remove Cover to Adjust
02. Screwdriver
03. Self-locking Adjuster Screw
03 04. Pressure Setting Gauge
05. Indicator
01 04
n t
e
05
Y m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E n p
F2894a01
C a q i u i
E N M E
Figure 12-18: Pressure Switch Adjustment
R o r o r
1. Remove the pressure adjustment screw cover to gain access to the adjustment screw.
E E f f
F E
2. Turn the adjustment screw clockwise to lower the actuation pressure setting. Turn the adjustment screw counter-
E S S
clockwise to raise the actuation pressure setting. Pressure settings are as follows:
R U U
T T
GSPS - 2400 psi (165 bar) with rising pressure
O
N NO
UGPS - 600 psi (41.4 bar) with falling pressure
O
D DO
LGPS - 600 psi (41.4 bar) with falling pressure
3. After adjustment, install the pressure adjustment screw cover.

12.7.3.4 Solenoid Valves
The system uses three grease solenoid valves:
• Grease Vent Solenoid Valve GVS (05, Figure 12-14)
• Upper Grease Solenoid Valve UGS (10, Figure 12-15)
• Lower Grease Solenoid Valve LGS (11, Figure 12-15).
The GVS is located on top of the tank and is used to depressurize the grease system after a lube cycle. The UGS
t
and LGS valve are located on the control panel are used to control which injectors (upper grease or lower grease)
n
will get grease during a lube cycle depending on the operating mode the drill is in.
Y e
m
NL uip ion
! WARNING
O q t
hazardous voltage can cause burns, injury, or even death. Disconnect, lock out, and tag
L f E ra
the power source that feeds this device to prevent power from being applied while
I A e
inspection and repairs are being performed. Before beginning repairs, try the operational
o p
R ce O
controls to verify that the intended power source is disconnected.
E t
AT nan en
M te m
High-pressure oil or grease can spray and penetrate skin or eyes causing severe injury.
E i n i p
Use extreme caution when working around operating lubrication system and wear
C a q u
appropriate face and body protective devices. Shut down the machine, and lock out and
N M E
tag the controls before performing inspection, service and maintenance of the lubrica-
E r r
tion system. Obtain medical aid immediately for lube spray into eyes or penetration into
the skin.
R
E E fo f o
Removal
E F S E
R U U S
T T
O
N NO
2. Remove the electrical connector from the solenoid.
O
D DO
3. If the solenoid is not actuating the valve, remove the screws on top of the valve to detach the solenoid. Inspect
the valve for signs of malfunction. If the valve is damaged, replace the entire solenoid valve.
4. Check operation of the solenoid with a 24VDC power source. If faulty, replace the solenoid. Check operation of
the valve after installation.
Repair
component maintenance procedures. Repair of the solenoid valve is limited to the replacement of worn or dam-
aged parts.
Installation

1. Connect the wiring to the solenoid.
2. Bleed the grease system. Refer to Subtopic 12.7.4.7, Bleeding The System.
12.7.4 Lubrication Injectors
The lubrication injectors are pressure-operated and spring-reset. They are mounted on manifolds, located in
groups strategically positioned on the drill. The Lincoln SL-V injectors used on this drill deliver a measured volume
of lubricant to the lubrication point. The volume is adjustable from 0.008 - 0.080 in3 (1.31 - 13.10 cc) (refer to Sub-
topic 12.7.4.2). The injectors have dual outlets, allowing them to be crossported to deliver increased amounts of
lubricant to the lube point.
n t
The injectors operate within a pressure range between 1,850 and 6000 psi (128 and 415 bar).
Y e
m
NL uip ion
Maximum vent pressure (the pressure the system must get below to allow the injectors to reset after a cycle) is
1000 psi (70 bar).
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

12.7.4.1 Theory of Operation
01 02 03 04
08
07
t
06
e n
Y m
NL uip ion
O q t
05
A L f E ra
I o p e
ER ce O
t
AT nan en
BD1214a01
LEGEND
M te m
01. Stage 1 05. Slide Valve
02. Stage 2 06. Measuring Piston
03. Stage 3
E i n i p 07. Discharge Chamber
C a q u
04. Stage 4 08. Indicator Stem
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
Figure 12-19: SL-V Injector Operation

12.7.4.2 Output Volume Adjustment
In addition to lubricating the various components in the lubrication system, the lubricant
supplied to the lube point flushes dirt and other impurities from the lube point (compo-
nent). Reducing the amount of lubricant to the lube point can result in excessive wear
and premature component failure. Contact your P&H MinePro Services representative
before changing (especially before reducing) the amount of lubricant being supplied to
the lube point.
1. Remove the plastic cap (01) and o-ring (02).

n t
Y e
m
NL uip ion
2. Loosen adjusting screw locknut (04).
3. Turn the output adjustment screw (03) outward (counter-clockwise) to increase the amount of lubricant to the
O q t
lube point - maximum 0.08 in3 (1.31 cc). Turn the output adjustment screw inward (clockwise) to decrease the
L f E ra
amount of lubricant delivered to the lube point - minimum 0.015 in3 (0.25 cc).
A
I o p e
R ce O
4. Tighten the output adjusting screw locknut to lock the adjusting screw in place.
E t
AT nan en
5. Replace the o-ring if needed and install the o-ring and cap.
M te m
E i n i p
C a q u LEGEND
E N M E
01. Cap
r r
02. O-ring
R
E E fo f o
01 03. Output Adjuster Screw
04. Locknut
E F S E
R U U S 02
T T
O
N NO
03
O
04
D DO
BD1215a01
Figure 12-20: Injector Volume Adjustment

12.7.4.3 Injector Removal
Refer to Figure 12-21 and remove an injector as follows:
LEGEND
01. Injector
02. Gasket
03. Manifold
04. Gasket
05. Adapter Bolt
t
06. Feeder Lines
n
01
Y e
m
06
NL uip ion
O q t
A L f E ra
I o p e
R ce O
02
E t
AT nan en
03
M te m
E i n i p
C a q u
N M E
04
RE o r r
E E f f o 05
E F S E
R U U S
T T
R59518D_
O
N NO Figure 12-21: SL-V Injector Removal/Installation (Typical)
O
D DO ! WARNING
Accidental drill movement during service procedures can result in serious personal
injury or death. Always park on level ground, and use lockout and tagout procedures to
prevent accidental start-up and/or motion.
1. Use lockout and tagout procedures to prevent accidental movement or startup.
2. Remove the feeder lines (06) from the injector being removed.
3. Loosen and remove the adapter bolt (05), gaskets (04 and 02) and the injector (01) from the injector manifold
(03). Discard the gaskets.

Refer toFigure 12-22 for disassembly and reassembly.
LEGEND
15
01. Injector Assembly
16 02. Cap
02 03. O-ring*
15
04. Adjusting Screw
05. Lock Nut
17
03 06. Piston Stop Plug
t
07. O-ring*
n
08. Backup Washer
e
04 18
09. Seal
Y m
10. O-ring
NL uip ion
05 01 11. Piston
12. O-ring*
O q t
19
13. Connector
06
14. Injector Body
A L f E ra 15. O-ring (2)*
I o e
07
16. O-ring*
R ce O p
17. Spring*
08
E
18. Spring*
t
AT nan en
09
20 19. Spring Seat
01 20. Body and Plunger Assembly
10
21. Screw (2)
M te m
22. Gasket*
21
E p
23. Manifold
i n i
11
u
24. Gasket*
NC a q 25. Adapter Bolt
M E
22
* Repair Kit - Includes Items:
E r r
03, 07, 12, 15-18, 22 and 24
R o
12
f o
23
FE E f
E S S E
R U U
14 24
T T
O
N NO
13
25
O
D DO F5760A
Figure 12-22: Injector Components (Typical)
12.7.4.5 Repair
Repair of SL-V injector is limited to replacing worn or defective parts. Whenever an SL-V injector is disassembled,
all gaskets, o-rings, and packings should be replaced.

Refer to Figure 12-21 and install the injector as follows:
1. Place the injector (01) and a new gasket (02) on the manifold (03).
2. Install a new gasket (04) on the adapter bolt (05).
3. Install adapter bolt through the manifold and thread it into the bottom of the injector. Tighten the adapter bolt to
45-50 ft-lbs (61-68 Nm).
t
4. Install the feeder lines into the injector body ports (06).
e n
5. Bleed the air from the injector and feeder line, refer to Bleeding Air from Feeder Lines, below.
Y m
NL uip ion
6. Start up the drill using lockout and tagout procedures.
12.7.4.7 Bleeding The System

O q t
A L f E ra
e
During component replacement procedures, or as a means of resolving a lubrication fault, it may become neces-
I o p
sary to remove air from the supply or feeder lines. Air can be introduced into the lubrication system for several rea-
sons:
R ce O
E t
AT nan en
• Because lubricant levels in the reservoir become too low before refilling.
M te m
• Because the lubrication pump is improperly primed.
E i n i p
C a q u
• During component replacement.
E N M E
R o r o r
E E f f
F E
It is necessary to bleed air from the system to prevent lack of proper lubrication from causing
E S S
damage to drill components and to keep the lubrication fault alarm from sounding.
R U U
T T !
The following procedures are provided for bleeding air from the automatic lubrication system.
O
N NO WARNING
O
D DO
Inadvertent movement of the drill during the following procedures can result in injury or
death. Be sure that an operator is stationed at the controls to prevent inadvertent opera-
tion of any drill components.
Bleeding Air From Supply Lines (System)
! WARNING
High-pressure oil or grease can spray and penetrate skin or eyes causing severe injury.
Use extreme caution when working around operating lubrication system and wear
appropriate face and body protective devices. Obtain medical aid immediately for lube
spray into eyes or penetration into the skin.

1. Set all brakes.
2. Start the machine. Station the operator at the controls to prevent inadvertent operations of the drill.
3. Be sure that the grease pump is primed and free of air. If necessary, adjust the lube cycle time and interval at
the GUI to slow grease pump operation.
4. Start a manual lubrication cycle using the GUI. It will be necessary to start a manual lubrication cycle several
times to complete the bleeding process.
5. Bleed each supply line in the lubrication system to be bled starting with the shortest section and working up to
the longest section. Bleed each section as follows:
n t
e
A. If there are fittings that could trap air, as shown in Figure 12-23, start with the fitting closest to the grease
Y
pump; remove each plug in order and run the grease pump until lubricant flow is free of air or foreign matter.
m
NL uip ion
Then install and tighten the plug, and move on to the next fitting.
O q t
A L f E ra LEGEND
I o p e 01. Tee
R ce O
02. Plug
E t
AT nan en
02
01
M te m
E i n i p
C a q
F3261a01
u
E N M E
R o r o r
Figure 12-23: Bleeding Air at Fitting
E E f f
B. Remove the plug(s) at the end of the section. It will be located on the injector manifold as shown in Figure
12-24.
E F S E
R U U S
T T
LEGEND
O
N NO
01. Plug
02. Manifold
O
D DO
01
02 F3262a01
Figure 12-24: Bleeding Air at Manifold

C. Operate the lubrication pump until lubricant flow is free of air or foreign matter. Use a drain pan to collect the
lubricant discharged during the bleeding process.
D. Install the plug.
6. Bleed air from each section in the lubrication system until all sections of the lubricant supply lines are bled.
7. After all air is removed from the grease system, manually cycle the lubrication system via the GUI Lube screen
and check all injectors for proper operation.
Bleeding Air from Supply Lines After Component Replacement
t
When installing new or repaired lubrication components such as the injectors, air is introduced into the grease sys-
n
e
tem supply lines. This air will cause a fault warning alarm to sound, or, if undetected, could cause excessive wear
Y
and premature component failure.
m
NL uip ion
When bleeding air from the supply lines after installation of a component, it is only necessary to bleed air from the
O q t
section of supply line into which the component was installed.
L f E ra
To bleed air from the supply lines after installation of a component, proceed as follows:
A
I o p e
R ce O
1. Start the drill. Station the operator at the controls to prevent anyone from operating the drill while performing
E
bleeding procedures.
t
AT nan en
2. If necessary, adjust the lube cycle time and interval at the GUI to slow grease pump operation.
M te m
p
3. If an injector, or set of injectors, was installed, remove the plug(s) at the injector (Figure 12-24). If a pressure
E i n i
switch was installed, or if a hose or pipe was replaced, loosen the next fitting in that section of the supply line.
C a q u
Collect the lubricant discharged during the bleeding process in a drain pan.
E N M E
r r
A. Start a manual lubrication cycle using the GUI. It will be necessary to start a manual lubrication cycle several
R fo o
times to complete the bleeding process.
FE E f
E
B. Close the air flow control valve. Record the number of turns required to close the valve.
E
R U U S S
C. Open the flow control valve enough so that the grease pump runs slowly.
T T
4. Operate the grease pump until lubricant flow is free of air or foreign matter.
O
N NO
5. Replace the plug and tighten the fitting.
O
D DO
6. After all air is removed from the system, manually cycle the lubrication system via the GUI Lube screen and
check the injector(s) for proper operation.

Bleeding Air from Feeder Lines
LEGEND
01. Injector
01 02. Filler Fitting
03. Cap
02 04. Grease Gun Nozzle
03 05. Feeder Line to Lube Point
04
n t
Y e
m
NL uip ion
O q t
L f E ra
05
I A e
F322a01
R ce O o p
E
Figure 12-25: Bleeding Air from Feeder Lines (Typical)
t
AT nan en
To bleed air from feeder lines, refer to Figure 12-25 and proceed as follows:
M te m
E p
1. Disconnect the feeder line at the lube point.
C a q i n u i
2. Remove the cap from the filler fitting on the injector.
E N M E
R o r o r
3. Using a grease gun containing the same type of grease being used in the lubrication system, attach the grease
f f
gun nozzle and pump grease through the feeder line until clean grease, free of dirt and contaminants, exits the
feeder line.
FE E
E S S E
4. Remove the grease gun, replace the cap on the filler fitting, and connect the feeder line at the lube point.
R U U
T T
12.7.4.8 System Start-up After Repair
O
N NO
When returning the drill to service after repairs, make the following checks:
O
D DO
1. Check the lubrication intervals on the GUI Lube screen. Adjust if necessary.
2. Manually cycle the grease system and check the following for proper operation:
A. Observe the pressure gauge, pressure switches and the Upper Grease Solenoid to verify proper operation and
adjustment. Adjust as required.
B. Observe injectors for proper operation. Check injector indicators for complete motion. SL-1 injector indicators
will lower when the injector discharges lubricant. The indicator will remain in the lowered state until the pump turns
off, and will then raise when the injector is reset.

Grease pump does not run Circuit breaker off or AC800 Con- Turn on circuit breaker or AC800
troller off Controller
Faulty grease system pressure Repair or replace pressure switch.

switch (GSPS)
Faulty grease pump Repair or replace grease pump
Grease pump does not Leak at hoses or connections Check condition of hoses and
build pressure
n t tightness of connections. Replace

faulty hoses. Tighten all connec-
Y e tions.
m
NL uip ion
Pockets of air in system Bleed lube lines
Obstructed pump inlet Clean pump inlet and check valves
O q t as required. Drain and clean tank
A L f E ra interior to remove debris as
I e
required.
R ce O o p
Faulty vent valve Repair or replace valve.
E t
AT nan en
Faulty pump Repair or replace grease pump.
Grease pump operates but cycle Incorrect pressure switch setting Set pressure switch to 2400 psi.
M te m
does not complete
Faulty pressure switch Repair or replace pressure switch.
E i n i p
C a q u
Faulty vent valve Clean, repair or replace valve.
E N
Lack of grease at lube point
M E
Leaking lines Inspect hose from lube point to
r r
injector for loose connections or
R o o
ruptured hose. Correct deficien-
E E f f cies.
E F S E Blocked line Check injector stem for movement
R U U S during lube cycle. If unit is not

working, disconnect supply hose
T T
and flush at the fitting with a
O
grease gun to clear line. Connect
N NO
supply hose.
Faulty injector Repair or replace faulty injector.
folds
O
D DO
Lack of grease at injector mani- Clogged or ruptured
supply hose(s)
Disconnect supply hose and flush
using a grease gun to clear the
line. Replace faulty hose and con-
nect hose after service.
Blocked manifold Remove injectors or measuring

valves. Disconnect supply hose
and flush manifold using a grease
gun to clear. Install injectors or
valves and connect hose after ser-
vice.

Inadequate grease at lube points No grease supply Check grease tank and replenish
as required.
Incorrect viscosity Check grease weight. Grease may

be too heavy for operating envi-
ronment.
Leaking lines Inspect applicable lines for leak-

age. Correct deficiencies.
Faulty grease pump Repair or replace grease pump.
n t
Table 12-10: Troubleshooting Guide (Continued)
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

320XPC-UDC Mechanical Systems Manual Mast
Section 13
Mast
t
The mast (Figure 13-1) supports the drilling components including the rotary machinery, pulldown/hoisting mecha-
n
nism and brakes, guide rollers, pipe handling components, and some of the bit air components.
e
Y m
NL uip ion
The mast is mounted on hinge pins to allow the mast to be raised to the vertical position from the stored horizontal
position. The hinge pins are located at the top of the mast support frame uprights. Raising and lowering of the mast
is accomplished by two operator-controlled hydraulic cylinders that are connected to the mast and the main frame.
O q t
L f E ra
The mast is locked in the vertical drilling position by the two operator-controlled, hydraulically-actuated anchor
A
I o e
pins. The mast is also supported in the drilling position by two articulated back braces that are pinned to the mast
R ce O p
and the front jack caps. Hydraulically-actuated locking collars slide over the back brace joints to secure the
E
extended braces. When the mast is lowered, the locking collars are retracted and the back braces automatically
t
AT nan en
fold. Each back brace has an adjusting screw to allow for adjustment of fixed length.
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

Sec13Mast.fm -13.1- Section 13, Version 00 - 07/12
Mast 320XPC-UDC Mechanical Systems Manual
13.2 Mast Components
06 LEGEND
01. Mast Weldment
02. Back Brace (2)
03. Hoist Cylinder (2)
04. Drilling Deck
05. Rotary Carriage
01
t
06. Crown Block and Auxiliary
n
Winch Sheave Support
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
05
E i n i p
C a q u
E N M E 02
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
04
03
BD1129a01
Figure 13-1: 320XPC Mast

Section 13, Version 00 - 07/12 -13.2- Sec13Mast.fm
13.2.1 Mast Weldment
Refer to Figure 13-1. The mast is made of structural steel, welded in a lattice arrangement to provide strength and
light weight. The four legs of the mast are tied together at the top by a crown block; the crown block also supports
the auxiliary winch sheaves. The mast acts as a support structure for the rotary carriage, which contains the rotary
motion motor and transmission as well as the pulldown motor and transmission. The rotary machinery is covered in
Section 15, Rotary Machinery.
The rearward part of the mast is provided with racking on both sides. This racking meshes with drive pinions on the
carriage to permit the pulldown and hoist systems to move up and down the mast. The pulldown machinery is cov-
ered in Section 14, Hoist/Pulldown Machinery.
13.2.1.1 Mast Weldment Repair

n t
Y e
m
Refer to Figure 13-1. It should seldom, if ever, be necessary to remove the entire mast assembly, except in the
NL uip ion
event of severe damage to structural parts. Most service and replacements of components can be performed in the
field. During maintenance procedures, apply standard torque to fasteners, unless otherwise specified. Refer to
O q t
Appendix A for general mechanical maintenance procedures, and to Appendix B for general hydraulic component
L f E ra
maintenance procedures.
I A o p e
R ce O
13.2.2 Ladder
E t
AT nan en
A ladder is mounted to the right side of the mast to permit inspection of the upper structure. The ladder is equipped
with the Saf-T-Climb® system (Figure 13-2).
M te m
E i n i p Figure 1. Pawl in unlocked position as
C a q u worker climbs. The mechanism allows
N M E
hands-free climbing.
RE o r r
o
Figure 2. Pawl automatically slides into
E E f f locked position during fall. When
F E
descending, the pawl must be manu-
E S S
ally released at each catch point.
R U U
T T
Always use the correct harness when
using the Saf-T-Climb system.
O
N NO
O
D BracesDO
Figure 13-2: Saf-T-Climb Operation
13.2.3 Back
Two articulated structures are pinned to the mast and to the mast rest. When the mast is hoisted to its vertical posi-
tion, the back braces extend to form a support for the mast. Hydraulically-actuated locking collars slide over the
articulated joints to secure the extended braces. When the mast is lowered, the locking collars are retracted and
the back braces automatically fold. Each back brace has an adjusting screw to allow adjustment of the fixed length.
13.2.4 Mast Lock Assembly
The mast is locked in the vertical drilling position by the two operator-controlled, hydraulically-actuated anchor
pins.

13.2.5 Mast Hoist Cylinders
The mast is raised and lowered by two large-bore, long-stroke hydraulic cylinders. The cylinder rod end is mounted
with a clevis and pin joint to the mast support. The cylinder barrel end is clevis and pin mounted to the mast.
13.2.6 Auxiliary Winch
Please refer to Section 18, Auxiliary Winch in this manual for information and repair procedures regarding the aux-
iliary winch.
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

13.2.7 Back Braces
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
LEGEND O
N NO
O
01. Band 08. Lower Clevis 15. Washer (6)
D DO
02. Hydraulic Cylinder (3) 09. Nut RH 16. Cotter Pin (6)
03. Locking Collar 10. Extension Rod 17. Collar Pin (6)
04. Upper Brace 11. Nut LH 18. Lockwire (To secure Item 19)
05. Pin (4) 12. Roll Pin (2) 19. Drilled Head Capscrew (2)
06. Clevis Pin (2) 13. Hinge Pin (2) 20. Lockwasher (2)
07. Lower Brace 14. Link 21. Nut (2)
Figure 13-3: Back Brace (exploded view)

13.2.7.1 Removal
The mast must be locked in the vertical upright position to service the back brace
assemblies. Back braces should be serviced one at a time.
To remove one back brace assembly, refer to Figure 13-3 and proceed as follows:
! WARNING
n t
e
Y m
bodily injury and/ or death. Lockout and tagout the drill operating controls to prevent
NL uip ion
accidental operation.
O q t
1. Lock out and tag the drill operating controls to prevent inadvertent startup or movement of the drill during main-
L f E ra
tenance activities.
I A o p e
2. Securely fasten locking collar (03) and cylinders (02) in the extended (locked) position with rope, or other
R ce O
means, to prevent retraction of the cylinders when the hydraulic hoses are disconnected.
E t
AT nan en
! WARNING
M te m
E n i p
Hot hydraulic oil under pressure can spray and burn with extreme force and volume
C a q i u
N
hydraulic system or machine startup during service or maintenance. Allow the hydraulic
E r M E
system to cool prior to any maintenance or repair. Slowly release pressure or vent cir-
R o o r
f
E E f
F
E S S E
3. Tag and disconnect the hydraulic hoses and fittings to the back brace cylinders. Cap and/or plug all hoses and
R U U
fittings to prevent contamination of the hydraulic system. Refer to Appendix B for information on hydraulic con-
T T
nections.
O
N NO ! WARNING
O
D DO
are not supported by the machinery during any maintenance. The brace assembly
weighs approximately 2,400 lbs. (1,091 kg).
4. Support the upper and lower ends of the brace assembly with a suitable hoist and sling.
5. Remove four pins (5) and drive out the clevis pins (6) to unfasten the brace assembly. Remove the brace
assembly and place it in an appropriate location for disassembly.

1. Remove lockwire (l8) and two capscrews (19), lockwashers (20) and nuts (21). Remove the band (01).
2. Remove two cotter pins (16), washers (15) and collar pins (17). Remove the cylinder (03).
3. Repeat Step 2 for the other two cylinders (03).
n t
e
Note the position of the extension rod engagement before disassembly. Nut (11) has lefthand
threads.
Y m
NL uip ion
4. Unscrew lower clevis (08), nuts (9 and 11) and extension rod (10). Use the special spanner wrench tool
O q t
5002096 to loosen the nuts.
A L f E ra
5. Remove roll pins (12), hinge pins (13) and link (14)
I o p e
R ce O
6. Separate braces (04 and 07) and collar (03).
E t
AT nan en
13.2.7.3 Cleaning, Inspection and Repair
M te m
Clean and inspect the back brace components in accordance with the general cleaning and inspection procedures
E n i p
described in Appendix A of this manual. Repair consists of the replacement of all worn or damaged components.
C a q i u
Refer to the Parts Manual for component identification.
E N M E
r
13.2.7.4 Assembly
R fo o r
E E f
E F S E
S
1. Place collar (03) onto the upper brace (04). Connect link (14) to upper brace (04) and lower brace (07) with
R U U
pins (13) and roll pins (12).
T T
2. Apply anti-seize compound to the threads of the lower clevis (08), nuts (9 and 11) and extension rod (10).
O
N NO
Screw these parts into the into lower brace (07). Use special spanner wrench tool 5002096 to install the nuts.
O
3. Attach the base ends of the hydraulic cylinders (03) to the brackets on the upper brace (04) with cotter pins
D DO
(16), flat washers (15) and collar pins (17).
Be sure that the cylinder ports are aligned correctly to mate with the hydraulic hose assemblies.
4. Position and install band (01) onto the lower base ends of cylinders (03). Secure the band with two capscrews
(19), lockwashers (20) and hex nuts (21). Apply lockwire (18).
5. Attach the rod ends of the hydraulic cylinders to the brackets on the collar (06) with cotter pins (16), flat wash-
ers (15) and collar pins (17).

1. Position the upper and lower braces in a straight line, then slide locking collar (03) into locking position over the
middle joint.
2. Securely fasten locking collar (03) and cylinders (02) in the extended (locked) position with rope, or other
means, to prevent unlocking the back braces.
! WARNING
n t
e
Inadvertent operation of the blasthole drill during maintenance on the machine could
Y m
cause severe bodily injury and/or death. Lockout and tagout the drill operating controls
NL uip ion
to prevent accidental operation.
O q t
3. Lock out and tag the drill operating controls to prevent inadvertent startup or movement of the drill during main-
L f E ra
tenance activities.
I A o p e
! WARNING
ER ce O
t
AT nan en
M te m
E i n i p
bly, assembly and installation. Provide appropriate support for any components that are
C a q u
not supported by the machinery during any maintenance.
E N M E
r
4. Using a suitable hoist and sling, lift up the back brace assembly and position it so that the upper and lower
R o o r
ends are aligned with the mounting caps.
f
FE E f
E S S E
R U U
T T
If the back brace cannot be connected because the brace is too short or too long, adjust the
extension rod as required. Refer to Subtopic 13.2.7.6.
O
N NO
5. Insert pin (06) and install pins (05) to attach the brace to the front jack caps.
O
D DO
There must be a minimum of 4 inches (100 mm) of adjusting screw threads engaged with
both the clevis and upper brace. Less thread engagement could result in brace failure.
6. Align the upper brace end with the mast cap. If the cap and clevis cannot be aligned, loosen nuts (9 and 11)
and adjust the rod (10) to permit alignment. Measure and record the distance between the clevis and lower
brace. This distance will be used in checking and adjusting the other back brace if serviced.
7. Check the length adjustment for the back brace on the other side. Adjust as required.
8. Connect the hydraulic hose assemblies in accordance with their identification tags.

9. Bleed the back brace hydraulic circuits.
13.2.7.6 Adjustment
When adjusting back braces, be certain that sufficient extension rod threads are
engaged. A minimum of 4 inches (100mm) of threads must be engaged on each end.
Insufficient thread engagement may cause the back braces to collapse when the back
braces are under load.
n t
Refer to Figure 13-4. If the back braces are too long when installed, the mast anchor pins will engage but the brace
e
will cock and the collar will not slide into place. If the back braces are too short when installed, the mast will lean
Y m
NL uip ion
forward and the anchor pins will not engage to lock the mast. Use the special back brace spanner tool 5002096
(provided) to loosen or tighten the locknuts (02). Using a bar through the hole provided, adjust the extension rod
(04) as required. Be sure to tighten the locknuts after adjustment.
O q t
A L f E ra
I o e
01 02 03 LEGEND
R ce O p 01. Clevis
E
02. Locknuts
t
AT nan en
03. Lower Back Brace
04. Extension Rod - See Caution
05. Mast Rest Weldment
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
F
04
E S S E
R U U
T T
BD1200a01
05
O
N NO
O
D DO To prevent back brace damage, a minimum
thread engagement of 4 inches (102 mm) must
be maintained at each end of the extension rod
(04). The thread on each end of the extension
rod is 7 inches (178 mm) long. Therefore, no
more than three inches (72 mm) of thread
should be exposed at either end.
Figure 13-4: Back Brace Adjustment

13.2.8 Back Brace Locking Collar Cylinder
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S Figure 13-5: Back Brace Locking Collar Cylinder
T T
O
N NO
13.2.8.1 Removal
O
The back brace locking collar cylinder is removed as part of the back brace removal procedure. Refer to Subtopic
D DO
13.2.7.1.
Move the cylinder to a clean work area for disassembly.
1. Extend piston rod to make clearance for spanner wrench.
2. Clamp the cylinder body in a vise and loosen the cylinder head with a spanner wrench.

3. Unscrew the cylinder head until the threads become disengaged from the cylinder body, then remove the pis-
ton/piston rod and cylinder head assembly from the cylinder body.
4. Remove the locknut from the piston rod. Then separate the piston, wipers (01), seal assembly (02), O-ring
(03), backup ring (04), washer, and cylinder head assembly from the piston. Discard all seal parts.
5. Remove and discard O-rings (05 and 09), backup ring (06), rod seal (07), and rod wiper (08) from the cylinder
head. Note the orientation of these components for assembly.
t
Clean and inspect all cylinder components in accordance with the general cleaning and inspection procedures
n
described in Appendix A of this manual. After cleaning and inspection, cover all parts with a light film of oil and pro-
e
tect the parts from dirt and moisture. Cylinder repair consists of the replacement of wipers, seals, and all worn or
Y m
damaged components. See the LinkOne electronic parts manual for component identification.
13.2.8.4 Assembly
NL uip ion
O q t
L f E ra
I A o p e
1. Lubricate and install O-rings (05 and 09), backup ring (06), rod seal (07), and rod wiper (08) on the cylinder
head.
ER ce O
t
AT nan en
2. Install the cylinder head assembly on the piston rod.
M te m
3. Lubricate and install piston, wipers (01), seal assembly (02), O-ring (03), and backup ring (04) on the piston.
E i n i p
C a q u
4. Install the washer and piston assembly on the piston rod with the locknut and torque securely.
E N M E
5. Lubricate the bore of the cylinder body (with hydraulic oil, and insert the piston/cylinder head assembly). Take
R o r r
care to avoid cutting or pinching the seals and O-rings during insertion.
o
E E f f
F
6. Thread the cylinder head into the bore of the cylinder body, and torque securely with a spanner wrench.
E S S E
R U U
7. Retract the piston rod and install port plugs to prevent contamination of the hydraulic system with dirt.
T T
O
N NO
Cylinder is installed as a part of installing the back braces. Refer to Subtopic 13.2.7.4
O
D DO

13.2.9 Mast Locking Assemblies
08
Rear
View
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
R ce O
BD1200a01
E
01 02
t
AT nan en
M te m
E n i p
07 03
C a q i u
06
E N M E 04
R o r o r
E E f f
E F S E
R U U S 05
BD1200a01
T T
Bottom View
LEGEND O
N NO
O
01. Left Hand Mast Lock Cylinder 05. Drilled Pin and Two Cotter Pins (4 places)
D DO
02. Right Hand Mast Lock Cylinder 06. Left Lock Pin Retract Hose
03. Right Lock Pin Extend Hose 07. Left Lock Pin Extend Hose
04. Right Lock Pin Retract Hose 08. Proximity Switch (2 on each cylinder)
Figure 13-6: Mast Lock Pin Cylinder Installation
The mast lock cylinders may be removed from the drill with the mast either raised or low-
ered. The lock pins may be removed and replaced with the mast vertical but only one at a
time. The mast must be locked in the vertical position with the back braces before start-
ing the removal procedure.

13.2.9.1 Removal
1. Check to be sure that the mast back brace locking collars are in their locked position and the other lock pin is
engaged.
! WARNING
t
cause severe bodily injury and/or death. Lock out and tag out the drill operating controls
n
Y e
m
2. Lock out and tag out the drill operator controls to prevent inadvertent startup during maintenance procedures.
NL uip ion
O q t
! WARNING
A L f E ra
I o p e
R ce O
E t
AT nan en
M te m
E i n i p
3. Tag and disconnect the hydraulic hoses and fittings from the mast lock cylinder. Cap and/or plug all hoses and
C a q u
cylinder ports to prevent contamination of the hydraulic system. Refer to Section B, General Hydraulic System
N M E
Maintenance for information on hydraulic connections. Plug the cylinder ports tightly to keep the cylinder rod
E r
from extending or retracting during transport off the drill.
R fo o r
FE E ! f
WARNING
E S S E
R U U
Some blasthole drill components are extremely heavy. Dropping or mishandling of these parts
T T
can cause severe personal injury or death, and damage to the equipment. Always support heavy
components using a suitable hoist or other means for removal, disassembly, assembly and
O
N NO
installation. Provide appropriate support for any components which are not supported by the
machinery during any maintenance. The mast lock cylinder weigh 56 lbs (25 kg) and the
O
D DO
lock pin weighs 44 lbs (20 kg).
4. Remove the cotter pins and cylinder pins (05) from the ends of the cylinder
5. If a locking pin is to be replaced, drive it out and replace immediately to maintain the locked condition.
1. Extend piston rod to provide clearance for a spanner wrench.
2. Clamp the cylinder body in a vise and loosen the cylinder head with a spanner wrench.

3. Unscrew the cylinder head until the threads become disengaged from the cylinder body, then remove the pis-
ton/piston rod, bearing retainer and cylinder head assemblies from the cylinder body.
4. Remove the locknut from the piston rod. Then remove the U-cup retainers, O-rings (07), and U-cups (06) and
piston bearing. Note the orientation of these components for assembly. Discard all seal parts.
5. Remove the bearing/seal retainer and cylinder head assembly from the piston rod.
6. Remove O-ring (05), backup ring (04), rod bearings, and packing set (03) from the bearing/seal retainer. Dis-
card all seal parts.
7. Remove O-ring (02) and rod wiper (01) from the cylinder head.
n t
e
Y m
NL uip ion
Clean and inspect all cylinder components in accordance with the general cleaning and inspection procedures
described in Appendix A of this manual. After cleaning and inspection, all parts must be covered with a light film of
O q t
oil and protected from dirt and moisture. Cylinder repair consists of the replacement of wipers, seals, and all worn
L f E ra
or damaged components. See the LinkOne electronic parts manual for component identification.
13.2.9.4 Assembly
I A o p e
ER ce O
t
AT nan en
1. Lubricate and install O-ring (02) and rod wiper (01) on the cylinder head.
M te m
E n i p
2. Lubricate and install packing set (03) and rod bearings in the bearing/seal retainer.
C a q i u
N
3. Lubricate and install O-ring (05) and backup ring (04) on the bearing retainer.
E r M E
R fo o r
FE E f
E S S E
R U U
T T
O
N NO
O
D DO

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO Figure 13-7: Mast Lock Cylinder
O
D DO
4. Install the cylinder head and bearing/seal retainer assemblies on the piston rod.
5. Lubricate and install the U-cup retainers, O-rings (07), piston bearing and U-cups (06) on the piston rod. Be
sure that the orientation of these parts is correct.
6. Install the locknut on the piston rod and torque securely.
7. Lubricate the bore of cylinder body with hydraulic oil, and insert the piston cylinder head assembly. Take care
to avoid cutting or pinching the seals and O-rings during insertion.
8. Thread the cylinder head into the bore of the cylinder body, and torque securely with a spanner wrench.
9. Retract the piston rod, and install port plugs to prevent contamination of the hydraulic system with dirt.

! WARNING
t
e n
WARNING
Y
!
m
NL uip ion
O q t
L f E ra
I A e
o p
R ce O
E t
AT nan en
2. Position the cylinders in the guide plates and lock pins.
M te m
3. Install the cylinder and end bar pins and the cotter pins to secure the ends of the cylinder(s).
E i n i p
4. Install the hydraulic hose assemblies to the cylinder ports in accord with the identification tags.
C a q u
N M E
5. Operate the mast lock cylinders until full hydraulic pressure is achieved. This will ensure that the air has been
E r
purged from the system.
R fo o r
E E f
6. Check operation of the mast lock indicating lamps.
F
E S S E
7. If the lock pins are in position and the lamps are illuminated, continue with operation or shutdown as desired.
R UCylinderU
T T
13.2.10 Mast Raise/Lower
O
N NO
The mast is raised and lowered by two large-bore, long-stroke hydraulic cylinders. The cylinder rod end is mounted
with a clevis and pin joint to the mast support. The cylinder barrel end is clevis and pin mounted to the mast.
O
D DO
13.2.10.1 Removal
The mast raise/lower hydraulic cylinders must be removed from the drill to service the seals and rod wipers. The
mast must be locked in the vertical position with the back braces also in their locked positions before starting the
removal procedure. To remove the cylinders, Refer to Figure 13-8 and proceed as follows:

1. Check to be sure that the mast locking pins and the back brace locking collars are in their locked positions.
01
A
02
A
03
n t
e
04
Y m
NL uip ion
05
O q t
L f E ra
06
I A o p e
ER ce O SECTION A-A
t
AT nan en
M te m
E i n i p
C a q u
09
E N M E
R o r o r
E E f f
E F S E B
S
08
04
R U U
T T
O
N NO
07 10 B
O
D DO
VIEW B-B
BD1202a01
LEGEND
01. Mast 06. Right Hand Mast Lift Cylinder - Rod End
02. Bar 07. Mast Lower Support
03. Capscrew and Lockwasher (2 places) 08. Pin
04. Grease Fitting 09. Right Hand Mast Lift Cylinder - Head End
05. Mast Tilt Pin 10. Cotter Pin
Figure 13-8: Mast Raise/Lower Cylinder Installation

! WARNING
! WARNING
n t
e
Y m
NL uip ion
O q t
A L f E ra
I o e
3. Tag and disconnect the hydraulic hoses and fittings from the mast raise/lower cylinders. Cap and/or plug all
R ce O p
hoses and cylinder ports to prevent contamination of the hydraulic system. Refer to Appendix B, General
E
Hydraulic System Maintenance, for information on the hydraulic connections. Plug the cylinder ports tightly to
T an nt
keep the cylinder rod from extending or retracting during transport off the drill.
A
M ten me
! WARNING
E i n i p
C a q u
N M E
E r r
R fo o
bly, assembly, and installation. Provide appropriate support for any components which
E E f
E F S E
S
4. Support the rod end (top) of the cylinder with a suitable hoist.
R U U
T T
5. Remove the two capscrews, lockwashers, and retainer bar from each end of the pin that fastens the rod end of
O
N NO
the cylinder to the mast, then drive out the pin.
6. Remove the pin from the head end clevis and mounting bracket, and lift the cylinder free of the bracket.
O
D DO
7. Move the cylinder to a clean work area for disassembly.
1. Disconnect and remove tube (04). Remove adapters (03 and 05):
2. Remove screws (02) and counterbalance valve (01).
3. Extend piston rod to make clearance for spanner wrench.

Do not clamp on the body diameter. Damage to the cylinder could result.
4. Secure the fixed end of the cylinder in a suitable vise or fixture.
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
Figure 13-9: Mast Raise/Lower Cylinder
O
D DO
5. Using a spanner wrench, unscrew retainer (03) from barrel (12). Pull the entire piston rod assembly from the
body.
6. Remove bearings (07) and seal (08) from the piston. Unscrew the piston from the piston rod. Remove O-ring
(16) from the piston rod and discard.
7. Remove O-ring (10) and backup ring (1 1) from the cylinder head. Discard all seal parts.
8. Slide the cylinder head and retainer with rod bearing (09), seal (12), O-rings (13 and 14) and wiper (15) from
the piston rod. Remove and discard all seal parts.

Clean and inspect the cylinder as described in Appendix A. Repair of the mast cylinder is limited to replacement of
the rod wipers, O-rings, bearings and seals. Refer to the LinkOne electronic parts manual for component identifica-
tion.
13.2.10.4 Assembly
1. Lubricate and install O-ring (14) on the retainer. Slide assembled retainer onto the piston rod.
n t
2. Lubricate and install rod bearing (09), seal (12), O-rings (13 and 14) and wiper (15) in the cylinder head. Slide
e
the assembled cylinder on the piston rod.
Y m
NL uip ion
3. Lubricate and install O-ring (10) and backup ring (1 1) on the cylinder head.
O q t
4. Lubricate and install O-ring (16) on the piston rod. Screw the piston onto the piston rod.
A L f E ra
e
5. Lubricate and install bearings (07) and seal (08) on the piston.
I
R ce O o p
6. Lubricate the bore of cylinder body with hydraulic oil, and insert the piston/cylinder head assembly. Take care
E t
to avoid cutting or pinching the seals and O-rings during insertion.
AT nan en
7. Thread the retainer into the bore of the cylinder body and torque securely with a spanner wrench.
M te m
E n i p
8. Attach counterbalance valve (01) to he cylinder with screws (02).
C a q i u
N
9. Retract the piston rod and install port plugs to prevent contamination of the hydraulic system with dirt.
E r M E
R o r
10. Install adapters (03 and 05). Connect tube (04).
E E f f o
F
E S S E
R U U
T T ! WARNING
O
N NO
O
D DO
! WARNING
bly, assembly, and installation. Provide appropriate support for any components which

2. Support the rod end (top) of the cylinder with a suitable hoist, and lift the cylinder into mounting position on the
drill deck.
3. Install the head end clevis to the mounting bracket on the drill deck, while supporting the cylinder directly above
the bracket. Do not apply side force with the hoist to avoid damaging the cylinder or mounting bracket.
4. While continuing to support the top end of the cylinder with the hoist, swing the top of the cylinder toward the
mast. Adjust the extension of the cylinder until the rod mounting hole is aligned with the mounting bracket on
the mast.
5. Insert the pin through the mast bracket and cylinder, and lock the pin in position with the pin retainer bars, cap-
screws, and lockwashers.
n t
e
6. Remove the hoist from the top of the cylinder.
Y m
NL uip ion
7. Install the hydraulic hose assemblies to the cylinder ports in accordance with the identification tags.
O q t
8. Before lowering the mast, operate the mast raise/lower cylinder several times, holding the valve in the “raise”
L f E ra
and “lower” positions until full hydraulic pressure is achieved. This will ensure that the air has been purged
A
from the system.
I o p e
13.2.11 Mast Lower Assembly
ER ce O
t
AT nan en
Refer to Figure 13-10. The mast bottom plate (02) is bolted to the bottom of the mast. A drill bushing is welded to
the bottom plate in line with the drilling centerline. The bushing is fitted with a dust deflector which is secured with
M te m
four removable T-bolts and a deflector ring (see Figure 13-11).
E i n i p
C a q u
Clean and inspect components as described in Appendix A. Refer to the LinkOne electronic parts manual for com-
N
ponent identification.
E r M E
R o r
Remove components selectively for repair or replacement. The location and method of attachment is shown in Fig-
f o
E E f
ure 13-10.
E F S ! E
R U U S WARNING
T T
O
N NO
cause severe bodily injury and/or death. Lockout and tagout the blasthole drill operating
controls to prevent accidental operation.
O
D DO ! WARNING
parts can cause severe personal injury or death and damage to the equipment. Always
support heavy components using suitable hoist or other means for removal, disassem-
bly, assembly and installation. Provide appropriate support for any units which are not
supported by the equipment machinery during any maintenance. The bottom plate
assembly weighs approximately 4,327 lbs (1,967 kg).

LEGEND
01. Mast
02. Mast Bottom Plate
03. 5” Long Hex Head Cap Screw (10)
04. Retaining Pin (4)
05. Hex Nut and Lockwasher (10)
06. Retaining Plate (2)
07. Lockwasher (8)
08. 2” Hex Head Cap Screw (8)
n t
Y e
m
NL uip ion
A
O q t
A L f E ra
01
I o p e
R ce O
07
E t
AT nan en
08
M te m
E i n i p
C a q u
N
02
M E
A
RE o r r
f f o
01
E E
05
E F S E 03
R U U S 03
06 04
06
T T
O
N NO
04
05
O
D DO View A-A
BD1203a01
Figure 13-10: Lower Mast Assembly
13.2.11.1 Dust Deflector
Refer to Figure 13-11. To remove the dust deflector, loosen the four threaded handles (06) until the four T-bolts (01)
can be swung away to remove the dust deflector (03). Install the parts in the reverse order of removal.

04
n t
08
Y e
m
NL uip ion
09
10
05
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
07
E i n i p 02
06
C a q u
E N M E
R o r o r
f
01
FE E f
E S S E
R U U
03
T T
F8075
LEGEND
O
N NO
01. Tee Bolt (4) 06. Threaded Handle (4)
O
02. Ring 07. Washer (4)
D DO
03. Dust Deflector 08. Capscrew (3)
04. Dust Deflector Support 09. Washer (3)
05. Mounting Plate 10. Locknut (3)
Figure 13-11: Dust Deflector
13.2.11.2 Mast Hinge Pins
The mast must be lowered to the horizontal position before replacing pivot pins. Support the lower end of the mast
with a suitable crane. Replacement parts should be available so that repair can be effected as soon as possible
after hinge pin removal.

Refer to Figure 13-12.Remove two cotter pins (04) and drive out drilled pin (01). Pull out the mast pivot pin (02).
Remove the lube fittings from the mast pivot pin. Install the parts in the reverse order of removal. Lubricate the
mast pivot pin as specified in Subtopic 12.5.2.
LEGEND
01. Drilled Pin
01 05 02. Mast Pivot Pin and Grease Fittings
03. 1-8 UNC X 2” Threaded Hole for
t
pulling pin
n
02 04. Cotter Pin (2)
e
05. Mast Lower Support
Y m
03 06. Bushing (2)
NL uip ion
O q t 06
L f E ra
04
I A o p e
ER ce O R58192F1b
t
AT nan en
Figure 13-12: Mast Pivot Pin and Bushing Sectional View
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

13.2.11.3 Bailing Air Components
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
LEGEND
01. Union 10. Bracket 19. Bearing
02. Hose Clamp 11. Tray Bracket 20. Hex Head Capscrew
03. Upper Air Hose 12. Bracket 21. Lockwasher
04. Upper Hose Trough 13. Lower Hose Trough 22. Retainer
05. Hex Head Capscrew 14. Lower Air Hose 23. Shaft
06. Locknut 15. Standpipe 24. Cotter Pin
07. Nut 16. Bracket 25. Trademark Plate
08. Hex Head Capscrew 17. Bracket
09. Tray Bracket 18. Sheave
Figure 13-13: Mast Bailing Air Components

The location the bailing air components is shown on Figure 13-13. The hoses are attached to the air pipes with
unions and hose clamps. Remove and install to as required to replace any parts that are deteriorated or otherwise
damaged.
13.2.11.4 Mast Repair
Under most conditions, the mast need not be removed from the drill either to service the components it supports or
to repair its structure. Contact your local P&H MinePro Services representative regarding mast structural repairs
and/or physical removal from the drill.
n t
Y e
m
NL uip ion
Table 13-1 provides generic guidelines to aid in troubleshooting problems of the mast and related components.
O q t
Problem
A L f E ra
Probable Cause Remedy
Winch does not run at rated speed

I o p e
Winch sheaves are not turning Inspect winch sheaves for
ER ce O
freely obstruction, binding or damage.
Remove any obstruction, lubri-
t
AT nan en
cate bearings, or replace damaged
parts. Leak at brake piston
M te m Relief valve set too low Relief valve should be set to 2200
E i n i p psi (152 bar). Refer to Section 9,
C a q u
Hydraulic System.
E N M E
Binding winch drum Check mounting of winch. Winch
r r
must be level. Refer to installation
R o o
instructions.
E E f f
F
Winch motor malfunction Repair winch motor.
E S
Winch will not reverse
S E Leak at brake piston lnspect O-rings at brake piston.
R U U Replace O-rings.
T T Defective seal at brake release Check for leakage between motor
O
N NO
channel adapter and brake housing which
indicates O-ring failure. Replace
O-rings.
O
D DO
Plugged brake release passage Remove winch motor and adapter.
Clean brake release passage.
Insufficient hydraulic pressure. Check pressure. Brake releases at

approximately 600 psi (41 bar).
Refer to Section 9, Hydraulic Sys-
tem.
Table 13-1: Mast Troubleshooting

Problem Probable Cause Remedy
Oil leakage at winch breather and/ Damaged seal between drum inte- Replace oil seal. Seal failure may
or at brake housing and drum rior and brake housing be caused by excessive pressure
doe to incorrect hydraulic oil or a
restriction in the return line to the
tank. Check for deficiencies and
correct.
Oil leakage at winch motor flange Loose motor mounting Tighten mounting screws
and adapter
Faulty O-rings between adapter Replace O-rings
and motor flange
Winch brake will not hold

n t
Wire rope is attached to wrong Check wire rope installation. Cor-
e
cable rect deficiency.
anchor slot
Y m
NL uip ion
Excessive back pressure causes Check for obstruction in the return
O q t
brake to release line to tank. Correct deficiency.
A L f E ra
Damaged brake plates lnspect brakes. Replace damaged
I e
brake plates. Check oil for con-
R ce O o p
tamination which will cause fail-
ure. Replace oil in system if
E t
contaminated.
AT nan en
Hydraulic control malfunction Hydraulic control malfunction
Winch brake vibrates

M te m Entrained air in hydraulic oil Check for foam in oil. Check sys-
E n p
when lowering a load
i
tem for
C a q i u
leaks.lnvestigate cause. Correct
N
deficiency.
E r M E
r
Winch brake running hot due to lnvestigate cause. Correct defi-
R
E E fo f o
insufficient
oil flow
ciency.
Return line oil flow should be
E F S E approximately
R U U S 3.5 gpm (13 Ipm) when the

winch is reversed.
T T
O
N NO
Damaged over-running clutch Inspect clutch sprags. Repair
clutch.
O
Damaged brake plates Inspect brakes. Replace damaged
D DO
brake plates. Check oil for con-
tamination which will cause fail-
ure. Replace oil in system if
contaminated.
Mast anchor pins secure but indi- Indicator lamp burned out Replace lamp.
cators do not illuminate
Repair sticking switch linkage. Adjust limit switch.
Repair sticking switch linkage.
Replace faulty limit switch.
No power at switch or lamp Investigate. Correct deficiency.
Table 13-1: Mast Troubleshooting (Continued)

Mast bounces during raising or Air trapped in cylinders Bleed air from hydraulic control
lowering circuit. Pressurize cylinders at end
of stroke and hold at pressure
until pressure reaches maximum.
Stroke cylinders to full length of

stroke.
Faulty counterbalance valve Replace counterbalance valve.

Refer to Section 9, Hydraulic Sys-
tem.
Erratic movement of
n t
Air trapped in cylinder(s) Bleed the circuit and stroke the
e
hydraulic cylinder(s) and/or hydraulic circuit cylinder(s) full travel.
Y m
NL uip ion
Binding mechanism Lubricate the mechanism.
Check alignment and repair any
O q t deficiencies.
A L f E ra Replace failed cylinder
I o p e
Hydraulic control circuit malfunc- lnvestigate cause of malfunction.
ER ce O
tion Refer to Section 9, Hydraulic Sys-
t
tem for information
AT nan en
Table 13-1: Mast Troubleshooting (Continued)
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

320XPC-UDC Mechanical Systems Manual Hoist/Pulldown Machinery
Section 14
Hoist/Pulldown Machinery
t
Refer to Figure 14-1. The Hoist/Pulldown drive system is mounted in the rotary carriage. The pulldown gearcase
e n
(01) drives the shipper shaft (03) and pulldown drive pinions (06). Power is provided by an electric motor (04). The
drive pinions (06) and idler pinions (08) engage the racks which are welded to the mast vertical framework. The
Y m
NL uip ion
idler pinions also engage the racks to provide stability in carriage movement. Guide rollers (07), mounted to the
carriage on the side opposite the drive and idler pinions, maintain proper carriage tracking. A disc-type pulldown
brake (02) provides braking if the hoisting or pulldown systems lose control or power, and when the machine is not
O q t
in operation. The brake is mounted on the end of the intermediate shaft. A resolver (refer to Figure 14-2) senses
L f E ra
rotation of the pulldown gearcase and signals the AC800 control system, which translates pulldown movement into
A
I o e
the corresponding drilling depth. The resolver is mounted below the pulldown gearcase.
R ce O p
E t
AT nan en
02 03 04 05
LEGEND
M te m
01. Pulldown Gearcase
06 02. Pulldown Brake
E i n i p 03. Shipper Shaft
C a q u
04. Pulldown Motor
N
01 05. Pulldown Motor Blower
E r M E 06. Drive Pinions (1 each side)
R r
07. Guide Rollers (6 sets)
E E fo f o
08. Idler Pinions (1 each side)
09. Rotary Drive Motors (2)
F
07
E
10. Rotary Gearcase
E
R U U S S
T T
O
N NO
O
D DO
10 09 08
BD0574a01
Figure 14-1: Rotary Carriage Assembly

Sec14Pulldown.fm -14.1- Section 14, Version 00 - 07/12
Hoist/Pulldown Machinery 320XPC-UDC Mechanical Systems Manual
14.1.1 Hoist/Pulldown Components
The following major components make up the hoist/pulldown assembly:
14.1.1.1 Pulldown Motor L# 83013-1
Refer to Figure 14-1. An electric motor (04) is mounted on a support at the upper end of the rotary carriage. It is
coupled to a triple-reduction gearcase (01). The pulldown motor is cooled by air through an electric motor blower
(05).
14.1.1.2 Pulldown Gearcase 914J434F1
n t
Refer to Figure 14-1. The triple-reduction gearcase (01) is driven by the electric motor (11). A disc-type hydraulic
Y e
brake (02) is attached to the gearcase intermediate shaft to hold the carriage when it is at rest. This is a holding
m
NL uip ion
brake only. Dynamic braking is accomplished using the electric motor’s reversing capabilities.
O q t
The pulldown gearcase output shaft (also referred to as the shipper shaft), extends out both sides of the gearcase.
On each end of the shipper shaft is a pinion that meshes with racking that is attached to the mast legs. These pin-
L f E ra
ions drive against the racking to move the carriage up or down.
A
I o p e
R ce O
15R55D1
14.1.1.3 Pulldown Brake
E t
AT nan en
The hoist/pulldown brake (02, Figure 14-1) is spring set and hydraulic released. Braking action is provided by a
stack of two rotating brake discs and three stationary plates (wear, center, and pressure). The lined brake discs are
M te m
splined to a hub on the pulldown gearcase intermediate shaft. When the brake is set, powerful springs apply brak-
p
ing force to the pressure plate, holding the pulldown gearcase and preventing it from moving.
E
C a q
R37819D1
14.1.1.4 Pulldown Motor Blower i n u i
E N M E
R o r o r
The pulldown motor is air-cooled by the electric motor blower (05, Figure 14-1), attached to the motor housing.
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

Section 14, Version 00 - 07/12 -14.2- Sec14Pulldown.fm
14.1.1.5 Pulldown Resolver Assembly 975N20F1
Refer to Figure 14-2. The pulldown resolver is attached to a shaft on the pulldown brake. It senses the relative
position of the rotary carriage in the mast and reports this position to the programmable logic controller (AC800
control system). The AC800 control system then uses the information to monitor and control hoisting and pulldown
functions.
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NL uip ion
O q t
A L f E ra
I o p e
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AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

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NL uip ion
O q t
A L f E ra
I o p e
ER ce O
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AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
LEGEND
T T
O
N NO
01. Resolver Assembly
02. Hex Head Capscrew (2)
03. Tapped Plate (2)
08.
09.
10.
Drilled Head Capscrew (4)
Tie Wire
Resolver Clamp
15.
16.
17.
Resolver Shaft
Flexible Shaft Cable
Insulating Bushing (4)
O
D DO
04. Rubber Shim (2)
05. Resolver Bracket
06. Setscrew (2)
11.
12.
13.
Washer (2)
Locknut (2)
Resolver
18.
19.
20.
Conduit (2)
Insulated Clamp
Hex Head Capscrew
07. Hub (welded in place) 14. Flexible Shaft Coupling 21. Locknut
Figure 14-2: Pulldown Resolver Installation

14.2 Pulldown System Maintenance
14.2.1 Pulldown Motor 83013-1
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NL uip ion
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A L f E ra
I o p e
ER ce O
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AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
LEGEND
O
D DO
02. Blower
13.
14.
Screw
Shim
25.
26.
Tapped Block
Nut
38.
39.
Nipple
Stopcock
03. Screw 15. Shim 27. Screw 40. Screw
04. Washer 16. Shim 28. Screw 41. Dowel
05. Rain Shield 17. Shim 30. Shim 42. Magnetic Drain Plug
06. Gasket 18. Shim 31. Shim 43. Coupling Guard
07. Screw 19. Lock Washer 32. Shim 44. Top Guard
08. Blower Base 20. Screw 33. Shim 45. Front Guard
09. Motor Gasket 21. Special Washer 34. Coupling 46. Screw
10. Screw 22. Conical Washer 35. Screw
11. Motor 23. Lock Nut 36. Motor Support
12. Motor Support 24. Pulldown Base 37. Pipe Cap
Figure 14-3: Pulldown Assembly

14.2.1.1 Removal
The machinery carriage should be positioned at deck level to permit convenient access and resting on the drill bit,
or otherwise supported, to prevent falling. Refer to Figure 14-3 and proceed as follows:
! WARNING
t
work.
e n
! WARNING
Y m
NL uip ion
O q t
L f E ra
A
I o e
R ce O p
! WARNING
E t
AT nan en
Dropping or mishandling of heavy drill parts can cause severe injury, or death. Always
M te m
move heavy components using the auxiliary winch, or suitable lifting device, and slings
E i n i p
for removal and installation. Determine and provide support for components, which may
C a q u
release or move any during maintenance.
E N M E
r r
1. Disconnect, lock out, and tag the power source that feeds system to prevent power from being applied while
R
E E fo
service is being performed.
f o
F E
2. Remove the blower. Refer to Subtopic 14.2.2.1.
E S
R U U S
3. Tag and disconnect wiring to the pulldown motor.
T T
O
4. Remove the mounting hardware and disconnect the halves of coupling (34).
N NO
5. Remove locknuts (23), conical washers (22), washers (21), and capscrews (35) from the motor flange.
O
D DO
6. Use a suitable lifting device to support the weight of the motor (11). Remove locknuts (23), conical washers
(22), washers (21), and capscrews (13) to detach motor support (12) and motor. Record the thickness and
number of shims (14 through 18). Maneuver the motor to clear the flanged support (36), and remove to an
appropriate area.
7. Remove capscrews (20), washers (19), and support (12).
8. Remove the nut, bent washer, and key from the end of the motor shaft.
Clean and inspect parts as described in Appendix A of this manual. Repair consists of the replacement of worn or
damaged parts. Observe all safety precautions.

14.2.1.3 Assembly and Installation
LEGEND
02
01. Adjusting Capscrew and Nut 03
02. 0.19" (4.8 mm) Shaft-to-Shaft Clearance
03. Key, Bent Washer, and Nut are supplied
with the motor
04. Key is supplied with the pinion
n t 04
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NL uip ion
O q t
A L f E ra
I o p e
ER ce O
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AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
01
E F S E
S
Figure 14-4: Pulldown Motor Alignment
R U U
T T
Refer to Figure 14-4 and assemble the pulldown motor components in the reverse order of disassembly. Note the
O
following:
N NO
1. On the coupling, bend the tab on the lockwasher to lock the nut.
O
D DO
2. Using a suitable lifting device, position motor (11), with support (12), over shims (14 through 18) on base (24).
Install the same shim stack that was removed.
3. Install the motor mounting hardware.
4. Refer to and align the motor to the transmission within 0.002" (0.05 mm) TIR. If necessary, remove or add
shims to adjust the vertical position of the motor. Loosen nuts and adjust the capscrews to align the horizontal
position of the motor. Tighten the nuts after adjustment. Confirm that the coupling is aligned within .002"
(0.05mm) TIR.
5. Install the coupling mounting hardware.
6. Be sure all mounting hardware and electrical connections are tight.

14.2.2 Pulldown Motor Blower R37819D1
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NL uip ion
O q t
A L f E ra
I o p e
R ce O
LEGEND
E
01. Blower
t
AT nan en
02. Wheel
03. Motor
M te m
E i n i p
C a q u
Figure 14-5: Pulldown Motor Blower
E N M E
r
14.2.2.1 Removal and Disassembly
R fo o r
E E f
The machinery carriage should be positioned at deck level to permit convenient access and resting on the drill bit,
F E
or otherwise supported, to prevent falling. The blower can be serviced in place unless complete replacement is
E S S
required. Proceed as follows:
R U U! WARNING
T T
O
N NO
Inadvertent machine movement can cause serious injury, or death. Do not perform main-
O
D DO
work.
! WARNING
power source that feeds this device to prevent power from being applied while inspec-

2. Refer to Figure 14-5. Tag and disconnect wiring to the blower motor).
3. Remove locknuts (04), lock screws (05), and shield (06).
4. If necessary, remove lock screws (02) to remove blower (03), gaskets (07 and 09), and base (08).
5. Refer to Figure 14-5. Remove wheel (02) and motor (03).
t

e n
Y m
NL uip ion
Assemble the motor blower components in the reverse order of disassembly. Note the following:
O q t
1. Be sure that wheel (02, Figure 14-5) is locked and properly positioned on the shaft of motor (03). The wheel
L f E ra
should not contact the housing.
I A o p e
2. Be sure all mounting hardware and electrical connections are tight.
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

14.2.3 Pulldown Gearcase 914J434F1
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NL uip ion
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A L f E ra
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ER ce O
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E N M E
R o r o r
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E F S E
R U U S
T T
O
N NO
O
D DO
Figure 14-6: Pulldown Gearcase

LEGEND
01. Gearcase 16. Gear 32. Tapered Bearing 48. Pipe Reducer
02. Cover 17. Shipper Shaft 33. Ball Bearing 49. Countersunk Plug
03. Hex Hd Capscrew 18. Key 34. Input Pinion 50. Ball Bearing
04. Dowel 19. Shipper Shaft 35. Ball Bearing 51. Seal
05. Locknut 20. Snap Ring 36. Spacer 52. Seal
06. Base 21. Gear 37. Roller Bearing 53. O-ring
07. O-ring 22. Key 38. Shim 54. Seal Housing
08. Cover Gasket 23. Ball Bearing 39. Shim 55. Drilled Hd Capscrew
09. Inspection Cover 24. Spacer 40. Shim 56. Disc Brake
10. Breather Filter 25. Quill Pinion 41. O-ring 57. Spacer
11. Lockwire 26. Drilled Hd Capscrew
n t 42. Seal Housing 58. Low Speed Pinion
e
12. Drilled Head Cap- 27. Retaining Ring 43. Seal 59. Ball Bearing
Y
screw 28. Seal 44. Lockwire 60. Shim
m
NL uip ion
13. Pipe Nipple 29. Seal 45. Drilled Hd Capscrew 58. Shim
14. Pipe Coupling 30. Lockwire 46. Gear 59. Shim
15. Breather Filter 31. Seal Housing 47. Oil Level Gauge 60. End Cover
O q t
A L f E ra
I o p e
ER ce O
The pulldown gearcase assembly is a triple-reduction-type unit. The input pinion is direct-coupled to the pulldown
DC drive motor. Power is transmitted from the input pinion to the gear on the quill pinion-gear set, which rotates on
t
AT nan en
its own bearings on the shipper shaft. The quill pinion drives the low-speed gear that is splined to the low-speed
pinion. The low-speed pinion drives the main gear that is keyed to the shipper shaft. The pulldown brake is
M te m
mounted to the low-speed pinion. The pulldown gearcase can be serviced in place providing suitable lifting and
E p
handling equipment is available to remove heavy components.
14.2.3.1 Removal
C a q i n u i
E N M E
R o r o r
The rotary machinery carriage should be positioned at deck level to permit convenient access to the pulldown
f f
gearcase and resting, or supported on the deck. Refer to Figure 14-6 and proceed as follows:
FE E ! WARNING
E S S E
R U U
T T
O
N NO
work.Dropping or mishandling of heavy drill parts can cause severe injury or death.
O
D DO
Always move heavy components using the auxiliary winch, or suitable lifting device, and
slings for removal and installation. Provide support for components which may release
or move any during maintenance.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance work.
2. Disconnect coupling (34). Refer to Subtopic 14.2.1.
3. Remove the pulldown brake if desired. Refer to Subtopic 14.2.4.
4. Remove the pulldown pinions. Refer to Subtopic 14.2.8.

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NL uip ion
O q t
A L f E ra
I o p e
ER ce O
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AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
Figure 14-8: Rotary Carriage Components

LEGEND
01. Bearing Housing 26. Shim, .1046" thick 51. Drilled Head Capscrew
02. Angle Support 27. Shim, .0598" thick 52. Hex Coupling Bolt
03. Spreader 28. Shim, .020" thick 53. Drilled Shank Capscrew
04. Hex Nut 29. Spherical Bearing 54. Guide Roller Pin Retainer
05. Cotter Pin 30. Tapered Sleeve 55. Idler Shaft Retainer
06. Hardened Washer 31. Bearing Housing 56. Motor
07. Guide Roller 32. Lock Nut 57. Rotary Gearcase
08. Hex Head Capscrew 33. Hardened Washer 58. Washer
09. Locking Compound 34. Hex Nut 59. Drilled Head Capscrew
t
10. Conical Lockwasher 35. Angle Support 60. Deflector Bar
n
11. Retainer 36. Hex Coupling Bolt 61. Deflector Bar
e
12. Shim, 12GA 37. Drilled Shank Capscrew 62. Conical Lock Washer
Y m
13. Shim, 16GA 38. Guide Roller 63. Drilled Head Capscrew
NL uip ion
14. Shim, .020" 39. Hex Coupling Bolt 64. Tie Wire
15. Bushing 40. Snap Ring 65. Tapped Block
O q t
16. Spacer 41. Bearing Retainer 66. Resolver Bracket
17. Guide Roller Pin 42. Snap Ring 67. Pulldown Assembly
18. Drilled Shank Capscrew 43.
A L f E ra
Spherical Bearing 68. Drilled Shank Capscrew
I o e
19. Shaft Retainer 44. Idler Pinion 69. Hex Coupling Bolt
R ce O p
20. Capscrew 45. Bearing Spacer 70. Air Pipe
21. Tie wire 46. Bearing Retainer 71. Conduit U-Bolt
22. Conical Washer
E 47.
t
Idler Pinion Shaft 72. Hex Bolt
AT nan en
23. Drive Pinion 48. Relief Fitting 73. Moving End Bracket
24. Socket Head Capscrew 49. Bushing 74. Plain Washer
M te m
25. Bearing Retainer 50. Hex Coupling Bolt 75. Locking Flange Nut
E i n i p
C a q u
N M E
5. Refer to Figure 14-8 and remove the spreader (03) from the mast to allow access to the pulldown machinery.
E
R o r o r
f f
6. Remove bearing housings (01 and 31) from the mast.
FE E
E
gearcase base.
S E
7. Refer to Figure 14-6. Remove locknuts (23), capscrews (40), and conical washers (22) from the pulldown
S
R U U
T T
8. Remove pulldown gearcase assembly (01).
O
N NO
O
D DO
The machinery carriage should be resting or supported on the deck to permit convenient access to the pulldown
gearcase. Disassembly can be accomplished with the gearcase on the drill.
! WARNING
work.

! WARNING
Dropping or mishandling of heavy drill parts can cause severe injury, or death. Always
move heavy components using the auxiliary winch, or suitable lifting device, and slings
for removal and installation. Provide support for components which may release or
move any during maintenance.
Follow general maintenance instructions provided in Appendix A. Refer to Figure 14-6 and proceed as follows:
2. Remove the pulldown brake. Refer to Subtopic 14.2.4.

n t
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3. Drain the gearcase.
NL uip ion
4. Remove lockwire (41) and capscrews (42). Pull seal housing (39) and shims (36, 37, and 38).
O q t
L f E ra
5. Remove capscrews (03) and locknuts (04). Remove cover (02) and gasket (07).
I A o p e
6. Lift the entire shipper shaft (with gears, spacers, and bearings) from gearcase base (06). Remove this unit to
R ce O
an appropriate area for repair. Support the shaft and components on suitable blocking to permit disassembly.
E t
AT nan en
Remove parts as required. Pinion (22) and gear (18) are keyed and held together with snap ring (17).
7. Remove lockwire (28) and capscrews (27). Remove end cover (60) and shims (57, 58, and 59).
M te m
E n i p
8. Remove lockwire (12) and capscrews (52). Remove seal housing (51): O-ring (50), and seals (49 and 48).
C a q i u
N
9. Support gear (43). Push pinion (55), with bearing (56 and 47), from the base. Remove bearings and spacer
(54).
E r M E
R fo o r
E E f
10. Remove pinion (55) from gear (43).
E F S E
11. Remove the coupling halve from input pinion (32).
R U U S
12. Remove lockwire (28) and capscrews (27). Remove the input pinion seal housing (29), O-ring (30), bearings
T T
(31 and 33) with ring (24), and seals (25 and 26).
O
N NO
13. Remove lockwire (12) and capscrews (23). Remove ring (24) and seals (25 and 26).
O
D DO
14. Remove seal housing (29), O-ring (30), and bearings (31 and 33).
14.2.3.4 Assembly
Assemble parts in the reverse order of disassembly. Refer to Figure 14-6 and note the following:
1. Shim low-speed pinion (55) for 0.005" to 0.010" (0.13 to 0.25 mm) axial endplay, using shims (57,58, and 59).

2. Shim shipper shaft (15) for 0.001" to 0.003" (0.025 to 0.075 mm) axial preload using shims (36, 37, and 38).
3. When installing seals in housing (29), the lip (spring side) on inner seal (25) must face inward and the lip on
outer seal (26) must face outward. Fill the cavity between the seals with grease.
14.2.3.5 lnstallation
Install components in the reverse order of removal. Refer to Figure 14-4 and note the following:
1. Align coupling (34) as described under PULLDOWN MOTOR on page 12-6.
t
2. Be sure breather/filter (10: Figure 12-10) and stopcock (39, Figure 12-51 are installed properly,
3. Fill the pulldown gearcase with oil.

e n
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NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

14.2.4 Pulldown Brake
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NL uip ion
O q t
A L f E ra
I o p e
ER ce O
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AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
LEGEND
O
N NO
O
D DO
01. Pulldown Gearcase 10. Hydraulic Ports (2)
02. Intermediate Shaft 11. Resolver Shaft
03. Spacer 12. Cover
04. Brake Hub 13. Ring
05. Housing 14. Piston
06. Wear Plate 15. Spring
07. Brake Discs 16. Drive Plate
08. Pressure Plate 17. Shims
09. Tapped Lifting Holes 18. Center Plate
Figure 14-10: Pulldown Brake
The brake should be inspected for hydraulic leaks and disc contamination every month. Brake wear should also be
checked every month.

14.2.4.1 Inspection
The machinery carriage should be positioned at deck level to permit convenient access to the pulldown brake and
resting on the drill bit, or otherwise supported, to prevent falling. Proceed as follows:
1. Inspect the brake and lines for hydraulic leaks and disc contamination.
2. Listen for unusual noise or clatter when the brake is turning (released). This may indicate brake unbalance or
excessive wear.
3. Check for heat buildup after the brake has been free-running for a period of time. Excessive heat could indicate
t
insufficient clearance.
e n
4. Visually inspect the area near the brake for friction pad particles, which would indicate a problem.
Y m
NL uip ion
14.2.4.2 Checking Lining Wear
O q t
L f E ra
LEGEND
I A e
01. Piston
R ce O o p
02. Drive Plate
03. Stud Nut
E t
04. Shims
AT nan en 01 A: Brake Set Position
M te m
B: Brake Released Position
p
C: Piston Stroke
E
C a q i n u i
E N M E
R o r o r
f
A
FE E f
E S S E
R U U
T T
B
O
N NO
C
O
D DO
02
04 03
Figure 14-11: Pulldown Brake Wear Check
Lining wear is checked by measuring piston movement. Refer to Figure 14-11 and proceed as follows:

! WARNING
Inadvertent machine movement or operation can cause serious injury, or death. When
necessary to operate the blasthole drill while making an adjustment or performing a
check, obtain the assistance of a second person who is thoroughly familiar with the
machine. Have the assistant at the control panel to be sure that nothing is actuated that
may be hazardous to you or the machine.
1. Lower the carriage to provide convenient access to the pulldown brake. The carriage must be resting on the
drill bit, or other suitable support.
n t
2. With the brake set, measure and record how far the piston protrudes from the drive plate (Dimension A).
Y e
m
NL uip ion
3. With the brake released, measure and record how far the piston protrudes from the drive plate (Dimension B).
4. The difference between Dimension A and Dimension B is the piston stroke. If the piston stroke exceeds 0.260"
(6.6 mm), proceed as follows:
O q t
A L f E ra
I e
A. Release the brake.
R ce O o p
B. Back off the stud nuts evenly and in steps until sufficient gap exists between the drive plate and the housing
E t
to slide the drive plate back approximately 1/16" (1.6 mm).
AT nan en
C. Spread a shim at the split line and remove it by slipping the shim over the drive plate.
M te m
D. Tighten the stud nuts to 70 to 80 ft-lbs (93.5 to 108 N.m).
E i n i p
C a q u
E. Engage the brake. Check for approximate 0.16 inch (4 mm) stroke.
E N M E
R o r o r
E E f f
F E
Before removing the second and third shims, remove the brake discs and inspect for
E S S
equal wear on the lining surfaces. If wear is unequal, interchange the positions of the
R U U
brake discs within the brake as an attempt to equalize wear. When all shims have been
T T
removed and piston travel approaches .260" (6.6 mm), the brake must be replaced.
O
N NO
O
D DO
Only qualified technicians should rebuild these brakes. P&H Mining Equipment recommends
that brakes be returned to the nearest P&H MinePro Services facility for rebuild.

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
LEGEND
01. Hex Nut 09. Pressure Plate 17. Piston
02. Lock Pin 10. Center Plate 18. O-ring
03. Rod Bolt 11. Hex Head Screw 19. O-ring
04. Housing 12. Lock Washer 20. O-ring
05. Wear Ring 13. Cover 21. Ring
06. Brake Disc 14. Socket Head Capscrew 22. Seal
07. Drive Plate 15. Spring 23. Seal
08. Shim 16. Breather
Figure 14-12: Pulldown Brake Exploded View

The rotary machinery carriage should be positioned at deck level to permit convenient access to the brake and
resting on the drill bit, or otherwise supported, to prevent falling. Disassemble to the extent necessary to make
repairs.
! WARNING
work.
n t
Y e
m
NL uip ion
High-pressure oil could cause the free lines to “whip” or spray hot oil, causing injury. Be
sure the hydraulic system is not pressurized before loosening or removing connections.
O q t
! WARNING L
A f E ra
I o p e
R ce O
Dropping or mishandling of heavy drill parts may cause personal injury, or death. Always
E t
AT nan en
move heavy components using the auxiliary winch, or other suitable lifting device, and
slings for removal and installation. Provide support for components that may release or
move during any maintenance.
M te m
E i n i p
C a q
u
E N M E
r
2. Remove the setscrew and disconnect the flexible shaft from the end of the resolver shaft. Refer to Figure 14-2.
R fo o r
E E f
3. Refer to Figure 14-12. Remove cover screws (11), lockwashers (12), and cover (13).
F
E S S E
4. Refer to Figure 14-2 Remove the shaft plate screws and resolver shaft.
R U U
T T
5. Refer to Figure 14-12. Remove capscrews (14) from piston (16).
O
N NO
O
D DO
Do not remove stud nuts (01) while capscrews (14) are out. This will release brake spring pres-
sure and make assembly more difficult.
6. Pull piston (16) from drive plate (07). Two threaded bores in the piston facilitate piston removal.
7. Remove O-ring (17) and seal (21 and 22) from the piston. Remove O-rings and seals carefully to avoid
scratching or marring sealing surfaces, which could cause leakage and brake malfunction.
8. Remove ring (20) and O-rings (18 and 19).
9. Back off hex nuts (01) incrementally and uniformly to release spring pressure. Remove nuts and withdraw drive
plate (07) and remove shims (08).

10. Remove pressure plate (09), discs (06), center plate (10) and wear ring (05) from housing (04).
! WARNING
Dropping or mishandling of heavy drill parts can cause personal injury, or death. Always
To remove the entire assembled brake, remove nuts (01), support the brake with a suitable lifting device, and pull
t
the unit from the pulldown gearcase. Remove lock pins (02).

e n
Y m
NL uip ion
Clean and inspect parts as described in Appendix A of this manual. In particular, inspect brake discs for damaged
linings. Inspect plates for gouging of brake surfaces. Repair consists of the replacement of worn or damaged parts.
Observe all safety precautions.
O q t
A L f E ra
I o e
14.2.4.5 Assembly
R ce O p
E
Assemble the brake in the reverse order of disassembly. Note the following:
t
AT nan en
1. Clean the brake hub splines and brake disc splines. Apply a light coating of hydraulic oil to the splines. Refer to
M te m
Figure 14-12.
E i n i p
2. Refer to Figure 14-12. Install the same number of shims (08) as removed. If new brake discs (06) have been
C a q
installed, use three shims.
u
E N M E
r
3. When installing drive plate (07), tighten hex nuts (01) uniformly and in a pattern to compress the brake springs
R o o r
(15). Torque the stud nuts to 70 - 80 ft-lbs (93.5 - 108 Nm). Apply Loctite, or equivalent sealing agent, to the
f
stud nuts.
FE E f
E S S E
R U U
T T
Do not permit outer O-rings or seals to become pinched when installing the ring and pis-
O
N NO
ton. If damaged, the O-rings or seals will not seal properly, causing leakage and malfunc-
tion.
O
D DO
4. Before installation, lubricate new O-rings and seals with a light coating of clean hydraulic oil.

14.2.5 Pulldown Resolver
n t
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NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
LEGEND
O
N NO
01. Resolver Assembly 08. Drilled Head Capscrew (4) 15. Resolver Shaft
O
02. Hex Head Capscrew (2) 09. Tie Wire 16. Flexible Shaft Cable
D DO
03. Tapped Plate (2) 10. Resolver Clamp 17. Insulating Bushing (4)
04. Rubber Shim (2) 11. Washer (2) 18. Conduit (2)
05. Resolver Bracket 12. Locknut (2) 19. Insulated Clamp
06. Setscrew (2) 13. Resolver 20. Hex Head Capscrew
07. Hub (welded in place) 14. Flexible Shaft Coupling 21. Locknut
Figure 14-13: Pulldown Resolver
14.2.5.1 Removal
The machinery carriage should be positioned so it is resting on the deck. Refer to Figure 14-13 and proceed as fol-
lows:

! WARNING
work.
Proceed as follows:
2. Remove the hex socket capscrews in coupling (14).

n t
Y e
m
3. Loosen nuts (12), and remove resolver (13).
4. Remove coupling (14) and shaft (15).

NL uip ion
O q t
L f E ra
5. If cable (16) needs to be replaced, proceed as follows:
I A o p e
A. Remove the setscrew in the bushing on the flexible shaft cable at the resolver end.
ER ce O
t
B. Refer to Figure 12-9. Remove the setscrew and disconnect the flexible shaft cable from the brake end.
AT nan en
C. Remove setscrew (06) and withdraw cable (16).
M te m
D. Remove the cable from bushing (17) and conduit (18).
E i n i p
C a q u
E. Remove bushing (17) and conduit (18) if replacement is required.
E N M E
r
6. Remove bracket clamp (lo), bracket (05), plate (03), and shim (04) if necessary.
R fo o r
E E f
7. Remove related connecting parts for the cable that are on the pulldown brake as required. Refer to PULL-
F E
DOWN BRAKE on page 12-1.
E
R U U
14.2.6 Cleaning, InspectionS S
and Repair
T T
O
N NO
O
D DO
1. Examine the coupling for stretching, bending, and twisting distortion. Replace damaged coupling.
2. Check for continuity across the resolver stator windings S1- S3 (terminals 2 and 5) and S2-S4 (terminals 4 and
6) and rotor winding R1-R2 (terminals 1 and 2) with an ohmmeter. Replace the resolver if there is an open or
dead short across any winding.
14.2.7 Assembly and Installation
Assemble and install parts in the reverse order of removal. Refer to Figure 14-13 and note the following:
1. After installing shaft (15) in cable (16), and tightening the cable setscrew, install coupling (14) on shaft (15).

2. Position resolver (13) in clamp (10) so the resolver keyway is in line with the case connector. Slide the resolver
into the coupling so there is approximately ¼” (6.4 mm) between the resolver and coupling. Tighten the cou-
pling capscrews to 8 to 10 ft-lbs (10.8 to 13.6 Nm).
3. Inspect the coupling to be sure it is not distorted. Apply Loctite, or equivalent sealant, to the coupling cap-
screws.
4. Start up the drill and check pulldown operation. Verify the zero setting of the resolver.
14.2.8 Pulldown Pinions R5544D1
t
The pulldown drive pinions are mounted to the ends of the shipper shaft, which is driven by the pulldown motor and
n
gearcase. The idler pulldown pinions are mounted on shafts on the rotary gearcase. Grease to lubricate the pull-
e
down and idler pinion bearings and the gear racks is provided by the automatic lubrication system.
Y m
NL uip ion
14.2.8.1 Pinion Maintenance
O q t
The machinery carriage should be positioned at deck level to permit convenient access to the pulldown pinions,
L f E ra
and resting on the drill bit or otherwise supported to prevent falling.
A
I o p e
! WARNING
ER ce O
t
AT nan en
M te m
work.
E i n i p
C a q u
N M E
E
R o r o r
f
FE E f
E
2. Remove lockwire (08), capscrews (20), lockwashers (22), and drive pinions (23).
E
R U U S
3. Remove snap ring (40). S
T T
O
4. Clean, inspect, and repair parts as described in Appendix A.
N NO
5. Install pinions in the reverse order of removal.
O
D DO
Be sure to align the indexing marks on the pinions (23) and shipper shaft splines.
14.2.9 Idler Pinions R7560D3
The idler pinions should be repaired or replaced if the splines are worn excessively, or if rotation is not true. The
mast should be lowered to its horizontal position to repair or replace the drive pinions. Refer to Figure 14-14 and
proceed as follow:

! WARNING
Inadvertent operation of the drill during service, inspection, or maintenance on the
machine can cause severe bodily injury, or death. Use lockout and tagout procedures to
prevent accidental operation of the drill.
1. Lock out and tag the drill operator controls to prevent inadvertent start-up during maintenance procedures.
2. Remove snap ring (40) and bearing retainer (41) from one idler pinion (44).
t
3. Remove second snap ring (42) from idler pinion shaft (47), and remove pinion (44) from the shaft. Remove a
n
third snap ring (40), spacer (46), and bearing (43) from pinion (44).
Y e
m
4. Remove capscrews (08), and lockwashers (10) from the rotary gearcase. Remove idler shaft retainer (55) and
NL uip ion
shims (12, 13 and 14). Record the number of shims used.
5. Withdraw idler shaft (47) from the gearcase.

O q t
A L f E ra
e
6. Repeat steps 2 through 5 for the other idler pinion.
I
R ce O o p
7. Clean, inspect and repair parts as described in Appendix A.
E t
AT nan en
8. Assemble and install parts in the reverse order of removal. Use shims (12, 13 and 14), as needed, so that the
shoulder on idler shaft (47) is tight against the gearcase.
M te m
E n i p
9. Before operating the hoist/pulldown system, initiate a manual lubrication cycle to be sure that the pinions are
adequately greased.
C a q i u
E N M E
r
14.2.10 Guide Rollers R54362F3
R fo o r
E E f
The guide rollers are mounted on bearing housings and the rotary gearcase. The clearance between the rollers
F E
and mast legs can be adjusted to maintain proper pinion contact with the pulldown racks.
E
R U U
14.2.10.1 Removal S S
T T
O
The mast should be positioned in the down or lowered position so the weight of the carriage is resting on the pin-
N NO !
ions. Refer to Figure 14-14 and proceed as follows:
D DO O WARNING
work.
2. Remove capscrews (08) and lockwashers (10) from the rotary gearcase. Remove guide roller pin retainer (54)
and shims (12, 13 and 14). Record the number of shims used.
3. Withdraw roller pin (17) with roller assembly (38) from the gearcase. Remove spacer (16) and bushing (15).

4. Repeat preceding steps 2 through 3 for the other guide rollers.
05 LEGEND
03
01. Roller Carrier
06 05 03. Backup Roller with Bearings
04. Roller Pin
07 05. Thrust Washer
06. Hex Head Capscrew
06
n t 07. Hex Locking Nut
e
07 08. Socket Head Capscrew
Y m
09. Hex Locking Nut
NL uip ion
04
10. Bumper
11. Washer
O q t
12. Grease Fitting
01
L f E ra
14
I A o p e 12
05
ER ce O
t
AT nan en
09
03
M te m
05
E i n i p
C a q11
u
N
06
E r M E
R fo o r
f
02
E E
10 08
E F S E
R U U S F7601A
T T
O
N NO
Figure 14-14: Guide Rollers
O
D DO
1. Remove nuts (07) and capscrews (06) from roller pins (04). Remove roller pins (04), rollers (03) and thrust
washers (05).
2. Remove capscrews (06), washers (11) and bumper (10).
3. Remove capscrews (08) and eccentric bushings (02).
Clean and inspect parts as described in Appendix A. Repair consists of the replacement of worn or damaged parts.
Observe all safety precautions.

14.2.10.4 Assembly
Assemble the rollers in the reverse order of disassembly. Refer to Figure 14-14.
1. Position eccentric bushing (13) so that the eccentric is closest to rollers (03).
2. Install one capscrew (08) and locknut (09) to attach the eccentric bushing until the guide rollers are installed.
1. Lubricate the guide rollers at installation.

n t
Y e
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2. Insert idler pin (14) through each guide roller (07) and thrust washer (13), and mount on gearcase (47) or hous-
NL uip ion
ing (01 or 22).
O q t
3. Assemble and install keeper plate (11) with mounting hardware in the reverse order of removal. Use shims (12)
L f E ra
as needed so that there is minimum clearance between the guide roller and thrust washer.
I A o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

14.2.10.6 Roller Adjustment
LEGEND
02. Roller
03. Mast Cord
A = 0.125 in. (3 mm)
n t
Y e
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NL uip ion
03
A
O q t
A L f E ra
I o p e
ER ce O
t
02
AT nan en
M te m
E p
BD0552a01
C a q i n u i
E N 01
M E
R o r o r
E E f f Figure 14-15: Roller Adjustment
E F S E
S
The mast should be positioned in the down, or lowered, position. Refer to Figure 14-15 and proceed as follows:
R U U
T T
1. Lower the mast so that the pinion shrouds are resting on the rack shrouds.
O
N NO
2. Remove the four socket head capscrews from the eccentric bushing (01).
O
D DO
3. Turn the eccentric bushing until a gap (A) of 0.125 in. (3 mm) is obtained between all of the rollers (02) and the
back of the mast chord (03).
4. Follow steps 1 through 3 for all three remaining roller carriers.

Erratic Hoist/Pulldown Operation Electrical malfunction Investigate control and power circuits
for cause of incorrect operation.
Insufficient Hoist/Pulldown Power Pulldown brake not fully released Check operation of brake.
Mechanical failure of gearcase Inspect the pulldown gearcase for
interference, damaged components or
other malfunction.
Incorrect voltage to drive motor Investigate control and power circuits
t
for cause of incorrect voltage.
Faulty drive motor
e n If motor control and power circuits are

functioning properly, inspect motor for
Y m
NL uip ion
evidence of overheating or other dam-
age.
O q t
No Hoist/Pulldown Power No voltage to drive motor Check for tripped circuit breaker in
power or control circuits. Investigate
A L f E ra cause of power interruption.
I o p e
Motor blower inoperative Check blower operation. Failure could
ER ce O cause motor overheating and shut-

down.
t
AT nan en
Faulty drive motor If motor does not run, inspect rotary
motor for signs of overheating and
M te m burnout.
E i n i p
Broken drive coupling Check condition on coupling.
C a q u
Failure of pulldown gearcase Check gearcase oil level and inspect
E N M E
magnetic plug for evidence of internal
r r
failure.
R
E E fo f
Hoist/Pulldown Operation Stalls
o Pulldown brake does not release Inspect hydraulic lines and connec-
tions to brake.
E F S E
S
Check hydraulic system.
R U U Pinions jammed or damaged Clean any debris or other material
T T
from racks.
O
N NO Electrical malfunction
Inspect pinions for damage.
Investigate control and power circuits
O
for cause of lack of power and repair
D DO
any deficiencies.
Pulldown Brake does not hold Worn linings Remove shim
Replace brake discs
Damaged or broken springs Replace springs
Pulldown Brake does not release No hydraulic pressure to brake Inspect hydraulic lines for loose con-
nections (leaks) and breaks.
Check reservoir oil level.
Internal leakage in brake Replace brake seals.
Table 14-1: Troubleshooting

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NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

320XPC-UDC Mechanical Systems Manual Rotary Machinery
Section 15
Rotary Machinery
t
Refer to Figure 15-1. The double-reduction, rotary gearcase (10) drives the drill bit and pipe string. Power is sup-
e n
plied by two reversible electric motors (09) and is transmitted through an intermediate drive shaft to the main drive
shaft. The motors are mounted on top of the gearcase. The drive shaft spindle terminates at the drill pipe coupling,
Y m
NL uip ion
which connects to the drill pipe. Internal lubrication is provided by a gear-driven oil pump. Pressurized bit air for the
pipe string is connected to the main drive shaft through a rotary seal and piping.
O q t
A L f E ra
e
02 03 04 05 LEGEND
I
R ce O o p
02. Pulldown Brake
E
03. Shipper Shaft
t
06
AT nan en
04. Pulldown Motor
05. Pulldown Motor Blower
M te m
06. Drive Pinion
01
07. Roller
E i n i p 08. Idler
C a q u
09. Rotary Drive Motor
N
10. Rotary Gearcase
E r M E
r
07
R
E E fo f o
E F S E
R U U S
T T
O
N NO
O
D DO
10 09 08
BD0574a01
Figure 15-1: Carriage Assembly

Sec15RotCarr.fm -15.1- Section 15, Version 00 - 07/12
Rotary Machinery 320XPC-UDC Mechanical Systems Manual
15.1.1 Rotary Gear Case
The rotary gearcase is mounted to the lower end of the carriage. Hoisting/pulldown components, which provide
vertical gearcase motion, are also mounted on the carriage. Refer to Section 14, Hoist/Pulldown Machinery for
information.
15.1.2 Rotary Drill Pipe Coupling
n t
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NL uip ion
O q t
02
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E n i p
01
C a q i u
E N M E
R o r o r
f f
LEGEND
E E
01. Duraquest Shock (R11920D1)
F E
02. Adapter (R12299D1)
E
R U U S S
F3486a
T T
O
N NO
Figure 15-2: Rotary Coupling Components
O
The rotary coupling consists of a short adapter and a shock assembly (which is a short section of pipe with a rubber
D DO
insert to absorb shock) that allows transition with the fine API thread on the rotary head to the coarse BECO thread
on the drill pipe. The coarse BECO thread is used in mine drilling applications because it can better withstand the
frequent coupling and breaking of pipe without being damaged beyond use.
A Duraquest shock subassembly is used as an adapter. This shock absorber coupling reduces the severity of
rotary and vertical vibrations. These are largely absorbed by the rubber element in the device. The reduction in
vibration severity translates into longer bit life and higher penetration rates. In addition, it will compensate for minor
drill stem misalignment.
Reducing the harshness vibrations also has benefits for the blasthole drill. These repeated shocks are often the
cause of fatigue cracks in the rotary head, mast and other structural components. Dampening these shocks can
reduce the amount of downtime for maintenance and increase the life of the drill and its components.

Section 15, Version 00 - 07/12 -15.2- Sec15RotCarr.fm
15.2 Rotary Machinery Components
15.2.1 Rotary Motor
Refer to Figure 15-1. The two rotary drive motors (09) are variable speed electric motors that are mounted on the
top of the rotary gearcase. Each motor is fitted with a pinion to transmit power to the intermediate drive shaft.
15.2.1.1 Removal
The rotary carriage should be positioned at deck level to permit convenient access to the rotary gearcase. Support
the drive motor during removal using a suitable hoist or other appropriate means.
n t
!
Y e
WARNING
m
NL uip ion
O q t
L f E ra
A
I o p e
R ce O
1. Disconnect, lock out, and tag the disconnect switch which feeds the machine to prevent power from being
E t
applied while service is being performed.
AT nan en
2. Tag and disconnect the wiring to the motors.
M te m
E n i p
3. Remove eight capscrews and lockwashers to free the motor.
C! WARNING
a qi u
E N M E
R o r o r
f f
FE E
E S E
S
R U U
T T
4. Carefully raise the motor straight up from the gearcase until the pinion clears the intermediate gear to prevent
O
N NO
damage to gear teeth.
O
5. Remove the hex nut and lockwasher from the motor shaft. Pull the pinion off the shaft using a suitable puller. It
D DO
may be necessary to heat the pinion before removal.
6. Remove the key from the motor shaft.
7. Place the motor in an appropriate repair area.

15.2.1.3 Assembly of Motor Pinion
01
LEGEND
01. Motor
02. Pinion
03. Nut
04. Gear
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S
02
E 03 04
R U U S
T T
O
N NO
Figure 15-3: Installing Motor Pinion
O
D DO
1. Remove any scoring from the motor pinion bore and the motor shaft.
2. Thoroughly clean the bore of the pinion and the pinion seating surface on the motor shaft using Toluol or Per-
chloroethylene. Do not use kerosene.
3. Spot the pinion on the shaft by hand to obtain at least a 75% fit. Check the fit with bluing. Remove the pinion.
4. Break all sharp edges on the motor key and keyway with a file to obtain approximately 1/64” (0.4 mm) radius at
each edge.
5. Install the key in the motor shaft to obtain a 75% fit. Check the fit with bluing.

6. Try the pinion on the shaft to be sure it does not bind on the key. Rework the key if binding is evident.
7. Clean the pinion and shaft again.
8. Place the pinion on the shaft and snap it into position by hand. Measure the “cold” position of the pinion using
a micrometer depth gauge. Mark the places where the depth gauge was resting so that measurements can be
made from the same positions after the pinion has been mounted.
Excessive heat can damage the pinion. The pinion must never be heated to a tempera-
ture above 374°F (190°C).
n t
Y e
m
9. Remove the motor pinion from the motor shaft. Heat the pinion in a suitable oven to the temperature specified
NL uip ion
in Table 15-1
Frame Shaft
O q t
Pinion Shrunk On Estimated Temperature
L f E ra
Diameter Dimension Pinion Difference
A
Advance
I
“D”
o
“X”
p e ºC ºF
K504T 3.000"
ER ce O
2.9935" 4.75" 0.020 to 0.025" 70 126
t
AT nan en
Table 15-1: Pinion Mounting Data (refer also to Figure 15-4)
M te m
E i n i p
C a q u "X"
E N M E
R o r o r
E E f f
E F S E
R U U S "D" ± .0015"
T T
O
N NO
O
D DO Figure 15-4: Pinion Dimensions
If the pinion is heated in oil, the bore must be thoroughly cleaned before mounting. The use of
an oven is recommended to avoid the cleaning step.

Pinion temperature is indicated as a temperature difference between the motor shaft and pin-
ion. This temperature is estimated only, and can be adjusted to maintain the specified advance.
Heat the pinion in the oven until the temperature is uniform at the required number of degrees
above the shaft temperature.
For example: if the shaft temperature is 78°F (25°C) and the estimated difference is 225°F (125°C), heat the
pinion to 302°F (150°C) for mounting.
10. A quick accurate method must be provided for measuring pinion temperature and the shaft before mounting
n t
the pinion. This can best be done with a hand pyrometer. When a hand pyrometer is not available, a celsius
e
thermometer can be used by placing putty over the thermometer to hold it against the pinion. Heat the pinion to
Y m
a few degrees above the desired temperature before removing the pinion from the oven. Wait until the pinion
NL uip ion
has cooled to the desired temperature, remove the thermometer, and quickly mount the pinion as described in
the following steps.
O q t
L f E ra
A. After assuring that the pinion bore is clean, quickly mount the hot pinion on the motor shaft. When the pinion
is nearly engaged with the taper fit (but not in contact), snap it forcibly into place with a quick push. It is
I A o e
important that the pinion be instantly snapped into position before it has cooled appreciably; otherwise the
p
R ce O
pinion will “freeze” to the shaft and cannot be adjusted further.
E t
AT nan en
B. Check the hot, or “shrunk-on,” position of the pinion on the shaft using a micrometer depth gauge. The
actual advance is the difference between the depth gauge readings at the hot and cold positions. To control
stresses in the pinion, the advance must be within the limits specified in Table 15-1.
M te m
E n i p
C. If the advance is not within limits, the pinion must be pulled and remounted.
C a q i u
D. Assemble the lockwasher and hex nut on the motor shaft, tighten firmly, and then lock.
E N M E
15.2.1.4 Motor Installation
R o r o r
E E f f
. Refer to Figure 15-3 and proceed as follows:
E F S E
R U U S
1. Immediately before installation, thoroughly clean the mounting surfaces on the motor and gearcase with Per-
chloroethylene or Toluol. Keep dust off the surfaces.
T T
O
N NO
2. Raise the motor with the winch and position it over the gearcase. Be sure that the motor duct is correctly posi-
tioned so it will mate with the blower duct when installed.
O
D DO
3. Apply a continuous, thin coat of non-hardening gasket sealer (Permatex No. 2 or equivalent) to the mounting
surface of the gearcase and around the eight bolt holes.
4. Without allowing extra “setting up” time for the sealer, mount the motor without damaging the sealer surface.
5. Carefully lower the motor straight down into the gearcase so the pinion engages the intermediate gear without
damage.
6. Apply a “no gall” thread lubricant to the entire thread and bearing surfaces of all eight mounting capscrews.
Remove excess lubricant.
7. Install the capscrews and the flanged lockwashers.
8. Torque the capscrews in stages to between 500 and 575 ft-lbs (678 and 780 Nm) using a tightening pattern.

Capscrews must be Grade 5 or better.
9. If any capscrews will not accept a torque wrench due to mechanical interference, use the following method:
A. Snug all capscrews to approximately the same initial torque, using a hand wrench.
B. Using a tightening pattern in several stages of tightening for all the accessible capscrews, torque to the
specified torque (preceding Step 8). Record how far the capscrews turn from the initial torque.
t
C. Using a hand wrench, tighten the remaining capscrews the same number of turns.
e n
D. Retorque the original capscrews that were tightened down with a torque wrench.
Y m
NL uip ion
E. Tighten the remaining capscrews the same amount.
O q t
10. Connect the electrical wiring to the rotary drive motor.
A L f E ra
11. Check and fill the rotary gearcase to the required lubrication level. Refer to Subtopic 12.3.1.
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

15.2.2 Rotary Gear Case
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
Figure 15-5: Rotary Gearcase

LEGEND
01.Lubrication Pump Gear 27. JIC Male Pipe Elbow 53. Seal Carrier
02. Snap Ring 28. Hose Assembly 54. Grease Fitting
03. Lubrication Pump Mounting 29. JIC Male Pipe Adapter 55. Seal
04. Hex Head Capscrew 30. Fitting 56. Seal Spacer
05. Lock Washer 31. Male Cross 57. Relief Fitting
06. Plain Washer 32. Rotary Gear Case 58. Drill Head Capscrew
07. Shoulder Bolt 33. Tapered Bearing 59. Main Rotary Shaft
08. Self-Locking Nut 34. Snap Ring 60. Tapered Bearing
09. Motor Pinion 35. First Intermediate Gear 61. Spacer
t
10. Seal Retainer 36. Spacer 62. Fitting
n
11. Seal Retainer Gasket 37. Intermediate Pinion 63. Magnetic Plug
e
12. Tapered Bearing 38. Tapered Bearing 64. Main Gear
13. Spacer 39.
Y
Shim
m
65. Pipe Bushing
NL uip ion
14. Lock Washer 40. Shim 66. Close Nipple
15. Take Up Nut 41. Shim 67. Drain Cock
O q t
16. O-ring 42. O-ring 68. Cover Gasket
L f E ra
17. Seal 43. Pump Housing 69. Gear Case Cover
18. Breather 44. Cover Gasket 70. Drill Head Capscrew
19. Pipe Coupling
I A45.
o
Cover
p e
71. Inspection Cover
R ce O
20. Pipe Nipple 46. Drain Cock 72. Inspection Cover Gasket
E
21. Hose Assembly 47. Socket Head Capscrew 73. Socket Head Capscrew
t
AT nan en
22. JEC Male Pipe Elbow 48. Lock Washer 74. Lubrication Pump
23. Hose Assembly 49. Drill Head Capscrew 75. Key
24. Straight Fitting 50. Lock Wire 76. O-ring
25. Close Nipple
M te m 51. Magnetic Plug 77. Socket Head Capscrew
E n p
26. Hose Assembly 52. Seal Retainer 78. Straight Fitting
C a q i u i
E N M E
r
R fo o r
E E f
The gearcase assembly consists of gear-driven main and intermediate drive shafts, main-gear driven oil pump for
F
internal lubrication, bit air coupling and tubing, and gearcase housing with drive motor mounts, access covers, and
E S E
breather. The drive shafts are supported in tapered roller bearings. The main drive shaft is bored so that bit air
S
R U U
entering the shaft at the top flows through to the drill pipe coupling and drill pipe. Refer to Figure 11-4 for an overall
view.
T T
O
N NO
It should seldom, if ever, be necessary to remove the entire rotary gearcase assembly. All adjustments, service,
and repair of components can be accomplished in the field, except in the event of extreme damage to internal
O
parts.
D DO

15.2.3 Bit Air Components
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
LEGEND
01. Air Pipe 06. Housing Cover 11. Take Up Nut
02. Hose Clamp 07. Pipe Coupling 12. Lock Wire, Lock
O
D DO
03. Air Hose 08. Air Swivel 13. Drill Head Capscrew
04. Self-Locking Nut 09. Special Flange 14. Swivel Housing
05. Stud 10. O-ring
Figure 15-7: Bit Air Components
The bit air components consist of a rotary air pipe with seals, swivel housing, pipe joint, and air pipe with seals and
related hardware. These components are mounted above the main drive shaft on the gearcase.
15.2.3.1 Removal And Disassembly
The rotary machinery carriage should be positioned at deck level to permit convenient access to the gearcase
assembly. Refer to Figure 15-7 and proceed as follows:

! WARNING
1. Shut down the drill. Lock out and tag the disconnects that supply electrical power to prevent inadvertent move-
ment of the drill during inspection, service, or maintenance.
2. Disconnect and remove the flexible pipe joint (03) at the air pipe (01) and remove clamps (02) as required.
n t
3. Remove air pipe (01) and pipe coupling (07) from the air swivel (08).
Y e
m
4. Disconnect lube hoses and related hardware (refer to inset A on Figure 15-5). If necessary, tie up the lower
NL uip ion
lube hose to prevent oil from draining from the gearcase. Remove parts as required.
O q t
5. Remove lockwire (12) and capscrews (13) that attach swivel housing (14) to the gearcase. Remove housing.
L f E ra
This will expose the main drive shaft adjustment components and seals.
15.2.3.2 Cleaning, Inspection And Repair

I A o p e
ER ce O
t
AT nan en
Clean and inspect parts as described in Appendix A of this manual. Observe all safety precautions. Replace all
worn or damaged parts. Refer to the LinkOne electronic parts manual for parts identification.
M te m
15.2.3.3 Assembly And Installation
E i n i p
C a q u
Install parts in the reverse order of removal. Refer to Figures 15-5, and 15-7.
E N M E
r
A. Position the swivel housing (14) on the gearcase so that the lube holes in the housing and in the seal
R o r
retainer are aligned. This is necessary to permit proper lube venting. Refer to Figure 15-8.
f o
FE E f
E S S E LEGEND
R U U 01. Housing
T T
O
N NO
O
D DO
BD0536a01
01
Figure 15-8: Swivel Housing and Air Pipe

15.2.4 Oil Pump and Lines
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
BD0633a01
Figure 15-9: Oil Pump Arrangement
The oil pump circulates lubricating oil to the gearing through hoses and fittings to both sides of the gearcase. The
pump is mounted behind the front covers on a bracket that is attached to the larger front cover. The main drive gear
meshes with the oil pump gear; meshing is adjustable. Oil flows through external hoses to fittings on top of the
gearcase.

15.2.5 Removal And Disassembly
assembly. Refer Figure 15-9 (see also Figure 15-5) and proceed as follows:
! WARNING
prevent accidental operation of the drill. Determine and provide support for components
t
which may release or move during any maintenance. Lock out and tag the disconnects
ery during inspection, service, or maintenance.

e n
that supply electrical power to the drill to prevent inadvertent movement of the machin-
Y m
NL uip ion
1. Shut down the drill. Lock out and tag the disconnects that supply electrical power to the drill, to prevent inad-
vertent movement of the machinery during inspection, service, or maintenance.
O q t
2. Drain the oil from the rotary gearcase.
A L f E ra
I o p e
R ce O
3. Disconnect the external hoses at the fittings and indicator on the gearcase assembly.
E t
AT nan en
4. Remove the lockwire and capscrews to detach the small cover and its gasket, and gain access to the oil pump.
M te m
5. Disconnect the hose from the gearcase cover bulkhead fitting to the pump flange.
E i n i p
6. Remove capscrews and lockwire to detach the large cover with attached pump, mount, and cover gasket.
C a q u
N M E
7. Remove the retaining ring from the oil pump shaft. Pull the pump gear up off the pump shaft. The shaft is
E r
keyed.
R fo o r
E E f
8. Remove socket head screws and lockwashers to detach the flange from the pump.
F
E S S E
9. Remove two socket head screws and lockwashers to detach the pump from the mount.
R U U
T T
10. Remove the capscrew and lockwasher from the slot in the pump mount.
O
N NO
11. Remove the capscrew and hex nut to detach the pump mount from the cover.
O
12. Remove fittings from the pump and case as required.
D DO
Refer to Figures 15-5, and 15-9 and proceed as follows:

! WARNING
prevent inadvertent operation of the drill.
1. Lock out and tag the disconnects that supply electrical power to the drill to prevent inadvertent movement of
the machinery during inspection, service, or maintenance.
2. Install the fittings into the pump and case.
n t
3. Install the capscrew and hex nut to attach the pump mount to the large cover. Install the capscrew and lock-
e
washer through the cover bracket and into the pump mount. Do not tighten at this time.
Y m
NL uip ion
4. Attach the flange to the pump with four socket head screws and lockwashers.
O q t
5. Attach the oil pump with the flange to the pump mount with two socket head screws and lockwashers.
A L f E ra
e
6. Push the pump gear onto the keyed pump shaft. Install the snap ring into the groove in the oil pump shaft to
secure the gear.
I
R ce O o p
E t
7. Position the large cover with attached pump and cover gasket on the gearcase. Apply a thin coat of sealant
AT nan en
(GE RTV-102 or Permatex No. 2) to the gasket and mounting surfaces. Install capscrews with lockwire to
secure.
M te m
E n i p
8. Connect the hose from the gearcase bulkhead fitting to the pump flange.
C a q i u
N
9. Adjust the drive gear to pump gear mesh. Refer to the topic, Adjustment, below.
E r M E
R o r
10. If removed, screw the indicator into the elbow.
E E f f o
F
11. Connect the hoses at the fittings on the gearcase assembly.
E S S E
R U U
12. Apply a thin coat of sealant (GE RTV-102 or Permatex No. 2) to the small cover, gasket, and mounting sur-
faces. Install the small cover and gasket with twelve capscrews. Apply lockwire to the capscrews.
T T
O
N NO
13. Check hose connections and fittings to be sure that connections are tight. Tighten loose connections as
required.
O
D DO
15.2.5.3 Adjustment
! WARNING

2. Remove the lockwire and capscrews to detach the small cover and its gasket, and gain access to the oil pump.
3. Loosen the adjusting capscrew in the slot in the mount.
4. Loosen the pivot capscrew and hex nut slightly
5. While holding the pump gear against the main drive gear for full tooth engagement without binding, tighten the
adjusting capscrew. Then tighten the pivot capscrew and hex nut.
6. Install the small cover and gasket with twelve capscrews and lockwire.
t
15.2.6 Intermediate Drive
e n
The intermediate shafts and gears are supported on roller bearings. Access is through the bottom of the gearcase
Y m
and the front cover. Shaft end play should be checked and adjusted anytime that the gearcase is down for other
NL uip ion
service or repair.
15.2.6.1 Check And Adjust end play

O q t
A L f E ra
I o e
Lower the carriage to a convenient level for access to the gearcase. A minimum of disassembly is required to
R ce O p
check and adjust intermediate shaft end play. The procedure is the same for each intermediate shaft. Refer to Fig-
E
ure 15-5 and proceed as follows:
t
AT nan en
! WARNING
M te m
E i n i p
Inadvertent operation of the drill during service, cause severe bodily injury, or death.
C a q u
Use lockout and tagout procedures to prevent inadvertent operation of the drill.
E N M E
r
1. Disconnect, lock out, and tag the disconnect switch which feeds the machine to prevent power from being
R o o r
f
FE E f
E
2. Remove the two drain cocks (46) from their covers (45). Allow oil to drain from the gearcase into a suitable
E S S
container.
R U U
T T
3. Remove socket head screws (47) and lockwashers (48) that attach the cover and gasket (44).
O
N NO
4. Remove plug (62). Install a dial indicator so that the spindle contacts the upper end of the intermediate shaft
through the plug hole. Zero the indicator.
O
D DO
5. Apply force to the bottom of the intermediate shaft and check the indicator reading. Intermediate shaft end play
should be 0.003 to 0.005" (0.076 to 0.127 mm).
6. If end play is not within tolerance, remove lockwire (50) and capscrews (49) which attach the bearing housing.
Remove housing (43), O-ring (42), and shims (39, 40 and 41).

7. Adjust for correct end play using existing shims and shims from the available shim pack. Refer to Figure 15-10
for a sectional view of installation.
03 04 05 06
02
n t
Y e
m
NL uip ion
O q t
01
A L f E ra
14
I o p e
ER ce O
t
13
AT nan en
M te m
E i n i p 12
C a q u
11
N M E
BD0538a01
E r
08
r
10 09
R
E E fo f o 07
LEGEND
E F S E
R U U
01. Motor Pinion
02. Drive Motor S 08.
09.
Socket Head Screws and Lockwashers
Drain Cock
T T
03. Intermediate Gear 10. Housing with Shims
O
N NO
04. Spacer 11. Capscrew with Lockwire
05. Intermediate Shaft 12. O-ring
06. Main Drive Gear 13. Cover and Gasket
O
D DO
07. Snap Ring 14. Roller Bearing
Figure 15-10: Intermediate Drive Shaft Installation
8. If further work is to be done on the rotary gearcase, shimming can be performed during assembly of the
gearcase. Note the thickness of the shim pack.
9. Apply a thin coat of sealant (GE RTV- 102 or Permatex No. 2) to the shims the mounting surface. Reinstall
pump housing and shims. Re-check end play.
10. Install cover (45) and gasket (44) with mounting hardware. Install lockwire (50) on capscrews (49) to secure the
housing. Apply lockwire to screw heads in pairs similar to the arrangement shown in Figure 15-8.
11. Install drain cock (46).

The rotary machinery carriage should be positioned at a convenient level to permit access to the gearcase assem-
bly. For drills with two drives the procedure is the same for each. Refer to Figure 15-5 and proceed as follows:
! WARNING
t
move during any maintenance. Inadvertent operation of the drill during service, inspec-
n
tion, or maintenance on the machine can cause severe bodily injury, or death. Use lock-
e
out and tagout procedures to prevent inadvertent operation of the drill.
Y m
NL uip ion
1. Disconnect, lock out and tag the disconnect switch that feeds the machine to prevent power from being applied
O q t
L f E ra
2. Check intermediate shaft end play. Refer to Subtopic 15.2.6.1.
A
I o p e
ER ce O
t
AT nan en
Note the number and size of the shims. This will be helpful information when adjusting shaft end
play.
M te m
E i n i p
3. Remove the front cover and oil pump. Refer to Subtopic 15.2.4.
C a q u
N M E
4. Remove the drive motor. Refer to Subtopic 15.2.1.
RE o r r
o
5. Remove snap ring (34) from intermediate shaft (37).
E E f f
F E
6. Support gear (35). Carefully push the intermediate shaft, with bearings in place, down through spacer (36), the
E S S
intermediate gear, and gearcase. Bearing (33) may tend to hang up and remain in its seat. To prevent damage
R U U
to the bearing, do not allow it to fall from the bearing seat.
T T
7. 7. Remove bearings (33 and 38) from the shaft and gearcase.
O
N NO
8. Remove intermediate gear (35) and spacer (36) through the front case opening.
O
D DO
1. Position intermediate gear (35) in the gearcase above main gear (64), and over the intermediate shaft bore.
Support the intermediate gear to prevent binding and damage during installation of the shaft.
2. Install upper bearing (33) and lower bearing (38) on intermediate shaft (37).

3. Carefully push the intermediate shaft with bearings in place through the lower shaft bore, spacer (36), and gear
(35) so that the upper bearing seats in the upper bearing bore. Be sure that the splines on the shaft and in the
gear are aligned to prevent binding and possible damage to the splines.
4. Install retaining ring (34) on the intermediate shaft.
5. Support the intermediate shaft assembly while installing housing (43).
6. Install the shims and adjust end play. Refer toSubtopic 15.2.6.1.
7. Install the oil pump. Refer to Subtopic 15.2.4.
n
8. Install the drive motor and pinion. Refer to Subtopic 15.2.1.
t
Y e
m
9. Fill the gearcase with oil. Refer to Subtopic 12.3.1.
15.2.7 Main Drive

NL uip ion
O q t
L f E ra
The main shaft rotates on roller bearings and is fitted with seals. Provision has been made for adjustment of bear-
I A e
ing preload. Refer to the topics, Main Drive Bearing Preload Check, and Main Drive Bearing Preload Adjustment.
R ce O o p
E
t
AT nan en
assembly. Refer to Figure 15-5 and proceed as follows:
M te m
!E WARNING
i n i p
C a q u
E N M E
r
R o r
f o
E E f
F E
E S
R U U! WARNING S
T T
O
N NO
O
D DO
2. Drain the oil from the rotary gearcase.
3. Remove the bit air components on the gearcase. Refer to the topic, Bit Air Components.
4. 4. Remove lock washer (14), take up nut (15), and O Ring (16).
5. Remove retainer (10) and gasket (11). Remove seal (17) from the retainer.

6. Disconnect the lube hose that is connected to the seal carrier (53) on the bottom of the rotary gearcase. Cap
the hose to prevent leakage.
7. Remove lockwire (24), capscrews (64) and carrier (54) with retainers (53).
8. If necessary, remove lockwire (50), capscrews (58), retainer (52) and seals (55), and spacer (56), from carrier
(53).
The main drive shaft could slip out of the case, causing personal injury or equipment
n t
damage. Provide support under the shaft when it is removed to prevent accidental dam-
e
age. Keep away from shaft during lifting, lowering, or moving.
Y m
NL uip ion
9. Carefully push the main drive shaft at the top to force the shaft out of the main gear and gearcase. The lower
main bearing cone (60) will come out with the shaft (59).
O q t
L f E ra
10. Remove main bearing (12) and spacers (13 and 61).
11. Remove main bearing (60).

I A o p e
ER ce O
t
12. Remove gear (64) through the front opening in the gearcase.
15.2.7.2 Repair
AT nan en
M te m
E n i p
C a q i u
E N M E
r
R fo o r
E E f
E F S E
S
1. Place gear (64) into the gearcase through the front opening so that it is aligned with the main shaft bore.
R U U
T T
2. Install bearing cup (13) into upper main shaft gearcase bore.
O
N NO
3. Install main bearing (60) and spacer (61) onto main shaft (66).
O
4. Carefully push the assembled main shaft through the gearcase, main gear (64), spacer (13) and bearing (12)
D DO
until the lower bearing seats in the gearcase bore. Be sure that the splines on the shaft and in the gear are
aligned to prevent binding and possible damage to the splines. Secure the shaft in this position.
5. If necessary, install new seal (17) into retainer (10). The seal spring must face the oil side (downward).
6. Install retainer with seal and gasket (11).
7. Install O-ring (18) and take up nut (15). Torque the take up nut enough to secure the main shaft. Install lock-
washer (14).
8. If necessary, install new seals (55) and spacer (56) into carrier (53). The seal springs must face the oil side
(upward) with the spacer in between.

9. Install retainer (52) on carrier (53) with lockwire (50) and capscrews (58).
10. Install assembled carrier and seal unit with lockwire (50) and capscrews (58).
11. Adjust preload in accordance with instructions under Subtopic 15.2.7.5. Be sure O-ring (16) is in position in the
bottom side of the take up nut.
12. Install oil pump and lines. Refer to Subtopic 15.2.4.
13. Install the bit air components. Refer to Subtopic 15.2.3.
14. Check gearcase lubrication level and replenish if necessary. Refer to the Lubrication section.
n t
e
15. If necessary, install the drill coupling components. Refer to Subtopic 15.1.2.
Y m
NL uip ion
16. Start up and operate the drill to verify proper operation. Inspect for leakage. Correct any deficiencies.
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

15.2.7.4 Main Drive Bearing Preload Check
n t
Y e
m
NL uip ion
O q t
01 02
A
03
L f E ra
I o p e
ER ce O
t
AT nan en
M te m
04
E i n i p
C a q u
E N M E
BD0533b01
LEGEND
R o r o r
E E
01. Rotary Gear Case
f f
03. Coupling
F E
02. Dial Indicator 04. Main Drive Shaft Spindle
E
R U U S S Figure 15-11: Checking Main Drive Bearing Preload
T T
O
The rotary gearcase main bearing preload should be checked every 1000 hours of operation, or 6 months, as a
N NO
minimum. Refer to Figure 15-11 and proceed as follows:
O
D DO
1. While drilling a hole, stop operation with the rotary gearcase 3 to 4 feet from the drill platform.
2. With the drill pipe weight suspended on the machinery, mount a dial indicator on the main shaft spindle to indi-
cate to the bottom of the gearcase.
3. Apply a 70,000 lb (311,360 N) pulldown force and observe the dial indicator. Any dial movement indicates the
need for preload adjustment. No dial movement indicates that preload is correct.
4. Release the pulldown force and remove the dial indicator.
5. Proceed with operation. If necessary, schedule adjustment at the earliest opportunity.

15.2.7.5 Main Drive Bearing Preload Adjustment
The rotary machinery carriage should be positioned above deck level to permit convenient access to the gearcase
assembly. Support the unit so that it is stable during removal and installation of components. Refer to Figure 11-9
and proceed as follows:
! WARNING
t
e n
1. Shut down the drill. Lock out and tag the disconnects that supply electric power to the machine to prevent inad-
Y m
vertent movement of the machinery during inspection, service, or maintenance.
NL uip ion
2. Disconnect and remove the bit air components from the gearcase. Refer to Subtopic 15.2.3.
O q t
L f E ra
3. Remove lockwasher (14) and remove the lockwasher.
I A o p e
4. Loosen take up nut (15), then Re-tighten to obtain zero main shaft end play. Check with a dial indicator.
ER ce O
t
5. Tighten take up nut from 9 to 15 degrees beyond “0” end play to obtain 0.003 to 0.005 inch (0.076 to 0.127
AT nan en
mm) preload on the bearings.
M te m
6. Hold the position of the take up nut. Apply anti-seize compound to the main shaft threads. Wipe off excess
E n i p
compound, then install lockwasher (14), lock down take up nut (15) and bend a tab on the lockwasher.
C a q i u
N
7. Install slinger ring (15) and retaining rings 16).
E r M E
R o r
8. Install bit air components that were removed in Step 2. Refer to the topic, Assembly and Installation, under Bit
Air Components.
E E f f o
E F S E
9. Check gearcase lubrication level and replenish if necessary. Refer to the Lubrication section.
R U U S
T T
O
N NO
O
D DO

15.2.8 Rotary Drill Pipe Coupling
01 02 03 04 05 06
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
04 07 08
M te m
BD0571b01
E i n i p
C a q u
LEGEND
N
01. Hex Head Cap Screws 05. Torque Limiter
02. Lift Ring
E r M E 06. Rubber Element
R o r
03. Pin Connection 07. Housing
04. Hex Head Bolt
E E f f o 08. BECO Box Connection
E F S E
R U U S Figure 15-12: Rotary Drill Pipe Coupling
T T
The rotary drill pipe coupling is manufactured to a strict set of design specifications that ensure control over
O
N NO
unwanted shock and vibrations, resulting in savings on equipment repair as well as savings on the overall drilling
operation.
O
D DO
Since the drill pipe coupling is designed to function as a system, all parts and components that are a part of the
system are required to ensure proper operation. Additionally, replacements should be made using OEM parts.
! WARNING
Inadvertent movement of the drill during maintenance activities can cause severe bodily
injury or death. When it is necessary to operate the machine before making an adjust-
ment, or during an operational inspection, obtain the assistance of a second operator
who is thoroughly familiar with the machine. Maintain constant communication and have
the operator at the control panel to be sure that nothing is actuated that can be hazard-
ous to you or the machine.

15.2.8.1 Inspection
The rubber element should be checked every 500 hours of operation as follows:
1. Drill down to the point where the rotary coupling is at eye level. Rest the drill bit at the bottom of the hole.
2. Inspect the rubber element. The rubber should maintain its original look and feel. If the rubber appears discol-
ored or deteriorated, or if it feels sticky or gummy, replace the element.
3. Inspect the housing in the area of the torque limiter lugs. If the lugs have peened the edge of the housing, the
metal could cut the rubber element. Remove peened metal from the housing using a hand grinder or sander.

n t
Y e
m
The rotary machinery carriage should be positioned at deck level to permit convenient access to the rotary drill
NL uip ion
coupling. Remove welded straps and disconnect the rotary drive shaft from the rotary coupler. Support the coupling
parts during removal of components. Refer to Figure 15-12 and proceed as follows:
O q t
! WARNING
A L f E ra
I o p e
R ce O
E t
AT nan en
M te m
1. Disconnect, lock out, and tag the disconnect switch that feeds the machine to prevent power from being
E i n i
p
C a q u
N
2. Remove the lift ring capscrews and remove the lift ring from the rotary coupling.
E r M E
R o r
3. Remove the torque limiter capscrews and discard them. Torque limiter capscrews should not be re-used.
f o
FE E f
E
4. Remove the torque limiter.
E
R U U S S
5. Remove the lower capscrews and discard them. Lower capscrews should not be re-used.
T T
6. Remove the element from the housing.
O
N NO
7. If the body or the BECO box connector require replacement, remove them from the drill string.
O
D DO
Clean, inspect, and repair parts as described Appendix A. Observe all safety precautions. Replace all worn or dam-
aged parts. Refer to the LinkOne electronic parts manual for parts identification.
Support the coupling parts during installation of the components. Refer to Figure 15-12 and proceed as follows:
1. If the housing or the BECO box connector was removed, replace the housing and/or the BECO box connector
onto the drill string.
2. Place the new element into the housing.

3. Use new bolts. Visually inspect bolt threads prior to installation. Threads must be clean and free of damage,
and the yellow Nylok™ patch must be in good condition.
4. Spray bolt threads and threaded holes in the element with a light cote of dry film corrosion preventative and let
dry.
5. Apply a small amount of grease to the first two or three threads of the bolt and screw it into the rubber element
as far as possible by hand.
n t
Install bolts slowly to minimize heat buildup, which could cause galling of the threads.
Y e
m
6. Using a 1" impact wrench, slowly run the bolts into the element the rest of the way.
NL uip ion
7. Torque bolts to 3,000 ft-lbs (4067 Nm). Verify torque after application. Re-check torque after bolts have had a
O q t
chance to “settle.”
15.2.9 Gearcase Removal and Installation

A L f E ra
I o p e
R ce O
The following procedures can be used if it is necessary to remove the entire gearcase. The pipe string must be
E t
AT nan en
removed. Proceed as follows:
15.2.9.1 Removal
M te m
E i n i p
The rotary carriage positioned to permit convenient access to the gearcase assembly. The unit may be serviced
C a q u
with the mast up or down. Use appropriate support in all cases.
E N ! M E
R fo fo r WARNING
r
E
F SE E
E
R U US
T T
O
N NO
O
D DO
2. Drain the rotary gearcase.
3. Disconnect the bit air components. Refer to Subtopic 15.2.3.
! WARNING
4. Remove the drive motors. Refer to Subtopic 15.2.1.

5. Remove the drill pipe coupling. Refer to Subtopic 15.1.2.
6. Disconnect the lube hose that is connected to the seal carrier on the bottom of the rotary gearcase. Cap the
hose to prevent leakage.
7. Place jack(s) underneath the rotary gearcase for support, and/ or a hoist from above.
8. Remove the idler pinions and related mounting parts. Refer to Section 14, Hoist/Pulldown Machinery.
9. Remove the lower guide rollers. Refer to Section 14, Hoist/Pulldown Machinery.
10. Remove lockwires, capscrews, bolts and nuts to detach the rotary gearcase.
n t
e
11. If used, lower the jack(s) so that the rotary gearcase clears the carriage legs. Move the rotary gearcase to an
Y m
appropriate area for repair.
NL uip ion
O q t
A L f E ra
! WARNING I o p e
E R ce O
t
AT nan en
M te m
E i n i p
C a q u
E N !r M E
R fo fo r
WARNING
E
F SE E
E
R U US
T T
O
N NO
2. Position rotary gearcase between the carriage legs so that the mounting holes in the case and carriage pads
are aligned.
O
D DO
3. Install capscrews, bolts, and nuts. Install lockwire.
4. Install the idler pinions and related mounting parts. Refer to Section 14, Hoist/Pulldown Machinery.
5. Install the lower guide rollers. Refer to Section 14, Hoist/Pulldown Machinery.
6. Install the drive motor(s). Refer to Subtopic 15.2.1.
7. Install the drill pipe coupling. Refer to Subtopic 15.1.2.
8. Install the bit air components. Refer to Subtopic 15.2.3.

9. Connect the lube hose to the seal carrier on the bottom of the rotary gearcase.
10. Check and fill gearcase. Refer to Subtopic 12.3.1.
11. Be sure all fasteners and connections, electrical and hydraulic, are secure.
12. Start up and operate the drill to verify proper operation.
n t
Table 15-2 provides general guidelines to aid in troubleshooting problems of the rotary machinery.
Y e
m
No Rotary Power No voltage to drive

NL uip ion
Check for tripped circuit breaker in power or control circuits.
O q t
motor
Investigate cause of power interruption. Refer to Section 15 for
A L f E ra
troubleshooting of electrical circuits. Repair deficiencies.
I
Faulty drive motor
o p e
If motor does not run, inspect rotary motor for signs of over-
or pinion
ER ce O heating and burnout. Refer to Section 15 for troubleshooting of

motor. Repair deficiencies.
t
AT nan en
If motor runs, drain gearcase.Remove front cover and inspect
for stripped pinion. Repair as required
M te m
E p
Damaged rotary Check gearcase oil level and inspect for leakage at seals.
gearcase
C a q i n u i Drain gearcase. Remove magnetic plug and inspect for metal
N
particles indicating excessive wear or damage.
E r M E
r
Remove front cover and inspect internal components for wear
R
E E fo f o
and damage. Repair as required.
F E
Insufficient Rotary Faulty rotary Drain gearcase. Remove magnetic plug and inspect for metal
E S S
Power gearcase particles indicating excessive wear.
R U U Remove front cover and inspect internal components for bind-
T T ing and damage. Repair as required.
O
N NO
Incorrect voltage to
drive motor
Investigate control and power circuits for cause of incorrect
voltage and repair any deficiencies. Refer to Section 15 for
O
troubleshooting of electrical system.
D DO Faulty drive motor If motor control and power circuits are functioning properly,
inspect rotary motor for evidence of overheating or other dam-
age. Refer to Section 15 for troubleshooting of motor. Repair
deficiencies
Faulty rotary If motor control and power circuits are functioning properly,
gearcase check gearcase oil level and inspect for leakage at seals.

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

320XPC-UDC Mechanical Systems Manual Pipe Handling Equipment
Section 16
Pipe Handling Equipment
n t
Y e 12
m
NL uip ion
10
O q t
A L f E ra
I o e
LEGEND
R ce O p
01. Upper Arm 09 01
E
02. Mast
t
AT nan en
03. Pipe Rack
04. Hydraulic Cylinder
05. Lower Arm (extended)
M te m
06. Pipe Rack (retracted)
E p
07. Pipe Holder
i n i
10
u
08. Pipe Wrenches
09. Deck Wrenches
NC a q 02
M E
10. Hydraulic Hoses
E r r
11. Upper Gate Control Handle
R o o
12. Upper Gate Arm (shown open)
E E f f
08
F E
03
E
R U U S S
T T
11
07
O
N NO 02
O
D DO
06
04
05
BD0544e01
Figure 16-1: Pipe Handling Equipment

Sec16Pipes.fm -16.1- Section 16, Version 00 - 07/12
Pipe Handling Equipment 320XPC-UDC Mechanical Systems Manual
16.1.1 Pipe Racks
Each pipe rack forms a long vertical cradle to handle a single length of drill pipe. Refer to Figure 16-1. The pipe
rack (03) is connected to inside mast members at the top and bottom by swing arms that allow the rack to be low-
ered from the retracted (stored) position to the drill centerline and vice versa. Movement of the pipe rack is accom-
plished by extension or retraction of a hydraulic cylinder (04) that is attached between the mast (02) and lower arm
(05). The pipe section is held in the pipe rack by a pipe holder (07) at the bottom and by a gate arm (12) at the top.
Two spring-loaded pipe wrenches or pawls in the pipe holder (07) grab the outside surface of the pipe to hold the
pipe during disconnection from the rotary head before returning the pipe to its stored position. The upper gate arm
(12) is opened or closed by a handle (11). Operation of the pipe rack is controlled by the operator through the
t
AC800 control system. Limit switches signal the AC800 control system to indicate operational conditions of the
n
pipe rack; that is, the pipe is in the pipe holder, the rack is retracted, and the gate is closed.
Y e
m
16.1.2 Deck Wrench
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
Figure 16-2: Deck Wrench
O
The deck wrench allows the operator to hold the pipe string while tools or pipe sections are being connected or dis-
D DO
connected. It consists of a pair of hydraulically actuated rams mounted on the drilling platform. Each deck wrench
unit consists of a housing, a sliding body with spring-loaded pawl, and a hydraulic cylinder that provides clamping
power. Each ram is located on opposite sides of the drill hole, just off of centerline.

Section 16, Version 00 - 07/12 -16.2- Sec16Pipes.fm
16.1.3 Breakout Wrench
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
Figure 16-3: Breakout Wrench
M te m
The breakout wrench (P&H SureWrench™) is used to loosen a pipe joint that is tighter than the joint at the rotary
coupling. Refer to Figure 16-3. The breakout wrench is mounted to the mast structure, and is operated by a set of
E i n i p
hydraulic cylinders. The breakout wrench is stored on a stand in the retracted position. The breakout wrench is fit-
C a q u
ted with inserts for gripping the drill pipe sections. These inserts are interchangeable, based on the drill pipe diam-
N M E
eter being handled.
RE o r r
E E f f o
E F S E
R U U S
T T
O
N NO
O
D DO

16.2 Pipe Handling Equipment Maintenance
Apply standard torque to fasteners unless otherwise specified. Refer to Appendix A for general
mechanical maintenance procedures, and to Appendix B for general hydraulic component
maintenance procedures. It is advisable to replace all seals and O-rings whenever hydraulic
components are disassembled. Refer to the LinkOne electronic parts manual for identification
of components and service kits.
16.2.1 Removing the Deck Wrenches

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
LEGEND
01. Capscrew 08. Grease Fitting
02. Lock Washer 09. Roll Pin
03. Retainer 10. Compression Spring
04. Grease Fitting 11. Pawl
05. Housing 12. Anchor Pin
06. Cylinder 13. Cotter Pin
07. Body
Figure 16-4: Deck Wrench

! WARNING
cause severe bodily injury, or death. Lockout and tag the drill operating controls to pre-
vent accidental operation.
1. Lock out and tag the drill operator controls to prevent inadvertent startup during maintenance procedures.
n t
High-pressure hydraulic or air systems can spray with extreme force and noise causing
e
severe injury. Slowly release pressure or vent circuits before loosening fittings or con-
Y m
nections. Wear appropriate face, ear, and body protective devices while venting air or
NL uip ion
hydraulic systems.
O q t
2. Tag and disconnect the hydraulic hoses from the deck wrenches.
A L f E ra
I o e
3. Remove the hydraulic fittings from the deck wrenches.
R ce O p
E
4. Tag and disconnect the lubrication hose assemblies from the deck wrenches.
t
AT nan en
5. Plug and/or cap all hose assemblies and hydraulic fittings to prevent contamination of the hydraulic system.
M te m
6. Remove cotter pins (13) and withdraw anchor pin (12) to free each deck wrench.
E i n i p
C a q
16.2.2 Disassembling the Deck Wrench
u
E N M E
r r
E ER fo f o
1. Remove capscrews (1) and lockwashers (2). Separate retainers (3) and remove from the cylinder rod.
E F S E
S
2. Withdraw housing (07) with pawl (11), spring (10), cylinder (06), and roll pin (09) from the working end of
R U U
wrench housing (05).
T T
O
3. Drive out roll pin (09), and remove pawl (11) and spring (10).
N NO
4. Tag and disconnect the hydraulic hoses from the deck wrenches.
O
D DO
5. Remove cylinder (06) from body (07).
6. Remove grease fittings (04), if necessary to replace.
16.2.3 Cleaning, Inspecting and Repaing the Deck Wrench
Clean and inspect the deck wrench components in accordance with the general cleaning and inspection proce-
dures provided in Appendix A of this manual. Repair consists of replacement of all worn or damaged components.
Refer to the LinkOne electronic parts manual for component identification.

16.2.4 Assembling the Deck Wrench
1. Install new grease fittings (04) if necessary.
2. Position hydraulic cylinder (06) in body (07).
3. Place spring (10) and pawl (11) in body (07). Align the mounting holes on the pawl and the body, and install roll
pin (09) to secure.
t
4. Install body (07) with pawl (11), spring (10), cylinder (06) and roll pin (09) into housing (05).
e n
5. Place retainers (03) on rod end of cylinder (06). Install capscrews (01) and lockwashers (02) to secure the
retainers.
Y m
16.2.5 Installing the Deck Wrench
NL uip ion
O q t
A L f E ra
I o p e
R ce O
1. Place each deck wrench in its position on the drill platform. Install anchor pin (12) and secure with cotter pins
E
(13).
t
AT nan en
2. Repeat the preceding Step 1 for the other deck wrench.
M te m
3. Install the lubrication hose assemblies on the deck wrenches. Manually lubricate the wrench pawls, as speci-
fied in Section 12, Lubrication.
E i n i p
C a q u
N M E
4. Install the hydraulic fittings on the deck wrenches.
R E o r r
5. Connect the hydraulic hoses to the deck wrenches. Bleed the hydraulic system.
E E f f o
F E
6. Recheck the security of the mounting and hydraulic connections.
E
R U U S S
7. Start the drill and check operation of the deck wrenches to be sure all functions work properly.
T T
O
N NO
O
D DO

16.2.6 Disassembling the Deck Wrench Cylinders 5010453
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
LEGEND
E i n i p
01. Piston Rod
C a q u06. Service Kit 11. O-ring
N M E
02. Cylinder Head 07. Rod Wiper 12. Wear Ring
E r
03. Piston 08. Rod Seal 13. Seal Assembly
04. Locknut
R fo o r 09. O-ring 14. O-ring
E E f
05. Barrel 10. Backup Ring
E F S E
S
Figure 16-5: Deck Wrench Cylinder
R U U
T T
O
N NO
1. Use a spanner wrench to loosen cylinder head (02); back it out, free of barrel (05).
O
D DO
2. Pull the entire piston and piston rod assembly out of barrel (05). Pull the assembly straight out, very carefully,
to avoid scoring the cylinder bore.
3. Remove locknut (04) and the slide piston assembly off piston rod (01).
4. Remove and discard O-ring (14) from inside of piston (03).
5. Remove two wear rings (12) and seal assembly (13) from the piston (03). Use care to avoid damage to the pis-
ton land areas during disassembly.
6. Remove cylinder head assembly off piston rod (01).
7. Remove backup ring (10) and O-ring (11) from the outside of cylinder head (02).

8. Remove rod wiper (07), rod seal (08), and O-ring (09).
16.2.7 Cleaning, Inspecting and Repairing the Deck Wrench Cylinders
Clean and inspect the hydraulic cylinder components in accordance with the general cleaning and inspection pro-
cedures described in Appendix B of this manual. None of the components are repairable, and must be replaced if
worn or damaged. Replace all seals and rings using available service kit. Refer to the LinkOne electronic parts
manual for component identification.
16.2.8 Assembling the Deck Wrench Cylinders
n t
Y e
1. Lubricate and install rod wiper (07), rod seal (08), and O-ring (09).
m
NL uip ion
2. Install cylinder head (02) on piston rod (01).
O q t
3. Lubricate and install backup ring (10) and O-ring (11) on the outside of cylinder head (02).
A L f E ra
I o e
4. Lubricate and install new O-ring (14) the inside of piston (03). Install piston with O ring on piston rod (01).
R ce O p
E
5. Lubricate and install two wear rings (12) and seal assembly (13) on piston (03). Use care to avoid damage to
t
AT nan en
the piston land areas during assembly.
M te m
6. Install locknut (04) on piston rod (01).
E
7. Lubricate the bore of barrel.
i n i p
C a q u
N M E
8. Install the entire piston and piston rod assembly into barrel (05). Insert the assembly, very carefully, to avoid
E r
scoring the cylinder bore.
R fo o r
E E f
9. Install cylinder head (02) into the barrel, and torque securely with a spanner wrench.
F
E S S E
R U U
T T
O
N NO
O
D DO

16.2.9 Aligning the Breakout Wrench
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
T an nt
Figure 16-6: Breakout Wrench
A
M ten me
! WARNING
E i n i p
C a q u
The rotating drill string or its associated moving components can entrap and crush per-
N M E
sonnel, resulting in severe injury or death. Do not enter the drilling platform and/or mast
E r r
area while the drill is operating. Notify the operator to shut down the drill and use lock-
R fo o
out/tagout procedures before conducting maintenance or service. When working in the
E E f
drilling and/or mast area while power is supplied to the drill, establish a procedure to
F E
maintain communications between the work crew and the person controlling the drill
E S S
operation and shut down.
R U U
T T
Refer to Figure 16-6
Step 1: O
N NO
Mount wrench to mast.
Step 2:
Step 3:
O
D DO
Add proper dies to match diameter of drill pipe.
Swing the breakout wrench into position to clamp around the pipe.
! WARNING
hoisting equipment to stabilize and lift heavy objects. The breakout wrench assembly
Step 4: Support the weight of the breakout wrench.

Step 5: Loosen the bolts on the breakout wrench mounting brackets.
Step 6: Using hydraulics, clamp the drill pipe with the wrench.
Step 7: Tighten the bolts on the mounting brackets to secure the position of the wrench.
Step 8: Swing the wrench in and out to check the final alignment. If better alignment is needed, repeat steps 3
through 7.
Step 9:
n t
Y e
m
01 02 03 04 05 06 07 08
NL uip ion
O q t
A L f E ra
I o p e
ER ce O 09
t
AT nan en
14
M te m
E i n i p 10
C a q u
E N M E
R o r o r
13
E E f f
E F S E
R U U S
T T
O
N NO
12 11
O
BreakoutWrench_TopView
LEGEND D DO
01. Pivot Tube 08. Breakout Wrench
02. Breaking Cylinder Rod-End Anchor Pin 09. Clamping Cylinder
03. Breaking Cylinder 10. Clamping Cylinder Base-End Anchor Pin
04. Clamping Cylinder Rod-End Anchor Pin 11. Cover
05. Cover 12. Breaking Cylinder Base-End Anchor Pin
06. Breakout Wrench Clamping Jaw 13. Sequence Valve
07. Jaw Die (3 used) 14. Breakout Wrench Arm
Figure 16-7: Breakout Wrench (Typical),

16.2.10 Inspecting the Breakout Wrench Die Teeth
If the teeth are dull or chipped, or if they are filled with dirt and metal, they will not have sufficient “bite” necessary
to grip and hold on to the drill pipe as the jaws are rotated. The jaws will slip. Before the effort is made to break a
pipe connection, ensure that all three dies have been inspected for damage and are free of debris.
16.2.11 Inspecting the Breakout Wrench Components
As the working parts wear, the clamping and breaking performance will suffer. Wearing parts cause the breakout
wrench geometry to be distorted when clamping around a drill pipe as designed. As a result, the dies will not main-
tain the required perpendicularity to the drill pipe. Thus, the dies will encounter point loading, which will result in the
t
dies slipping and chipping teeth instead of biting into the drill pipe as the jaws are rotated.
e n
Y
16.2.12 Inspecting the Drill Pipe
m
NL uip ion
The most common problem found with inadequate breakout wrench performance is due to the vigorous wear of
O q t
drill pipe. A drill pipe string regularly wears at different rates at different locations. Therefore, it is essential that
L f E ra
before attempting to break a drill pipe connection that the pipe circumference is measured and if necessary, that
new jaw dies are installed.
I A o p e
16.2.13 Lubricating the Breakout Wrench
ER ce O
t
AT nan en
Refer to Figure 16-8. Apply grease to the five grease fittings (01) on a monthly schedule or as needed. Use
extreme pressure, multi-purpose lithium grease, Material Specification P&H 472.
M te m
E i n i p
C a q u
E N M E LEGEND
r r
01 01. Grease Fitting (x5)
R
E E fo f o
E F S E
R U U S
T T
O
N NO
01
O
D DO
BreakoutWrench_TopView
Figure 16-8: Breakout Wrench Lubrication

16.2.14 Inspecting and Adjusting the Breakout Wrench Hydraulic Circuits
Refer to Subtopic: Stations 1 and 2: Breakout Wrench Circuits on page 9.61.
16.2.15 Pipe Racks
07
07
08
09
10
11
t
12
e n 06
Y
13, 14, 15
m
03
NL uip ion
04
16
18 05
O q t
19 17
L f E ra
21
I A e
20
o
02
p
22 23
R ce O
01
E
24
t
AT nan en
25
M te m 26
E n i p
27
C a q i u
28
N
04
E r M E 05
R fo o r
E E f
31
F
29
E
05 32
E S S
32
04
R U U 53 30 33
T T
56
O
N NO
55 36
52 54
37
34
O
D DO
28 35
44
45
04
40
39 05
23
46 22 25
42
50 24
49 43
47 38
42
48 41
24
51
04 05
Figure 16-9: Pipe Rack with Mechanically Operated Upper Gate (Typical)

LEGEND
01. Support Arm 19. Link Sleeve 39. Jam Nut
02. Gate Arm Support Plate (Note: 20. Sleeve Pin (2) 40. Adjustment Rod
Item 02 is welded to Item 01) 21. Cotter Pin (4) 41. Shoulder Screw
03. Upper Rack Pin 22. Pivot Pin (2) 42. Thrust Washer (2)
04. Lockwasher (6) 23. Rod Clevis (2) 43. Gate Handle
05. Hex Head Capscrew (6) 24. Jam Nut (3) 44. Spring (2)
06. Upper Arm 25. Adjustment Rod 45. Spring Seat (2)
07. Bronze Bushing (4) 26. Rack Weldment 46. Tapped Block
08. Upper Mast Pin 27. Hydraulic Cylinder 47. Lockwasher (4)
t
09. Retaining Ring (2) 28. Cylinder Pin (2) 48. Socket Head Cap Screw (4)
n
10. Hex Head Capscrew (4) 29. Tapped Bar 49. Proximity Switch
e
11. Anchor Block (2) 30. Pipe Plug 50. Mounting Plate
Y m
12. Upper Block (2) 31. Hex Head Capscrew (4) 51. Lower Rack Pin
NL uip ion
13. 0.12 Thick Shim (2) 32. Lower Block (4) 52. Grease Fitting (2)
14. 0.25 Thick Shim 33. Lower Block Shims (6) 53. Pipe Wrench Pin (2)
O q t
15. 0.5 Thick Shim 34. Lower Mount Pin 54. Hex Nut
16. Washer (4) 35. Retaining Ring (2) 55. Socket Head Set Screw
17. Self-Locking Nut (4) 36.
A L f E ra
Washer (4) 56. Lower Arm
I o e
18. Cylinder Link (Note: Item 18 is 37. Hex Nut (4)
R ce O p
welded to Item 19 38. Turnbuckle
E t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

16.2.16 Adjusting the Pipe Wrenches
Refer to Figure 16-11. Check engagement of the wrenches with pipe to be sure that the wrenches grab when pipe
is being disconnected. If not, loosen the locknut and adjust the setscrew (01) at the front of the pot to obtain correct
holding action. The setscrew bears against the wrenches (03 and 07) to set the closed position of the wrenches.
Tighten locknut after adjustment.
01 02
n t
Y e 03
m
NL uip ion
O q t
L f E ra
04
02
I A o p e
ER ce O
t
AT nan en
05
M te m
E i n i p
C a q u
N
06
E r M E
R fo o r
FE E
07
f
E S S E
R U U
T T
O
N NO
R56426_02a
O
D DO
LEGEND
01. Setscrew and Nut
02. Wrench Pin (x2)
05. Threaded Spring Seat (x2)
06. Spring Seat (x2)
03. RH Wrench 07. LH Wrench
04. Spring (x2)
Figure 16-11: Pipe Wrenches and Liners

16.2.17 Replacing the Pipe Rack Liners
03
01
02
n t
Y e
m
NL uip ion
O q t
04 06
06
05
A L f E ra
I o e
07
R ce O p 08
E t
AT nan en
07
07
M te m
E p
09
C a q i n u i
N M E
10
RE o r r
E E f f o
E F S
06
E
11
R U U S
12
T T
O
N NO
13
O
D DO
14
06
12
LEGEND
01. Locknut 06. Tie Wire 11. Threaded Spring Seat (x2)
02. Arm Liner 07. Trough Liner (x3) 12. 2.25 Long Drilled-head Bolt
03. Bolt 08. 1.5 Long Drilled-head Bolt 13. Pipe Rack Liner - 5.25 Long
04. Liner Support 09. LH Wrench 14. Pipe Rack Liner - 8 Long
05. 1.25 Long Drilled-head Bolt 10. RH Wrench
Figure 16-12: Pipe Wrenches and Liners

16.2.18 Removing the Pipe Rack Upper Support Arm (Gate)
! WARNING
The rotating drill or its associated moving components can entrap and crush people,
resulting in severe injury, or death. Do not enter the drill string and mast area while the
drill is operating. Shut down the machine before performing inspections, service, or
maintenance. Establish a procedure to guard against inadvertent equipment operation
t
or movement while conducting inspections. Use lockout and tagout procedures prior to
conducting maintenance or service.
e n
Y m
NL uip ion
1. Disconnect, lock out and tag the power source that feeds the system to prevent power from being applied while
O q t
L f E ra
! WARNING
I A o p e
R ce O
Falls from elevated mast can cause severe injury or death. Always use fall protection
E
devices, such as the Saf-T-Climb system, when climbing the mast ladder. Do not attempt
t
AT nan en
to perform maintenance or service from the ladder with the mast elevated. Lower the
mast or use appropriate work platforms to perform maintenance or service to the mast
M te m
or mast components.
E i n i p
C a q u
E N M E
r r
The pipe rack and mast should be in the drilling position to perform repairs which allows better
R fo o
access to components. It also eliminates the possibility of the rack dropping from the stored
E E f
position. Remove components selectively for repair or replacement.
E F S E
S
2. Remove four cotter pins (21) and two sleeve pins (20).
R U U
T T
O
N NO
The gate arm support plate (02) is welded to the support arm (01).
O
D DO
3. Withdraw the support arm (01) assembly from the link sleeve (19).
The link (18) is welded to the sleeve (19).
4. If the sleeve (19) requires replacement, remove the pin (22) from the rod clevis (23) and link (18).
5. Tie or otherwise support the upper end of the pipe rack.

16.2.19 Cleaning, Inspecting and Repairing the Pipe Rack Upper Support Arm
Clean and inspect components in accordance with the general cleaning and inspection procedures in Appendix A
of this manual. Repair consists of the replacement of all worn or damaged components. Refer to the LinkOne elec-
tronic parts manual for replacement parts.
16.2.20 Installating the Pipe Rack Upper Support Arm
Refer to Figure 16-9. and install the components in the reverse order of removal. Note the following instructions.
1. After installation, check gate operation. Gate arm (01) should fully close. If necessary, loosen the jam nuts (24)
t
on both ends of the adjustment rod (25) and turn the adjustment rod to achieve these conditions.
e n
2. Start the drill and operate to verify operation of the gates and latches.
Y m
NL uip ion
16.2.21 Adjusting the Pipe Rack Upper Support Arm (Gate)
O q t
L f E ra
! WARNING I A o p e
ER ce O
t
AT nan en
M te m
E p
C a q i n u i
N
E r M E
R o r
E E !
f f o
E F S EWARNING
R U U S
T T
O
N NO
devices when climbing the mast ladder. Do not attempt to perform maintenance or ser-
vice from the ladder with the mast elevated. Use appropriate work platforms to perform
O
maintenance or service to the mast or mast components.
D DO
The pipe rack and mast should be in the drilling position to perform repairs which allows better
access to components. It also eliminates the possibility of the rack dropping from the stored
position. Remove components selectively for repair or replacement.
1. Refer to Figure 16-9. Loosen the jam nuts (24) on both ends of the adjustment rod (25) and turn the adjustment
rod so that the gate arm (01) will fully close.
2. Tighten the jam nuts and test support arm operation again. Repeat Step 1 if necessary.

16.2.22 Removing the Pipe Rack Upper Arm
! WARNING
t
e n
Y m
NL uip ion
O q t
L f E ra
! WARNING
I A o p e
R ce O
E
devices, such as the Saf-T-Climb system, when climbing the mast ladder. Do not attempt
t
AT nan en
to perform maintenance or service from the ladder with the mast elevated. Lower the
mast or use appropriate work platforms to perform maintenance or service to the mast
M te m
or mast components.
E i n i p
C a q u
E N M E
r r
The pipe rack should be in the drilling position to perform repairs which allows better access to
R fo o
components. It also eliminates the possibility of the rack dropping from the stored position.
E E f
Remove components selectively for repair or replacement.
E F S E
R U U S
2. Remove four cotter pins (21) and two sleeve pins (20). Withdraw the support arm (01) with gate arm support
plate (02) from the link sleeve (19).
T T
O
N NO
3. Remove one snap ring from pivot pin (22) and remove pivot pin while supporting the adjustment rod (25).
4. If necessary, remove the sleeve (19) from the pipe rack weldment (26).
O
D DO
5. Tie or otherwise support the upper end of the pipe rack.
! WARNING
Some drill components are extremely heavy. Dropping or mishandling of these parts can
cause severe personal injury or death, and damage to the equipment. Always support
assembly and installation. Provide appropriate support for any components which are
not supported by the machinery during any maintenance. The upper arm assembly
weighs approximately 260 lbs. (120 kg).

6. Remove capscrew (15) and lockwasher (16) to remove the upper rack pin (17).
7. While properly supporting the upper arm (06), loosen locknuts (14) and capscrews (07) to release tension on
the upper pin (05). Remove one retaining ring (06) and push out upper pin (05) from the upper arm (04).
Remove the upper arm (04).
Clean and inspect components in accordance with the general cleaning and inspection procedures in Appendix A
of this manual. Repair consists of the replacement of all worn or damaged components. Refer to the LinkOne elec-
tronic parts manual for component identification.

n t
Y e
m
Install the components in the reverse order of removal. Refer to Figure 16-9. Note the following instructions.
NL uip ion
1. Refer to Subtopic 16.2.22.6, for service instructions for the gate cylinder (29).
O q t
L f E ra
2. After installation, check gate operation. Gate arm (01) should fully close and limit switch (26) should trip with
I A e
the cylinder extended. Adjust the clevis on the cylinder rod to achieve these conditions.
R ce O o p
3. If a new gate link and sleeve assembly are to be installed, the clearance between the gate arm bearing and the
E t
AT nan en
sleeve should be 0.060" (1.5 mm). Refer to Figure 16-9. This dimension is set at assembly of the parts when
the sleeve assembly and gate arm are installed and clamped to dimension. Then the sleeve and arm can be
drilled to allow insertion of the roll pin. Hole size is ½” (12.7 mm).
M te m
E n i p
4. Start the drill and operate to verify operation of the gates and latches.
C a q i u
N
16.2.22.3 Pipe Holder and Swing Arm
E M E
! r WARNING
R fo o r
FE E f
E S S E
Dropping or mishandling of heavy drill parts may cause severe personal injury, or death.
R U U
Always move heavy components using the auxiliary winch or other suitable lifting device
T T
and rigging for removal and installation. Provide support for components which may
O
release or move during any maintenance.
N NO
Removal and Disassembly
O
D DO
The pipe rack should be in the drilling position to perform repairs which allows better access to components. It also
eliminates the possibility of the rack dropping from the stored position. The location and arrangement of the pipe
holder (pot), lower swing arm and related parts are shown on Figure 16-9. Remove components selectively for
repair or replacement. Refer to Figure 16-9 and proceed as follows:
! WARNING
The rotating drill or its associated moving components can entrap and crush people
resulting in severe injury or death. Do not enter the drill string and mast area while the

1. Disconnect, lock open, and tag the power source which feeds the system to prevent power from being applied
High-pressure hydraulic or air systems can spray with extreme force and noise causing
t
loosening fittings or connections. Wear appropriate face, ear, and body protective
n
Y e
m
NL uip ion
2. Remove the wrenches. Refer to Subtopic 16.2.16.
3. Remove the limit switch. Refer to Subtopic 16.2.23.
O q t
L f E ra
4. Tie or otherwise hold the bottom of the rack in position.
I A o p e
R ce O
5. Refer to Subtopic 16.2.22.6, for service instructions for cylinder (27).
E t
AT nan en
6. Remove capscrews (15) and lockwashers (16) to detach pins (36 and 42).
7. Loosen hex nuts (45) and capscrews (40), remove retaining rings (43), and push out pin (42). Remove arm
(46).
M te m
E i n i p
C a q u
8. Refer to Subtopic 16.2.22.4, for service instructions for the cylinder (35).
E N M E
r
R fo o r
E E f
Clean and inspect components in accordance with the general cleaning and inspection procedures described in
F E
Appendix A of this manual. Repair consists of the replacement of all worn or damaged components. Refer to the
E S S
LinkOne electronic parts manual for component identification.
R U U
T T
Assembly and Installation
O
N NO
Refer to Figure 16-9 and install the components in the reverse order of removal. Note the following instructions:
O
D DO
1. Refer to Subtopic 16.2.22.4, for service instructions for cylinder (35).
2. Confirm that all grease fittings (23) are installed.
3. Confirm that the mounting and air and hydraulic connections are secure.
4. Start the drill and check operation of the racks and confirm that all functions work properly.

16.2.22.4 Pipe Rack Swing Cylinder R10271D3
LEGEND
01. Seal Kit
02. O-ring
03. Back-Up Ring
04. Wear Ring
05. Rod Seal
06. Rod Seal
07. Rod Wiper
08. Back-Up Ring
t
09. O-ring
n
10. Piston Seal
e
11. Wear Ring
Y m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
Figure 16-13: Pipe Rack Swing Cylinder
E N M E
r
The pipe rack swing cylinder is a double-acting hydraulic cylinder with “rod eye and clevis type” mounting provi-
sions.
R fo o r
FE E f
E
Removal
E
R U U S S
T T
eliminates the possibility of the rack dropping from the stored position. Refer to Figure 16-9 and proceed as follows:
O
N N O ! WARNING
O
D DO
cause severe bodily injury and/or death. Lock out and tag the drill operating controls to
prevent accidental operation.
High-pressure hydraulic systems can spray with extreme force and noise causing

2. Tag and disconnect the hydraulic hoses from swing cylinder (35). Cap or plug hydraulic fittings to prevent con-
tamination of the hydraulic system.
3. Support swing cylinder (35). Remove capscrews (15) and lockwashers (16) and withdraw pins (36). Remove
the cylinder.
Disassembly
1. Loosen and back out the cylinder head with a spanner wrench.
n t
2. Remove the cylinder rod with head assembly and piston assembly from cylinder body.
Y e
m
3. Remove the piston and cylinder head assembly from the cylinder rod.
NL uip ion
4. Remove and discard O-rings (02) and back-up ring (03) from the head.
O q t
L f E ra
5. Remove and discard wear rings (04), and seals (05 and 06) and wiper (07) from inside of the head.
I A o p e
6. Remove and discard wear ring (11), seal (10), O-ring (09), and back-up rings (08) from the piston.
ER ce O
t
AT nan en
Clean and inspect the hydraulic cylinder components in accordance with the general cleaning and inspection pro-
M te m
cedures in Appendix B of this manual. None of the components are repairable, and must be replaced if worn or
E n i p
damaged. It is advisable to replace all parts in the seal kit whenever the unit is disassembled. Refer to the LinkOne
C a q i u
E N M E
r
Assembly
R fo o r
E E f
Lubricate all seals, O-rings, back-up rings and rod wiper with hydraulic oil prior to installation. Refer to Figure 16-13
F E
and proceed as follows:
E
R U U S S
1. Install new wear O-rings (02) and back-up ring (03) on the head.
T T
2. Install new wear rings (04), seals (05 and 06) and wiper (07) inside of the head.
O
N NO
3. Install new wear ring (11) and seal (10) on the piston.
O
D DO
4. Install new O-ring (09), and back-up rings (08) in the piston.
5. Install the assembled piston and cylinder head on the cylinder rod.
6. Install the cylinder rod with head assembly and piston assembly into the cylinder body.
7. Install the cylinder head with a spanner wrench.

1. Support swing cylinder (35) in position on the pipe rack and clevis.
2. Insert cylinder pin (36) into rack clevis and the head end of cylinder (35). Install capscrew (15) and lockwasher
(16) to secure the pivot pin.
3. Insert a second pivot pin (36) on the rod end of cylinder (35) as described in preceding step 2.
t
4. Connect the tagged hydraulic hoses to cylinder.
e n
5. Start up the drill hydraulic system and bleed the hydraulic system at the cylinder.
Y m
NL uip ion
6. Start the drill and confirm operation of the rack lower and retract action.
16.2.22.6 Pipe Rack Gate Cylinder

O q t
A L f E ra
e
I o p
eliminates the possibility of the rack dropping from the stored position. Refer to Figure 16-9 and proceed as follows:
R ce O
E t
1. If necessary, lower the affected pipe rack to the drilling position.
AT nan en
M te m
! WARNING
E i n i p
C a q u
N
cause severe bodily injury and/or death. lock out and tag the drill operating controls to
E M E
r
R fo o r
E E f
E F S E
R U U S
T T
High-pressure hydraulic systems can spray with extreme force and noise causing
O
N NO
O
D DO
3. Tag and disconnect the hydraulic hoses from gate hydraulic cylinder.
4. Plug and/or cap all hose assemblies and hydraulic fittings to prevent contamination of the hydraulic system.
5. Support cylinder (29). Remove the pivot pin from the cylinder clevis and the head end of cylinder. Remove the
attaching capscrews to detach the cylinder. Unscrew the clevis.
Clean and inspect the hydraulic cylinders in accordance with the general cleaning and inspection procedures in
Appendix B of this manual. Replace faulty cylinders.

The location and method of attachment is shown on Figure 13- 6. Assemble the cylinder and related hardware in
the reverse order of removal.
1. Support gate cylinder (29) in position on the pipe rack
2. Connect the tagged hydraulic hoses to the cylinder.
3. Start up the drill hydraulic system and bleed the hydraulic system at the cylinder.
t
4. Start the drill and check the operation of the rack gate and/or latch.
16.2.23 Limit Switches

e n
Y m
NL uip ion
O q t
A L f E ra LEGEND
I o e
01. Socket Head
R ce O p
Capscrew
02. Lock Washer
E t
03. Limit Switch
AT nan en
04. Mounting Base
05. Spring
M te m
06. Plunger
p
07. Roll Pin
E
C a q i n u i 08. Trip Bar
09. Roll Pin
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
Figure 16-14: Pipe Holder Limit Switch
D DO
There are three limit switches mounted on each pipe rack. If a fault or malfunction occurs that is related to the limit
switch functions, isolate the cause and locate the switch. Refer to Figures 16-9, and 16-14.
Inspect the applicable switch for loose mounting and loose or disconnected wires. Repair any faulty condition. If the
wiring is good, inspect the switch for damage, distortion and wear. For the pot switch also examine the spring (Item
05, Figures 16-14,) and plunger (06). Replace all worn or damaged parts.

! WARNING
cause severe bodily injury and/or death. Lock out and tag the drill operating controls to
2. Disconnect, lock out, and tag the power source which feeds the system to prevent power from being applied
3. Tag and disconnect the wiring from the limit switch.

n t
Y e
m
4. Remove the mounting hardware and related parts to detach the switch.
NL uip ion
5. Check the on-off switch functions with an ohmmeter while actuating the switch manually. Replace a switch that
does not operate properly.
O q t
A L f E ra
e
6. Install a new switch with the same hardware and related parts.
I
R ce O
7. Connect the wiring to the limit switch. o p
E t
AT nan en
8. Start the drill and check operation of the limit switch.
M te m
E i n i p
C a q u
E N M E
r
Table 16-1 provides basic guidelines to aid in the troubleshooting problems of the pipe handling equipment.
R fo o r
Problem
F E E f Possible Cause Remedy
Not Operate
E S
Deck Wrench Slide Does
S EBinding mechanism Clean and lubricate slide.
R U U lnspect slide and housing for gall-
T T
ing.Repair as required.
O
N NO
lnspect for internal jamming. Check parts
and repair as necessary.
O
D DO
Hydraulic control circuit malfunc-
tion
lnspect hydraulic lines for leaks and/or
loose connections. Repair any deficien-
cies.
Investigate control circuits for cause of

incorrect operation and repair any defi-
ciencies.
Refer to Section 9, Hydraulic System for
troubleshooting of the auxiliary hydraulic
system.
Hydraulic cylinder malfunction Repair or replace faulty cylinder.

Deck Wrench Pawl Does Binding mechanism Clean and lubricate the pawl mechanism.
Not Return to Extended
Position Galled retainer pin. lnspect parts and
repair as necessary.
Weak or broken compression lnspect spring for damage or breakage.

spring Repair faulty spring.
Pipe Rack Does Not Swing Binding mechanism lnspect upper and lower swing mecha-
Properly nisms for foreign materials. Remove any
debris.
n t Lubricate pivot pins.
Y e lnspect for broken or binding arm pivot
m
pins. Repair as required.
NL uip ion lnspect for distortion of arms and sup-
O q t
ports. Repair or replace parts as neces-
sary.
A L f E ra
I e
Hydraulic cylinder circuit malfunc- lnspect hydraulic lines to swing cylinder
tion
R ce O o p
for leaks and/or loose connections. Repair
any deficiencies.
E t
AT nan en
Investigate control circuits for cause of
incorrect operation and repair any defi-
M te m
ciencies. Refer to Section 9, Hydraulic
System for troubleshooting of the auxil-
E i n i p iary hydraulic system.
C a q u
N
Swing hydraulic cylinder malfunc- Repair or replace faulty cylinder.
E r M E tion
R
Pipe Rack Gate Does Not
fo o r
Gate mechanism out of adjust- Adjust mechanism linkage.
Operate Properly
FE E f ment
E S S E Binding gate mechanism. lnspect mechanism for broken or binding

pivot pins, rods, levers and rod ends.
R U U Repair or replace parts as required.
T T lnspect for broken or deformed latch com-
O
N NO
Pipe Rack Pot Wrenches Binding wrenches or pivot pins
pression spring. Replace faulty spring.
lnspect pot for foreign materials. Remove
O
D DO
Do Not Hold Pipe any debris.
Lubricate wrench pins.
lnspect wrench pins for galling. Replace

damaged pins.
Wrenches our of adjustment Adjust wrench position in pot.
Weak or broken wrench spring Replace faulty springs.
Worn wrenches Replace worn wrenches.
Table 16-1: Troubleshooting Guide (Continued)

320XPC-UDC Mechanical Systems Manual House Pressurization
Section 17
House Pressurization
17.1 General
t
This section provides the information required to repair and maintain the machinery house pressurization compo-
nents.
e n
Y m
NL uip ion
Refer to Figure 17-1. Two electric motor-driven blowers (01) provide air under slight positive pressure to the
machinery house. This causes air to flow outward through any house openings which helps keep dirt out.
O q t
Outside air is drawn in by the blowers, forced through filter assemblies and out into the machinery house. This
L f E ra
ensures that the pressurized air within the house is clean and fresh. Air flows through the house and is exhausted
A
I o e
to atmosphere through openings in the house.
R ce O p
E
The blowers and filters are installed in a sheet metal housing (02) that is attached to the mast support weldment
t
AT nan en
(03). The filters separate dust and entrained particles from the input air stream and allow the resulting clean air to
enter the machinery house while dropping the separated particulate out of the machine.
M te m
LEGEND
E i n i p
C a q
01. Pressurization Blower (2)
u 01
N M E
02. Filter Housing
E r
03. Mast Support Weldment
r
03
R
E E fo f o
E F S E
R U U S
T T 01
O
N NO
O
D DO
320_LF view2a
Figure 17-1: House Pressurization

Sec17HouseP.fm -17.1- Section 17, Version 00 - 07/12
House Pressurization 320XPC-UDC Mechanical Systems Manual
17.2 Inspect Machinery House Blowers And Filters

The following paragraphs describe the inspection and maintenance procedures that should be followed when ser-
vicing the machinery house blowers and filters.
Inspect the pressurization system as follows:
! WARNING
Inadvertent operation of the drill during maintenance on the machine could cause severe
t
bodily injury or death. Lock out and tag out the drill operating controls to prevent acci-
dental operation.
e n
Y m
NL uip ion
1. Lock out and tag out the drill operating controls to prevent inadvertent startup or movement of the drill during
O q t
2. Remove all debris from the air inlet passages.
A L f E ra
I o e
3. Check each blower motor mounting for security.
R ce O p
E
4. Check that the blower blades are not damaged.
t
AT nan en
5. Remove the inspection cover on top of the filter housing. Check the filters for accumulated dirt and debris. A
M te m
light coating of dust on the cells is normal and will not impair operation or efficiency of the filters. However, the
cell blades may accumulate a thicker deposit of surface dirt due to the sticky nature of some types of dust, or
E i n i p
the presence of oil mist or similar vapor in the outside air. When the accumulated deposit reaches a thickness
C a q u
of 0.125 inch (3.2 mm), the cell blades should be cleaned. (Refer to for filter removal and cleaning proce-
N M E
dures.)
RE o r r
E E f f o
E F S E
R U U S
T T
O
N NO
O
D DO

Section 17, Version 00 - 07/12 -17.2- Sec17HouseP.fm
01 02 03 LEGEND
01. Access Cover
02. Filter Packs
03. Filter Housing
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
R57583F1_02b
E i n i p
C a q u
E N M E
Figure 17-2: House Pressurization
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

01
n t 320_LF view2a
Y e
m
NL uip ion
LEGEND 10. Motor and Fan Assembly (2) 20. Filter support (4)
01. Shroud 11. Blower Support (4) 21. Air Deflector (2)
02. Air Filter Assembly (5-cell) 12.
O q t
Locknut (32) 22. Expanded Steel
L f E ra
03. Flange Head Screw (88) 13. Flange Head Screw (24) 23. Flange Head Screw (24)
A e
04. Locknut (96) 14. Blower Support Shim - 10 GA. 24. Flange Head Screw (8)
05. Access Cover (2)
06. Self-tapping Screw (12)
15.
I
R ce O
16. o p
Blower Support Shim - 16 GA.
Pressure Unit Base
25.
26.
Shroud
Lube Access Cover (2)
E
07. Shroud Support (2) 17. Filter Support Shim - 10 GA.
t
AT nan en
08. Transition Duct (2) 18. Filter Support Shim - 16 GA.
09. Flange Head Screw (24) 19. Flange Head Screw (8)
M te m
E i n i p
C a q u
Figure 17-3: House Pressurization System
E N M E
R o r o r
E E
17.3 Filter Housing Removal
f f
E F S E
R U U S
T T
O
N NO
O
D DO

01
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E n i p
320_LF view2a
LEGEND
C a q i u
10. Motor and Fan Assembly (2) 20. Filter support (4)
01. Shroud
E N M E
11. Blower Support (4) 21. Air Deflector (2)
r r
02. Air Filter Assembly (5-cell) 12. Locknut (32) 22. Expanded Steel
R fo o
03. Flange Head Screw (88) 13. Flange Head Screw (24) 23. Flange Head Screw (24)
04. Locknut (96)
FE E f 14. Blower Support Shim - 10 GA. 24. Flange Head Screw (8)
E
05. Access Cover (2) 15. Blower Support Shim - 16 GA. 25. Shroud
E S S
06. Self-tapping Screw (12) 16. Pressure Unit Base 26. Lube Access Cover (2)
R U U
07. Shroud Support (2) 17. Filter Support Shim - 10 GA.
08. Transition Duct (2) 18. Filter Support Shim - 16 GA.
T T
09. Flange Head Screw (24) 19. Flange Head Screw (8)
O
N NO
O
D DO
Figure 17-4: House Pressurizer
! WARNING
bodily injury or death. Lock out and tag out the drill operating controls to prevent acci-
dental operation.

17.4 Filter Cleaning
Use the following procedure to clean the filter elements:
! WARNING
t
n
e
Y
not supported by the machinery during any maintenance. The filter assembly weighs
m
NL uip ion
approximately 745 lbs (339 kg).
O q t
1. Gain access to the filters by removing the sheet metal which encloses them.
L f E ra
2. Refer to Figure 17-5 and loosen the nuts which hold the blade pack clamp bars in place. Then rotate the clamp
A
I o
bars 90 degrees and remove the bullnose strips.
p e
ER ce O
3. Refer to Figure 17-6 and pull each of the blade packs out of the cell.
t
AT nan en
4. Thoroughly clean the blade packs in a detergent or other similar non-oily solution.
M te m
E i n i p
C a q u
N M E
If the cleaning process removes paint from the blades, they should be repainted prior to installa-
E r r
tion.
R
E E fo f o
5. After cleaning and drying the filter blade packs, coat the outside surfaces of the channels to which the blades
F E
are welded and the inside surfaces of the channels into which each blade pack slides with grease. This grease
E S S
lubricates the edge of the blade pack for easier installation and serves as a seal to prevent air and dirt bypass.
R U U
T T
6. Check bleed ducts for dirt buildup and clean if necessary. The only maintenance possible on the motor/blower
O
assemblies is blower replacement, motor replacement, or replacement of the blower and motor unit as an
N NO
assembly.
O
D DO
When ordering replacement parts for the blower/motor assembly always give all information on
the blower data plate.

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
Figure 17-5: Filter Packs
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
Figure 17-6: Blade Pack

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

320XPC-UDC Mechanical Systems Manual Auxiliary Winch
Section 18
Auxiliary Winch
18.1 General
t
A hydraulic motor driven winch is mounted on the mast support assembly to lift loads on the drilling platform. It fea-
e n
tures a one-way clutch, so that the winch will hold a load, yet will automatically release when the load is hoisted.
Winch wire rope feeds through guide sheaves mounted on a support bar on the mast crown. A remote pendant
Y m
NL uip ion
control is located in a cabinet on the right hand jack housing.
O q t
L f E ra
01 LEGEND
A e
01. Auxiliary Winch
I
R ce O o p
02. Mast Lower Support Crossmember
E t
AT nan en
M te m
E i n i p
C a q u
E N M E 02
R o r o r
E E f f
F E
23U52D1
E
R U U S S Figure 18-1: Auxiliary Winch
T T
Winch lifting capacity is based on an operating pressure of 2,000 psi (138 bar) and the number of wraps of 0.625
O
N NO
diameter wire rope on the drum (refer to Table 18-1, below).
O
D DO No. of Wire Rope Lifting Capacity
Wraps on Drum lbs. (kg)
0 16,360 (7436)
1 15,640 (7110)
2 13,820 (6282)
3 12,360 (5620)
Table 18-1: Auxiliary Winch Lifting Capacity

Sec18AuxWinch.fm -18.1- Section 18, Version 00 - 07/12
Auxiliary Winch 320XPC-UDC Mechanical Systems Manual
18.2 Winch Removal

1. Remove the clamps, hook and thimble from the end of the winch wire rope.
2. Tie one end of a 200 foot (30 meter) nylon, poly, or hemp line to the free end of the wire rope. Fasten the other
end of the line to the mast frame at a convenient point. This line will be used to pull the winch wire rope back
through the sheaves when the winch is reinstalled.
3. Operate the winch to rewind the wire rope onto the drum, allowing the wire rope and line to pass over the guide
sheaves and down to the drill deck. Fasten the wire rope to the drum to prevent unspooling. Untie the line and
fasten the end to the mast frame at a convenient point.
n t
WARNING
e
!
Y m
NL uip ion
O q t
L f E ra
A
I o e
R ce O p
E t
AT nan en
M te m
5. Be prepared to catch excess hydraulic oil when the hose connections are loosened. Tag and disconnect the
p
hydraulic hoses and fittings from the winch motor and brake housing. Cap or plug all hoses and motor ports to
E i n i
prevent undesired drainage and contamination of the hydraulic system. Refer to Appendix B for information on
C a q u
the hydraulic connections. Refer to Figure 18-2 for hydraulic hose routing.
E N M E
R o r o r
E E f f
LEGEND
F
01. Hydraulic Motor
01
E S S E 02. Winch Hook “Down” Hose
R U U
03. Winch Hook “Up” Hose
04. Winch Drain Hose
T T
O
N NO
02
03 O
D DO 04
23U52D1a
Figure 18-2: Auxiliary Winch Hose Connections

Section 18, Version 00 - 07/12 -18.2- Sec18AuxWinch.fm
! WARNING
not supported by the machinery during any maintenance. The auxiliary winch without
wire rope installed weighs approximately 745 lbs (339 kg).
6. Remove the capscrews and washers that attach the winch to the crossmember. Remove the auxiliary winch.
n t
7. Note the direction that the wire rope is wound on the winch drum. Remove the wire rope from the winch drum if
necessary.
Y e
m
NL uip ion
If components of the winch require repair, refer to the following component repair instructions as necessary:
Winch Motor Repair - Subtopic 18.4

O q t
A L f E ra
I o e
Winch Brake Repair - Subtopic 18.5
R ce O p
E
Winch Final Drive Repair - Subtopic 18.6
t
AT nan en
Winch Primary Drive and Drum Repair - Subtopic 18.7
M te m
E i n i p
18.3 Winch Installation
C a q u
E N ! M E
R fo for r
WARNING
E
F SE E
E
R U US
T T
O
N NO
not supported by the machinery during any maintenance. The auxiliary winch without
wire rope installed weighs approximately 745 lbs (339 kg).
O
D DO
1. Position the winch on the crossmember. Check the mounting surface for unevenness. Be sure that all four
mounting pads contact the mounting surface. If not, one pad should be shimmed to compensate. Install three
mounting capscrews and lockwashers. Measure the space underneath the fourth pad with a feeler gauge and
install shim stock of corresponding thickness with the capscrew and lockwasher.
2. Install the hydraulic hoses and fittings in accordance with the identification tags previously attached. Refer to
Figure 18-2, if necessary.
3. Be sure that the planetary is filled with lubricant. Refer to the lubrication section.
4. Start the drill and operate the winch to bleed air from the hydraulic circuit. Check for flow through the return line
when the winch is run in reverse to make sure that oil is being circulated through the brake. If not, investigate
the hydraulic circuit for the cause of malfunction and correct the problem.

5. Pull the wire rope through the mast sheaves using the temporary reeving line. Secure the free end of the wire
rope to the mast to prevent it from being pulled too far through the sheaves. Leave enough length of wire rope
to enable attachment to the winch drum.
! WARNING
bodily injury and/or death. Lockout and tagout the drill operating controls to prevent
accidental operation.
t
e n
7. Remove the temporary reeving line. Install the hook and thimble with clamps on the free end of the wire rope.
Y m
NL uip ion
! WARNING
O q t
L f E ra
Use the slot for clockwise rotation. Do not use the slot for counter-clockwise rotation.
A
The slots are marked. If the wire rope is wound onto the drum for counter-clockwise rota-
I o p e
tion, the winch will not have any braking. This could result in uncontrolled lowering of a
R ce O
load, resulting in personal injury and property damage. Be sure that the wire rope is
E t
AT nan en
installed into the slot (02, Figure 18-3) for clockwise forward rotation (clockwise when
looking at the motor end of the winch).
M te m
E i n i p
C a q u
E N M E
LEGEND
r r
01 01. Cable Anchor (shown enlarged for clarity)
R fo o
02. Cable Anchor Slot for Clockwise Hoisting*
FE E f
E
* Do not use the cable anchor slot on the
E S S
opposite side of the drum - it is used only
R U U
for counter-clockwise hoisting winches.
T T
O
N NO
O
D DO 02
BD1093a01
Figure 18-3: Wire Rope Installation
8. Detach the other end of the wire rope. Wrap the wire rope around the cable anchor and pull the anchor firmly
into the slot in the winch drum.
9. Operate the winch to wind the wire rope onto the winch drum. The wire rope will wind around the drum in the
proper direction. The drum should always have at least five wraps around the drum to be sure that the rope
does not come off the drum.

18.4 Winch Motor Repair

Refer to Figure 18-4. Motor repair requires removal of the motor from the winch motor adapter (21).
18.4.1 Removal And Disassembly
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15
n t
Y e
m
NL uip ion
O q t
L f E ra
01
I A o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u BD1093a01
16 17 18 19
E N 20
M E
21 22 23 24 25 26 27 28 29 30
R o r o r
f
LEGEND 16. Circulation Valve
FE E
01. Motor Drive Shaft
f 17. 1/8 NPT Pipe Plug (3)
E
02. Circlip 18. 1/4 NPT Pipe Plug
E S S
03. Shuttle 19. Lockwasher (8)
R U U
04. O-ring (3) 20. Hex Head Capscrew (8)
05. 1/8 NPT Cap Plug 21. Motor Adapter
T T
06. 1/8 NPT Pipe Plug 22. Bushing (4)
O
N NO
07. Seal - Gasket (2) 23. Seal - Backup (2)
08. Seal - SIde Channel (4) 24. Dowel Pin (4)
09. Gear Housing 25. Seal - End Channel (4)
O
D DO
10. Thrust Plate (2) 26. O-ring
11. Gear Set 27. Plug
12. Cover - Port End 28. Cap Plug - Plastic
13. 3/8 NPT Pipe Plug 29. 1/4 NPT Pipe Plug (2)
14. Hex Head Capscrew (4) 30. Motor Seal Kit (Includes Items 07, 08, 23, and 25)
15. Washer (4)
Figure 18-4: Auxiliary Winch Motor
1. 1. Remove four capscrews (14) and washers (15) from the motor housing.

When removing parts by prying, take care not to damage the machined surfaces of the parts.
2. Remove the end cover (12) together with two bushings (22). Two dowel pins (24), which are hollow to allow the
capscrews to pass through, will remain in either the cover or the gear housing.
3. Remove the matched gear set (11) from the gear housing (09). As the gears set is removed, the thrust plate
(10), two end seals (25), two side seals (08) and a backup seal (23) will also come off. Discard the seals.
t
4. Carefully pry off the gear housing (09) from the motor adapter (15). Use care to avoid damage to the splined
n
shaft (01) and gear bore. As the housing is removed, the thrust plate (10), two gasket seals (07), two end seals
e
(25), two side seals (08) and a backup seal (23) will also come off. Discard the seals. Leave the dowel pins
Y m
(24) in place.
NL uip ion
O q t
A L f E ra
The seal kit for the winch does not include the seals required to repair the motor. A separate
I o p e
seal kit is required. Refer to your LinkOne parts manual for ordering details.
ER ce O
t
AT nan en
18.4.2 Cleaning, Inspection and Repair
Clean and inspect parts as specified in Appendix A. Replace all worn and/or damaged parts. Replace all seals
using the motor seal kit.
M te m
18.4.3 Assembly and Installation E i n i p
C a q u
E N M E
r r
E ER
1. Apply grease to all seals.
fo f o
E F S E
S
2. Install two new end seals (25) and two new side seals (08) into openings in thrust plate (10).
R U U
T T
3. Install a new backup seal (23) over the top of the side and end seals with the tabs facing toward the thrust
O
plate.
N NO
4. Place the thrust plate assembly onto motor adaptor (21) with the backup seal (23) against the motor adaptor.
O
D DO
5. Install the gear set (11) into the bushings (22) in the motor adapter. The gear with internal splines engages with
motor drive shaft (01).
6. Install a gasket seal (07) on each side of the gear housing (09). Slide the gear housing, together with the gas-
ket seals, onto the motor adaptor (21) and two dowel pins (24). Tap the housing on tight using a soft faced
hammer.
7. Install the other thrust plate (10), complete with seals (25), (08), and (23), against the gear set. Make sure the
tabs on the backup seal (23) are facing outward toward the end port cover (12).
8. Install the port end cover (12) together with two bushings (22) onto the gear housing (09) and two dowel pins
(24). Tap the cover on tight using a soft faced hammer. Install four washers (15) capscrews (14), Torque the
capscrews to approximately 50 ft-lb (70 Nm).

18.5 Winch Brake Repair
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en F4291a
M te m
E n i p
LEGEND 12. Friction Plate (6) 39. Snap Ring

C a q
01. Hydraulic Motor w/Adapter
i 13.
14.
u
Brake Spacer
Snap RIng
40.
41.
Hex Head Capscrew (16)
Lockwasher (26)
03. Lockwasher (8)
E N M E
15. Clutch Aligner 42. Hex Head Capscrew (10)
r r
04. O-ring (3)* 16. Brake Hub
R fo o
05. Snap Ring 17. Sprag Clutch
F E E
06. Motor Drive Shaft
f 18. Sprag Clutch Aligner * Winch Seal Kit (Not SHown):
E
07. O-ring* 32. Brake Housing Includes Items 04, 07, 10, 33,
E S S
08. Brake Spring (10) 33. O-ring* and 38 for the brake assembly
R U U
09. Piston 34. Base Plate
10. O-ring* 36. Connecting Shaft
T T
11. Divider Plate (7) 38. Oil Seal*
O
N NO Figure 18-5: Auxiliary Winch Brake Components
O
D and O
18.5.1 Removal
D Disassembly
If the motor (01) does not require repair, do not remove it from the motor adapter. For motor
repair, refer to Subtopic 18-4.

! WARNING
The brake springs (08) are under considerable tension against the motor adapter.
Loosen the eight motor adapter-to-brake housing capscrews (02) one turn at a time, in
sequence, until the spring pressure is relieved. Failure to head may result in severe per-
sonal injury or death.
1. Observe the warning above and loosen the eight capscrews (02). Then, remove the capscrews (02) and lock-
washers (03) to remove the winch motor and adapter from the brake housing.
t
2. Remove and discard O-rings (04 and 33). The three O-rings (04) seal the pressure transfer holes for the auto-
n
matic brake release and are located between the brake housing and motor adapter.
Y e
m
3. Remove the ten brake springs (08).
NL uip ion
O q t
A L f E ra
e
The piston (09) is provided with two 5/8-11NC threaded holes on the piston face for removal
using a standard puller.
I
R ce O o p
E t
AT nan en
4. Pull the piston (09) from the brake housing (32). Remove and discard O-rings (07 and 10) from the piston.
M te m
E i n i p
C a q u
In Step 5, the friction (12) and divider (11) plates might remain in the brake housing
E N M E
r
5. Pull the drive shaft (06) together with the complete brake hub assembly (items 11, 12, 14 through 18, and 39)
R o
from the brake housing (32).
f o r
FE E f
E
6. Remove the snap ring (39) from the end of the motor drive shaft (06).
E
R U U S !S WARNING
T T
O
N NO
Minor scratches or other surface defects where the sprag clutch engages the motor
drive shaft and brake hub will result in brake failure and allow the load to drop. Be very
O
careful when removing the sprag clutch (17) and sprag clutch aligners (15 and 18) from
D DO
the brake hub (16) to prevent scratches or nicks. Failure to head may result in severe
personal injury or death.
7. Remove the motor shaft (06) from the sprag clutch aligners (15 and 18) and sprag clutch (17).
8. Remove the sprag clutch aligners (15 and 18) and sprag clutch (17) from the brake hub (16).
9. If the six friction plates (12) and seven divider plates (11) remained in the brake housing, remove them and the
brake spacer (13) from the brake housing (32).
10. Remove and discard the oil seal (38) from the connecting shaft (35). The connecting shaft will remain inside
the brake housing.

Do not remove the brake housing (32) unless repair of the drum (54) is required. Refer to Sub-
topic 18.7, Winch Drum Repair.
! WARNING
t
Minor scratches or other surface defects where the sprag clutch engages the motor
n
drive shaft and brake hub will result in brake failure and allow the load to drop. Inspect
e
Y
the sprag clutch (17), sprag clutch aligners (15 and 18) brake hub (16) for scratches and
m
NL uip ion
surface defects. If any are found, replace the motor drive shaft, sprag clutch and brake
hub as a set. Failure to head may result in severe personal injury or death.
O q t
! WARNING
A L f E ra
I o p e
R ce O
Damaged divider or friction plates (11 and 12) will reduce braking capacity and allow the
E
load to drop. Inspect the divider and friction plates for damage. If any damage is found,
t
AT nan en
replace the divider or friction plates as a set. Failure to head may result in severe per-
sonal injury or death.
M te m
E n p
1. Clean and inspect parts as specified in Appendix A.
C a q i u i
2. Replace all seals and O-rings using the winch seal kit. Replace all scored, worn and/or damaged parts (see
Warnings, above).
E N M E
R o r o r
f f
3. If the outside diameter of the piston is scratched, polish it with fine emery cloth. Wash the piston thoroughly
after polishing.
F E E
E S S E
4. Inspect the ten brake springs (08) for damage and measure the overall length. The free length of a new spring
R U U
is 2.27 in. (57.7 mm). If any spring is less than 2.21 in. (56.1 mm), replace all ten springs as a set.
18.5.3 Assembly andT T

N NO O
Installation
O
D DO
1. Apply grease liberally to new seals and O-rings during assembly.
2. If removed, install the snap ring (14) on the motor shaft (06) as shown.
3. Install the sprag clutch (17) in the bore of the brake hub (16). The clutch must be positioned so that when
viewed from the motor end, the drive shaft (06) will turn freely in the clockwise direction and lock in the counter-
clockwise direction.
4. Position the sprag clutch aligners (15 and 18) on each side of the brake hub (16). Carefully slide the motor
drive shaft (06) into hub and sprag clutch assembly until bottomed against the snap ring (14). Install the snap
ring (39) to secure the assembly on the drive shaft.

5. Install a new oil seal (38) in the bore of the connecting shaft (35).
6. Install the brake spacer (13).
! WARNING
Incorrect assembly of the divider and friction plates (11 and 12) will reduce braking
capacity and allow the load to drop. Assemble the divider and friction plate stack follow-
ing the procedure in Step 6. Failure to head may result in severe personal injury or death.
t
7. Starting and finishing with a divider plate (11), alternately install seven divider plates and six friction plates (12)
n
into the brake housing (32).
Y e
m
8. Carefully install the motor drive shaft and complete brake hub assembly into the brake housing while alinging
NL uip ion
the brake hub splines with the friction plate splines.
O q t
9. Apply grease to O-rings (07 and 10) and install them on the piston (09).
A L f E ra
10. Install the brake piston assembly in the brake housing (32) so that the spring holes facing outward.
I o p e
R ce O
11. Install the ten brake springs (08) into the piston as shown in Figure 18-6. There are sixteen holes for the
E t
springs, but only ten are used.
AT nan en
M te m 01
p
LEGEND 02
01. Brake Piston
E
C a q i n u i
02. Brake Springs Installed (10 total)
N M E
03. Empty Holes (6 total)
RE o r r
E E f f o
E F S E
R U U S
T T
O
N NO
03
O
D DO
BD1146a01
Figure 18-6: Brake Spring Arrangement in Piston
12. Apply grease to O-rings (04 and 33) and install. The three O-rings (04) should be installed in the recesses on
the motor adapter.
13. Slide the winch motor and adapter over the drive shaft (06) making sure that the splines on the motor drive
shaft and the pump gear engage and that the pressure transfer holes and brake spring holes are all aligned.
Install the eight capscrews (02) and lockwashers (03) to attach the winch motor and adapter to the brake hous-
ing (32). Tighten the capscrews evenly one turn at a time in a cross sequence to compress the brake springs
until the adapter is fully in place.

18.6 Winch Final Drive Repair
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
F4291b
C a q u
N M E
LEGEND 61. Pipe Plug (2) 73. Snap Ring (3)
E r
34. Base Plate 62. End Cover 74. Snap Ring
R fo
o r 63. O-ring 75. Sungear
E E f
41. Lockwasher (13) 64. Breather Relief 76. Retaining Ring
F
42. Hex Head Capscrew (5) 65. Planet Hub Stopper
E
55. Tie Bar (2)
S
54. Cable Drum (Reference)
S E 66.
67.
Sungear Stopper
Planet Hub * Winch Seal Kit (Not Shown):
R U U
56. Final Drive Housing 68. Snap Ring (3) Includes Items 57 and 63 for
T T
57. Oil Seal 69. Planet Pin (3) the final drive assembly
O
58. Ball Bearing 70. Thrust Washer (6)
N NO
59. Snap Ring 71. Planet Gear (3)
60. Retaining Ring 72. Loose Rollers (66)
O
D DO Figure 18-7: Auxiliary Winch Final Drive Components
18.6.1 Removal and Disassembly
1. Remove both pipe plugs (61) and drain the oil from the planetary and drum interior. Tip the unit at an angle to
drain all oil from the drum.
2. Remove the internal retaining ring (60), end cover (62) and O-ring (63). Discard the O-ring.
3. Remove the planet hub stopper (65) and sungear stopper (66).

4. Remove the planet hub assembly from the final drive housing (56).
5. To remove any of the three planet gears (71), remove snap rings (68 and 73) and press the planet pins (69)
from the planet hub (67). Slide the planet gears with the twenty-two needle bearings (72) and two thrust wash-
ers (70) out of the planet hub.
6. Remove the final sungear (75) from cable drum (54).
7. Remove eight capscrews (40) and lockwashers (41) to disengage the tie bars (55) from the final drive housing
(56).The five capscrews (42) and lockwashers (41) do not have to be removed unless the final drive housing
or base plate (34) needs to be repaired or replaced.
n t
8. Remove the snap ring (74). Using two pry bars inserted between the flange of cable drum (54) and final drive
e
housing (56), carefully pry the drum off of the ball bearing (58).
Y
L ip nm
9. Remove the snap ring (59) and pull the ball bearing (58) from the final drive housing (56). Remove and discard
N
O qu tio
the oil seal (57).
L f E ra
I A o p e
Clean and inspect parts as specified in Appendix A. Replace all seals and O-rings using the winch seal kit. Replace
all scored, worn and/or damaged parts.
ER ce O
t
AT nan en
1. Inspect the planet hub stopper (65) and sungear stopper (66) for excessive wear. Replace a stopper if its thick-
ness is less than 0.21 in. (5.3 mm) or if it is damaged.
M te m
E n i p
2. Inspect the two thrust washers (70) and sixty-six loose rollers (72) for excessive wear or damage. Replace
C a q i u
excessively worn or damaged washers. If the rollers are damaged or excessively worn, replace them as a set.
E N M E
r
R fo o r
E E f
F
E S S E
1. Install a new oil seal (57) in the final drive housing (56).
R U U
T T
2. Press the ball bearing (58) into the final drive housing (56). Install the snap ring (59) to secure the bearing.
N NOO
3. If removed, assemble the final drive housing (56) to the base plate (34) using five capscrews (42) and lock-
washers (41).
O
D DO
4. Align the cable drum (54) with the ball bearing (58). Apply pressure to the bearing inner race to press the drum
and bearing into place. Install snap ring (74) to secure the drum.
5. Install the sungear (75) in the drum (54).
6. Install the twenty-two loose rollers (72) into the planet gear (71). Use grease to hold the rollers in place.
7. Slide the planet gear (71) with loose rollers (72) and two thrust washers (70) into the planet hub (67). Align the
bores and press the planet pin (69) into place. Install two snap rings (68 and 73) to secure the pin.
8. Repeat Steps 6 and 7 for the other two planet gears.
9. Install the planet hub assembly into final drive housing (56).

10. Install the planet hub stopper (65) and sungear stopper (66) into the end cover (62).
11. Coat the O-ring (63) with grease and install in the groove in end cover (62).
12. Install the end cover (62) with O-ring (63) on the final drive housing (56) and secure with internal retaining ring
(60).
13. Fill the winch final drive housing with oil. Refer to Subtopic 12.2.3.
14. Install both pipe plugs (61).
n t
e
18.7 Winch Primary Drive and Drum Repair
Y m
NL uip ion
18.7.1 Removal and Disassembly
O q t
A L f E ra
I o p e
R ce O
The brake and final drive components must be removed before the drum can be disassembled.
E
Refer to Subtopic 18.5 and Subtopic 18.6 to remove these components.
t
AT nan en
M te m
1. Remove the remaining four capscrews (40) and lockwashers (41) from both tie bars (55) and remove the tie
bars from the assembly.
E i n i p
C a q u
N M E
2. Using a 1/2 inch capscrew [one of the motor adapter mounting capscrews (02, Figure 18-4) will work], remove
E r
the access plug (26) and O-ring (25) from the brake housing (32). Discard the O-ring.
R fo o r
E E f
3. Remove the eight capscrews (31) and lockwashers (30) from the bearing flange (29) by rotating the brake
F E
housing (32) until the access hole is over the top of them. After all eight capscrews are removed, remove the
E S S
cable drum (54) from the brake housing and primary planet hub assembly.
R U U
T T
4. Remove the internal retaining ring (20) from the inside of the internal gear (21).
O
N NO
5. Remove the primary planet hub assembly from the internal gear (21).
O
D DO
6. If any or all three of the primary planet gears (50) need to be removed, remove the snap rings (43 and 51) from
the planet pin (44) and press the planet pin out of the primary planet hub (47). Then, remove the primary planet
gear (50) together with twenty loose rollers (49) and two thrust washers (48) from the primary planet hub (47).
7. Remove the primary sungear (45) from the center of connecting shaft (35).
8. Remove the snap ring (19) from the end of the connecting shaft (35) and remove the internal gear (21) and
spacer (22) from the spline on the connecting shaft.
9. Remove the connecting shaft (35) from the brake housing (32). Remove and discard the O-ring (36).
10. Inspect the needle bearing (37) and remove and replace if necessary.

11. To separate the bearing flange (29) from the brake housing (32) use a standard bearing puller or insert two pry
bars in the slot between the bearing flange and the brake housing and pry the brake housing off of the ball
bearing (24).
12. Remove the internal snap ring (23) to remove the ball bearing (24) from the bearing flange (29).
13. Remove and discard oil seal (27) and O-ring (28).
LEGEND
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S F4291c
T T
O
LEGEND 34. Base Plate 51. Snap Ring
N NO
9. Snap Ring 35. Connecting Shaft 52. Cable Anchor
20. Retaining Ring 36. O-ring* 53. Pipe Plug
O
21. Internal Gear 37. Needle Bearing 54. Cable Drum
D DO
22. Spacer 38. Oil Seal * % 55. Tie Bar (2)
23. Snap Ring 40. Hex Head Capscrew (8)
24. Ball Bearing 41. Lockwasher (13) * Winch Seal Kit (Not Shown):
25. O-ring* 42. Hex Head Capscrew (5) Includes Items 25, 27, 28, 33,
26. Access Plug 43. Snap Ring (3) and 36 for the primary drive
27. Oil Seal* 44. Primary Planet Pin (3) and drum assembly
28. O-ring* 45. Primary Sungear % Removed in the brake repair
29. Bearing Flange 46. Primary Sungear Stopper procedure
30. Lockwasher (8) 47. Planet Hub
31. Hex Head Capscrew (8) 48. Thrust Washer (6)
32. Brake Housing 49. Loose Rollers (60)
33. O-ring * % 50. Planet Gear (3)
Figure 18-8: Auxiliary Winch Primary Drive and Drum Components

Clean and inspect parts as specified in Appendix A. Replace all seals and O-rings using the winch seal kit. Replace
all scored, worn and/or damaged parts.
1. Inspect the primary sungear stopper (46) for damage or excessive wear.
2. Inspect the thrust washers (48) and loose rollers (49) for excessive wear. Replace excessively worn or dam-
aged parts.

n t
Y e
m
NL uip ion
1. Install the twenty loose rollers (49) into the planet gear (50). Use grease to hold the rollers in place.
2. Slide the planet gear (50) with loose rollers (49) and two thrust washers (48) into the planet hub (47). Align the
O q t
bores and press the planet pin (44) into place. Install two snap rings (43 and 51) to secure the pin.
A L f E ra
I o e
3. Repeat Steps 1 and 2 for the other two planet gears.
R ce O p
E
4. Apply grease to a new oil seal (27) and press it into the bearing flange (29).
t
AT nan en
5. Press the ball bearing (24) into the bearing flange (29). Install the snap ring (23) into the bearing flange to
secure the bearing.
M te m
E i n i p
6. Press the bearing flange assembly unto the hub on the brake housing (32).
C a q u
N M E
7. Apply grease to O-ring (28) and install it on the bearing flange assembly.
RE o r r
8. If removed, install the needle bearing (37) into the connecting shaft (35).
E E f f o
F E
9. Apply grease to a new oil seal (38) and press it into the connecting shaft (35).
E
R U U S S
10. Apply grease to O-ring (36) and install it on the connecting shaft (35).
T T
11. Slide the connecting shaft assembly into the brake housing (32).
O
N NO
12. Place the spacer (22) on the shoulder of the internal gear (21) and then slide the internal gear assembly onto
O
the connecting shaft spline. Install the snap ring (19) onto the connecting shaft to secure the internal gear and
D DO
spacer.
13. Install primary sungear stopper (46) in the recess in the planet hub (47).
14. Slide the primary planet assembly (assembled in Steps 1 through 3 and 13) with the primary sungear stopper
(46) installed into the internal gear (21) while making sure the three primary pinion gears (50) mesh with the
splines on the internal gear (21).
15. Slide the primary sungear (45) through the internal gear and connecting shaft assembly while making sure the
splines on the primary gear (45) mesh with the three primary pinion gears (50).
16. Install the internal retaining ring (20) into the internal gear (21) to secure the planet assembly.

17. Position the cable drum (54) on the primary planet hub and brake drum assembly. Working through the the
access hole in the brake housing, line up each threaded hole in the cable drum with a mounting hole in the
bearing flange and install a capscrew (31) and lockwasher (30) until all eight capscrews are installed.
18. Lightly lubricate and install a new O-ring (25) on the access plug (26). Using a 1/2 inch capscrew, install the
access plug into the brake housing (32).
19. If removed, install five capscrews (42) and lockwashers (41) to attach the base plate (34) to the brake drum
housing (32).
20. Assemble and install the final drive components. Refer to Subtopic 18.6.3.
n t
21. Assemble and install the brake components. Refer to Subtopic 18.5.3.
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22. Install the remaining four capscrews (40) and lockwashers (41) to attach each tie bar (55).
NL uip ion
O q t
A L f E ra
Make sure the winch is filled with oil before operating. Refer to Subtopic 12.2.3.
I o p e
ER ce O
t
AT nan en
18.8 Auxiliary Winch Sheaves
M te m
E n i p
LEGEND
C a q i u
01. Bearing Retainer (4)
N
02. Bearing (4)
M E
03. Sheave (2)
R E o r r
04. Lock Pin
f o
05. Lockwasher (2)
F E E f 06. Tie Wire
E
07. Capscrew (2)
E
R U U S S
T T
O
N NO
O
D DO F4899C_a
Figure 18-9: Auxiliary Winch Sheaves
The two removable sheaves (03, Figure 18-9) for the auxiliary winch wire rope are installed at the ends of a support
on top of the mast crown block. The support and one sheave are extended beyond the rear side of the mast so that
the wire rope drops just behind the drilling centerline.

18.8.1 Removal
Lower the mast to its horizontal position to gain access to the mast crown block and sheaves.
To remove the sheaves without first removing the wire rope, place steel rods under the wire
rope and clamp them in position on the sheave support. This will hold the wire rope in place,
n t
and away from the sheaves, so that they can be removed. Do not clamp the wire rope in a
e
working section; this can cause rope damage, crushing, or kinking.
Refer to Figure 18-9 and proceed as follows: Y

L ip nm
N
! WARNING O qu tio
A L f E ra
I o p e
R ce O
E t
AT nan en
1. Lock out and tag out the drill operating controls to prevent inadvertent startup or movement of the drill during
M te m
E i n i p
C a q u
2. To remove a sheave, remove the tie wire (06) from the head of the capscrew (07).
E N M E
r
3. Remove the capscrew (07) and lockwasher (05). Support the sheave and then withdraw the lock pin (04) to
R o r
remove the sheave assembly (03 and 02) and bearing retainers (01) from the lock pin.
f o
F E E f
E
4. Remove the bearings (02) from the sheave.
E
R U U S
18.8.2 Cleaning, Inspection, S
and Repair
T T
O
Clean and inspect the sheave components in accordance with the general cleaning and inspection procedures
N NO
described in Appendix A of this manual. Sheave repair consists of the replacement of all worn or damaged compo-
nents. See the LinkOne electronic parts manual for component identification.
O
D DO
18.8.3 Installation
1. Install the two bearings (02) in the sheave (03).
2. Support the sheave and position it in the crown block support.
3. Insert the lock pin (04) through the support holes, bearing retainers (01 - one on each side of the sheave) and
sheave assembly.
4. Install the capscrew (07) and lockwasher (05) to secure the pin (04). Secure the capscrew with the tie wire
(06).

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NL uip ion
O q t
A L f E ra
I o p e
ER ce O
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AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

320XPC-UDC Mechanical Systems Manual Cab Climate Control
Section 19
Cab Climate Control
19.1 Mine Air Climate Control System
t
The Mine Air Systems SERIES MAS-1500 climate control unit is made of all stainless steel construction and
modular design.
e n
designed for deck mounting as shown in Figure 19-1. Easy access to all unit components is maintained through
Y m
NL uip ion
O q t
L f E ra
The units’ modular engineering design, makes it imperative that repairs are accomplished in
A
I o e
keeping with the original design, and that wiring, components, and circuitry are kept in original
R ce O p
format. Contact your local P&H MinePro representative with any questions regarding unit main-
E
tenance or repair.
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
Figure 19-1: Mine Air Climate Control Unit
The pressurizer unit filters and forces pressurized air into the re-circulated air stream.
The Mine Air unit may be serviced using a personal AC800 control system interface which plugs into the operator
control station for troubleshooting and diagnoses. Once the location of a fault is known, the module design allows
control modules to be changed out in 10 minutes and the problem corrected elsewhere with no down-time on the
equipment.

Sec19AirCond.fm -19.1- Section 19, Version 01 - 07/12
Cab Climate Control 320XPC-UDC Mechanical Systems Manual
19.1.1 Installation
Call your local P&H MinePro representative for installation of your Mine Air Climate Control unit.
The success of your Mine Air System depends on the consistency of installation and on-going
service and maintenance. Do not alter any aspect of the system without calling your local P&H
MinePro representative first.
! WARNING
n t
Y e
m
NL uip ion
drop, resulting in personal injury, death and/or damage to equipment. Use suitable
slings and hoisting equipment to stabilize and lift heavy objects. The air conditioner
O q t
assembly weighs approximately 750 lbs (341 kg).
A L f E ra
I o p e
ER ce O
t
AT nan en
For lifting the air conditioner assembly, use a spreader bar and lifting straps.
M te m
19.1.2 Function
E i n i p
The basic unit is built in two separate modules that are joined together to form the complete package. The two
C a q u
modules are the compressor/condenser module, and the evaporator/heater module. The unit is equipped with a
N M E
scroll compressor and has a built-in pressurizer (blower).
E
R o r o r
f
Basic filtration is provided for the circulating air. This filter system is built into the return air housing, and is designed
E E f
to remove common airborne dust particulates from the recirculated air.
F
E S S E
Make-up air provided by the pressurizer is filtered on the suction side of the pressurizer by a multi-stage filter. The
R U U
first stage is a cyclonic separator designed to remove the larger particles. The next stages are increasingly finer fil-
T T
ters, up to and including activated carbon filtration packages designed to remove silica dust from the make-up air.
O
N NO
Refer to Figure 19-2. Primary components of the Mine Air System are:
O
D DO
• Compressor (17) – pumps refrigerant, takes low pressure refrigerant and compresses it to high pressure
gas to the condenser.
• Condenser (01) – changes hot gas from the compressor from high pressure gas to a high pressure liquid.
• Condenser Fan (01a) – forces air through the condenser coils to absorb heat and remove it from the
refrigerant.
• Receiver (08) – stores liquid refrigerant.
• Liquid Line Drier (03) – prevents moisture, dirt, metal, and chips from entering the flow control.
• Sight Glass (06) – indicates level of refrigerant and moisture in the system.

Section 19, Version 01 - 07/12 -19.2- Sec19AirCond.fm
03 04 05 06 07 08
09a
01 01a 02
09
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NL uip ion 10
O q t
A L f E ra
I e
20
o
16 15 14 13 12 11
R ce O p 80°F (27°C) Ambient
E
75°F (24°C) Return Air
t
AT nan en
Refrigerant: R134A
19 18 17 ES04820b02
M te m
E i n i p
C a q u
LEGEND 08. Thermal Expansion Valve 14. High Pressure Safety Switch
N
01. Condenser Coil and Fan 09. Evaporator Coil and Fan Cut Out 250 PSI (17.3 bar)
02. Discharge Line
E r M E 10. 35-45 PSI (2.4-3.1 bar) Cut In 175 PSI (12.1 bar)
r
120-135 PSI (8.3-9.3 bar) Temp 25-35°F (-4-2°C) 15. 120-135 PSI (8.3-9.3 bar)
03. Filter Dryer R

E E fo
Temp 100-110°F (38-43°C)
f o
11. Equalizer Line 1/4" (6.4 mm)
12. Suction Line 3/4" (19.1 mm)
Temp 90-125°F (32-52°C)
16. 35-45 PSI (2.4-3.1 bar)
E F
04. Hot Gas Bypass Valve
S E
13. Low Pressure Switch Temp 30-40°F (-1-4°C)
S
05. Set to 25-30 PSI (1.7-2.1 bar) Set Point Cut Out 17. Compressor Assembly
R U U
06. Sight Glass and Moisture 10 PSI (0.7 bar) 18. Liquid Line 3/8" (9.5 mm)
T T
Indicator Set Point Cut In 19. Liquid Refrigerant Receiver
07. 120-135 PSI (8.3-9.3 bar) 25 PSI (1.7 bar) 20. 120-135 PSI (8.3-9.3 bar)
O
N NO
Temp 90-125°F (32-52°C) Temp 90-125°F (32-52°C)
O
D DO
Figure 19-2: Mine Air Diagram
• Thermal Expansion (TX) Valve (08) – controls the amount of liquid refrigerant entering the evaporator and
maintains the required pressure in the evaporator by measuring the temperature on the outlet of the
evaporator.
• Evaporator (09) – liquid refrigerant entering the evaporator from the thermal expansion valve is under low
pressure. This causes the refrigerant to vaporize (boil) and absorb heat.
• Evaporator Fan (09a) – forces air through the evaporator coil to absorb the heat and remove it from the coil.
• Hot Gas Bypass Valve (04) – uses the hot gas from the compressor to regulate the pressure in the
evaporator coil. This valve is used when there is a low heat load in the area that is being cooled.

• High Pressure Safety Switch (14) – safety device that opens the control circuit when there is high pressure
in the system (e.g., condenser fan not working).
• Low Pressure Switch (13) – device that opens the control circuit when there is low pressure in the system
(e.g., low on refrigerant).
As the compressor starts to pump, it takes low-pressure vapor (gas) and changes it to a super-heated vapor. The
compressor compresses the vapor, increasing both the pressure and the temperature. This is called the “heat of
compression.”
The super-heated vapor enters the top of the condenser coil. Flowing through the condenser, it will change states
from a vapor to a liquid by the removal of the heat that was picked up by the evaporator and heat of compression.
n t
The heat content of the refrigerant is transferred to the air blowing across the condenser coil, causing condensa-
e
tion of the refrigerant within the condenser. Refrigerant temperature is reduced; pressure stays the same.
Y m
NL uip ion
The high-pressure liquid flows through the receiver allowing for changes in the refrigerant charge and liquid vol-
ume. These changes are caused by expansion and contraction of the refrigerant as the temperature changes in
O q t
the evaporator.
A L f E ra
Liquid flowing through the sight glass indicates the level of refrigerant by the level of liquid visible in the sight glass.
I o p e
ER ce O
Operation of the thermostatic expansion (TX) valve meters the amount of refrigerant flowing into the evaporator.
This is done through both temperature and pressure. Temperature is monitored by a remote temperature-sensing
t
AT nan en
bulb. The bulb is located on the outlet of the evaporator. Pressure is sensed by the internal valve components. As
the temperature increases, the bulb warms up. This causes a higher pressure in the bulb that pushes down on a
M te m
diaphragm in the TX valve, causing it to open and allow more refrigerant to flow through the valve.
E i n i p
u
The liquid enters the valve at high pressure, high temperature, and high volume. The liquid flows through an orifice
C a q
in the valve, which causes a rapid change in the state of the liquid. The refrigerant rapidly changes from a high-
N M E
pressure, high-temperature liquid to a low-pressure saturated vapor. The rapid change of the state of the refriger-
E r r
ant causes a rapid decrease in temperature, causing a cooling effect.
R o
E E f f o
As saturated vapor starts flowing through the evaporator coil, air is moved across the coil causing the saturated
F E
vapor to absorb the heat that is being removed from the space being cooled. This heat being absorbed is mea-
E S
R U U S
sured in British Thermal Units (BTU). As the BTU’s are absorbed, the refrigerant changes again from a saturated
vapor to a vapor. The vapor flows from the evaporator coil to the compressor inlet and the cycle begins again.
T T
O
N NO
The hot gas bypass valve (04, Figure 19-2) is activated when it senses low pressure in the evaporator. The low
pressure is caused by a low heat load in the area being cooled. As it senses low pressure (through an external line
from the outlet of the evaporator), the valve opens up and allows for the hot gas from the compressor to enter at
O
D DO
the evaporator inlet. This provides an increase in pressure, which helps prevent the coil from freezing up.

19.1.3 Controls
01
04
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NL uip ion 02
O q t
A L f E ra
I o p e
ER ce O
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AT nan en
M te m
Console_LH_HVAC_MAS
03
LEGEND
E i n i p
C a q
01. HVAC Temperature Control
u 03. HVAC Cooling/Heating Select Switch
N M E
02. HVAC Air Circulation Switch 04. HVAC Fan Speed Switch
R E o r r
f f o
Figure 19-3: Controls
FE E
S
19.1.4 NORMAL OPERATION
E S E
R U U
The MAS 1500 is protected by the following:
T T
O
N NO
• 30 amp main breaker (not supplied with unit)
O
• 30 amp unfused disconnect
D DO
• 15 amp time delay fuses for compressor and motors
• 15 amp fuses for the control transformer
• 20 amp fuse for the micro-processor
• 20 amp fuses for the 12 KW electric heating
• Contactors and over-load relays with AUTO/MANUAL reset for compressor and motors (operation in MAN-
UAL reset is recommended)

19.1.5 REFRIGERATION
19.1.5.1 General
1. The entire refrigeration circuit is a closed loop system enclosed in the model MAS 1500 unit. Any service work
in this area should be done by someone who is certified in the Environmental Act Code of Practice, Refrigerant
Handling Section 40 CFR Part 82, and any local code or legal requirements.
2. Refrigeration service/repairs involves high pressures and extreme temperatures and only those people certi-
fied in the refrigeration trade, and using governmental approved equipment and procedures should proceed.
Failure to follow these instructions or failure to use the correct procedures and equipment may result in prose-
t
cution under one or more environmental protection law(s). Refrigeration service/repairs must be performed by
n
a certified technician ONLY.
Y e
m
3. The system is charged at the factory with Polyol Ester Oil (POE) a synthetic oil compatible with R-134a envi-
NL uip ion
ronmentally friendly refrigerant.
19.1.5.2 Normal Operating Pressure

O q t
A L f E ra
I o e
Operating pressures of R-134a on MAS 1500 are:
R ce O p
E
• LOW = 35-45 psig at 30-40 ° F
t
AT nan en
• HIGH = 120-135 psig at 90-125 ° F
19.1.5.3 Reset Devices

M te m
E i n i p
C a q u
The refrigeration module has the following reset devices:
E N M E
R o r o r
1. An automatic reset refrigerant high pressure switch that trips out at 250 PSIG and trips back in at 175 PSIG.
E E f f
2. An automatic reset refrigerant low pressure switch that trips out at 10 PSIG and trips back in at 25 PSIG.
E F S E
R U U S
T T
19.2 Maintenance
19.2.1 General O
N NO
O
D DO
The Mine Air System generally does not require internal maintenance or servicing. When service beyond the peri-
odic maintenance procedures described in this section is required, it should be performed only by personnel who
are qualified and authorized to work on HVAC equipment. Contact your local P&H MinePro Services representative
whenever advanced work is necessary.
Normal maintenance is limited to:
• Changing filters.
• Cleaning coils.
• Checking fasteners and fittings for tightness and inspecting the unit for structural damage or stress cracks.

Refer to Figure 19-1 and service or change filters as follows:
! WARNING
Contact with energized electrical circuits in the unit could cause severe personal injury
or death. Follow all lockout/tagout procedures to remove power to the unit prior to per-
forming any filter change.
• Follow all specific lockout/tagout procedures to remove power from the unit.
t
• Remove the pressurizer filter housing end cap (02) by the spring clips at the end, and dump the dust out.
e n
• Observe the filter element (01) and change if excessive dust buildup is evident.
Y m
NL uip ion
• Change the plenum filters (03) regularly. Determine frequency of change-out based on local conditions.
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

19.2.2 lnspect Operator Cab Air Filters
Refer to Figure 19-4. The operator cab is pressurized with filtered air for operator comfort. To ensure that air enter-
ing the operator cab is satisfactorily filtered, the filter elements must be visually inspected on a daily basis.
• Remove cover on right side of unit and visually inspect the two operator cab air filters (01) for dirt and con-
tamination. If necessary, clean or replace the filter elements.
• Visually inspect the pressurizer filter (02). Replace the filter element when it has accumulated a thin layer of
dust.
n t
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NL uip ion
O q t
A L f E ra 02
I o p e
ER ce O
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AT nan en
M te m
E i n i p
C a q u
N M E
F6748a
RE o r r
E E f f o
E F S E LEGEND
R U U S 01. Operator Cab Recirculation Air Filters

02. Pressurizer Filter
T T
O
N NO
O
D DO MAS 1500 Model
01
Figure 19-4: Filter Locations (MineAir - Typical)

19.2.3 Cleaning Coils
! WARNING
forming any coil cleaning.
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NL uip ion
O q t
A L f E ra
I o
02
p e
ER ce O
t
AT nan en
LEGEND
M te m
01. Condenser Section 01
02. Condenser Coil Assembly 04
03. Evaporator Section
E i n i p
C a q u
04. Evaporator Coil Assembly
03
E N M E
R o r o r
E E f f
ES04824a01
E F S E
R U U S Figure 19-5: Cleaning Coils
T T
O
19.2.3.1 Condenser Coil Assembly
N NO
Refer to Figure 19-5. The condenser section (01) is the end of the unit with the open grills, where the heat from the
O
D DO
cab is transferred to atmosphere. Inside the condenser section is the condenser coil assembly (02), an assembly
of copper tubing that needs to be kept clean and as free of dust as possible.
During preventive maintenance activities, clean the condenser coil as follows.
1. Follow all specific lockout/tagout procedures to remove power from the unit.
2. Open the hinged top cover, sliding the cover sideways off the hinges. Set the cover carefully to the side away
from the unit.

Compressed air can cause injury. Never direct compressed air at a person. Do not
breathe compressed air.
3. Using compressed air, blow the dirt from outside, through the stainless grating, through the coil and back into
the case.
4. When all dust and debris has been blown through, use the compressed air to blow as much dust from inside of
the case as possible.
5. Carefully reassemble the top cover.

n t
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6. Use lockout/tagout procedures to restore power to the unit.
7. Re-start the unit.

NL uip ion
O q t
L f E ra
19.2.3.2 Evaporator Coil Assembly
I A o p e
Refer to Figure 19-5. The Recirculation unit is located at the end with the larger top cover. Because this section of
R ce O
the Mine Air System is completely enclosed and in the filtered air flow, the inside of this section should stay clean
E t
AT nan en
and relatively dust free.
During preventive maintenance activities, check that the coil and heater elements are clean and free of dust. If dust
M te m
has entered the area, compressed air can be used to blow out the dust; however, this may cause dust to be blown
E n i p
into the operator’s cab. After using compressed air to clean unit, remember to change the plenum filters as
described in Subtopic 19.2.3.
C a q i u
19.2.4 Checking Fasteners andN
E r
Fittings
M E
R f o o r
F E E ! f
WARNING
E S S E
R U U
T T
O
forming any maintenance.
N NO
Follow all specific lockout/tagout procedures to remove power from the unit.
O
D DO
During preventive maintenance activities, check fasteners and fittings as follows:
• Attempt to move the compressor, the receiver, the heat regulator controller and both motors. If any
movement is felt, check mounting bolts at the loose component’s base and on any support bands. Check all
welds on main sub-frame in base of unit. Contact your local MinePro Services representative if any broken
welds or structural failures are evident.
• Check and tighten, if necessary, the six mounting bolts between the sub-frame, the condenser and the
mounting channels. The bolts should be torqued to 35 ft-lbs (47 N·m).
• Check and tighten, if necessary, the six mounting bolts between the subframe in the Blower/Heater pack
and the mounting channels. The bolts should be torqued to 35 ft-lbs (47 N·m).

• Check that all motors spin freely by hand. Replace motor if any grinding, squeaking, or roughness is felt.
• Check that power and controller cable connectors are locked in place and that cables are not chaffing or
scuffing on edges or being pressed against cooling coil fins.
• Clean coils. Refer to Subsection 19.2.3.
• Check refrigerant sight glass. The indicator in the center should be green.
• Close covers and verify the latch is secure.
• Check that the electrical box lid is tightly closed and that all fastening bolts are tight.
n t
e
19.2.5 Preventive Maintenance
Y m
NL uip ion
The following is a recommendation for performing preventive maintenance on the Mine Air System. Refer to Tables
19-1,, 19-2, 19-3, 19-4 and 19-5.
O q t
! WARNING L
A f E ra
I o p e
R ce O
E t
AT nan en
forming any maintenance.
M te m
Daily
E n i p
Check the Power Monitor – Reset it by turning the power on at the controller.
i
C a q
Check Filters.
u
E N M E
r
Inspect and empty the Precleaner if required. This is not required on self cleaning units.
R fo o r
E E f
Table 19-1: Preventive Maintenance - Daily
E F S E
Every 250
Hours R U U S
Change the return air filters and discard. The filters are not cleanable and cannot be reused.
T T
Inspect the pressurizer filter. Replace it every second preventive maintenance or when it
O
N NO
becomes too dirty.
Inspect the condenser coil and blow it out with compressed air if it becomes too dirty. Refer
O
to Subsection 19.2.3.
D DO Inspect all electrical connections. Tighten if necessary.
Reset the heating high limit switch if required.
Check the drain trap vacuum valves, in place soft/opening and sealing. Clean if required.
Check all controller functions.
Inspect all diffusers and louvres, replace any broken ones as required.
Adjust the airflow for best seasonal operation. Check with the operator and review unit oper-
ation.
Table 19-2: Preventive Maintenance - Every 250 Hours

Every 500 Change the pressurizer filter, wipe out all housing internal surfaces, and verify that all
Hours latches are tight.
Check the rubber vacuum valve on the bottom of the pressurizer canister in place and soft/
opening and sealing.
Verify that all fasteners are tight inside the unit and on the unit mounting rails. Check for
stress cracks.
Table 19-3: Preventive Maintenance - Every 500 Hours
Seasonal
n t
Check and clean the evaporator coil as required. Use water or spray cleaner.
Pre-
Y e
m
Cooling Check and clean condensate drains, ensure elbows and vacuum valves are in place and func-
NL uip ion
tional.
Inspect the condenser coil and blow it out with compressed air if it becomes too dirty. Refer
to Subsection 19.2.3.
O q t
A L f E ra
Check that condenser fan blades are tight, that it rotates freely and motor bearings are
smooth and quiet.
I o p e
ER ce O
Check and tighten all electrical connections for the condenser fan motor and compressor.
t
AT nan en
Start the cooling cycle by lowering climatrol set point below cab temperature. Check and
verify the operation of all components.
M te m
Check the compressor and verify correct operation. Check the oil level, the seal for leaks,
E i n i p
the belts and clutch operation.
C a q u
Verify that the refrigerant sight glass moisture indicator is green and the glass is clear.
E N M E
r r
Table 19-4: Preventive Maintenance - Seasonal Pre-Cooling
R
E E fo f o
Seasonal
E F S E
Check the operation of the heating coil by incrementing the set point to maximum and con-
Pre-
Heating
R U U S
firming temperature increase. Bleed any air.
T T
Check that the heating contactor is pulled in. If it is not, verify that the high limit klixons are
closed and the fuses are good.
O
N NO Verify that the LED is flashing on the ramp controller.
O
D DO
Table 19-5: Preventive Maintenance - Seasonal Pre-Heating

19.1.1 General Information
The modular design of the Mine Air Systems Unit allows for two options if a problem exists with either the electrical
or mechanical functions. The options are as follows:
First the entire unit can be replaced with an identical unit in under thirty minutes at the next convenient break in
production when a technician and hoist can be scheduled. If a spare unit is not available it is recommended that a
cap be placed on the weather guard roof top flanges until the unit can be replaced. This option provides the follow-
ing benefits:
• Minimizes downtime.
n t
Y e
m
NL uip ion
• Avoids downtime associated with the time consuming removal and storage of refrigerant.
O q t
• Allows a full service check up to be performed in a shop environment by qualified personnel or contractor.
L f E ra
Or the problem can be diagnosed and solved on the spot. Because of shovel downtime considerations and the
A
I o e
refrigeration code, problems solved in the field should be limited to the following categories:
R ce O p
E
• Fuses and breakers.
t
AT nan en
• Heating high limits.
• Pressure sensors.
M te m
E i n i p
C a q u
• Modular components like the Mine Logic Controller, pressurizer, or the relay box.
E N M E
r
• Condenser coil cleaning.
R fo o r
E E
• Electric elements.
F f
E S S E
• Motor, fan blades and wheels.
R U U
T T
The following diagrams are provided to assist in the troubleshooting process. Refer to Figure 19-6 if the unit is not
O
cooling and Figure 19-7 or Figure 19-8 if the unit is not heating. Start in the green field and continue until the prob-
N NO
lem is resolved.
O
D DO
If these diagrams do not resolve the problem, contact the local MinePro Services Office for more assistance.

Are both the

Is the rotation Contact your local
Are both C5 and C6 compressor Is the indoor fan
YES YES on both components YES YES MinePro Services
energized? and fan motor motor operating?
correct? Office.
operating?
NO NO NO NO
Check motors for open, Reverse the rotation Check the indoor
shorted or grounded at the motor connection fan circuit for proper
Reset overload. Check terminal.
Is either C5 or C6 windings. operation.
motor operation and YES DO NOT correct it at
overload tripped?
current draw. the electrical box.
NO
Check the wiring circuit
t
from the relay board
Is 24VAC
to the contactors.
n
present between
YES Check for an open
terminal J2 wire #34
overload switch or
e
and ground
inoperative contactor
Y
coil.
m
NL uip ion
NO
Is 24VAC Replace CR5.

present between If problem is not
O q t
terminals J1 wire #000 YES
resolved, replace the
and J2 wire relay board.
L f E ra
#34?
A
NO
I
Is 24VDC
o p e
R ce O
Is 24VDC Replace CR5.
present between present between If problem is not
YES YES
E
wires #15 and #16 wires #6 and #15 resolved, replace the
of terminal J1?
t
of J1? relay board.
AT nan en
NO NO
M te m
Replace the The circuit is not
Is the red complete between the
relay board.
LED illuminated at MLC and the relay
p
YES
E n i
output #10 of MLC? board. Check the
i
circuit for loose wires
C a q u
or a faulty connection.
N
NO
M E
Check MLC settings
and make sure the unit
E r
Are both is set for cooling and
r
green LED's the setpoint is lower
R o
YES
f o
illuminated at input than the cab
E E f
#7 and #8? temperature. If all
settings are correct,
F
replace the MLC.
E
NO
E S S
Perform continuity
R U U
Is there checks to make sure
continuity between a path exists between
YES
terminals TS-1 and the pressure switches,
T T
TS-2? relay board and the
MLC.
O
N NO
NO
Pressure switch fault.
Contact your local
MinePro Services ES2135_01
O
D DO
Office.
Figure 19-6: Mine Air Systems Troubleshooting - No Cooling

Is the heat
contactor, (C1) The HL140 or HL160
energized? safety switch is open.
Remove the blower
pack to verify.
NO NO
Is there
Is either C3-4 or Is 24VAC continuity between Check for a bad
C4-4 contacts YES present at terminal YES terminal J2-1 and TS-3? YES connection or a loose
closed? J2-1? Is the circuit wire.
closed?
NO NO
Check the auxilliary Either the control relay
t
contacts or the Is 24VDC (CR1) or the relay
Is 24VAC
n
fan circuit. present between board is faulty. Replace
present at terminal YES YES
terminals J1-7 the relay, if the problem
e
J1-1?
and J1-21? still exists, replace the
Y
relay board.
m
NL uip ion
NO NO
Is 24VDC Is the There is a faulty

Is 24VAC
Check F9 on the present between green LED for output connection at P4-1,
O q t
YES present at the YES YES
transformer. terminals J1-21 1 illuminated? P7-1 or the control
transformer?
and J1-22? (J4-1) cable
A L f E ra
NO NO NO
I o e
Check F1 and F2. There is a faulty Check MLC settings
R ce O p
Check the main power supply. Replace and/or replace the ES2136_01
power supply. the relay board. MLC.
E t
AT nan en
Figure 19-7: Mine Air Systems Troubleshooting - No Heating - C1 De-energized
M te m
E i n i p
C a q u
The heating circuits
Is there
are OK. Check IFM, air
Is the heat Is 6VDC and/or a current reading
N
flow and filters.
M E
contactor, (C1) YES 4-20mA pesent at YES found at SCR output? YES
(wires 106,
Contact the local
energized? SCR?
E
MinePro Services
r
206,306)
r
Office for assistance.
R fo o
NO NO
E E f
Check the auxilliary
F
Check the connections
E
Is there Is there
contacts at C1 (C1-4). Is 6VDC and/or at P1, terminals d, e
380/460VAC across 380/460VAC across
S
YES YES
E
Inoperative switch, 4-20mA pesent at YES and f. Remove the
S
terminals 1, 2 and 3 of terminals 4, 5 and 6 of
bad contacts or loose terminal J3-7? SCR? SCR. blower pack and
R U U
connections. check heaters.
NO NO NO
T T
Check the heat
O
contactor (C1) and Replace SCR control.
N NO
There is a faulty Is 6VDC and/or fuses F6, F7 and F8.
circuit on the relay YES 4-20mA pesent at
board. terminal J1-20?
O
D DO
NO
Is 6VDC and/or There are faulty

4-20mA pesent at YES connections. Check
terminal J8-1? P7, P4 and the cable.
NO
Is SAS Check MLC settings.

functioning normally? YES If necessary, replace
the MLC.
NO
ES2137_01
Replace the sensor.
Figure 19-8: Mine Air Systems Troubleshooting - No Heating - C1 Energized

n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

320XPC-UDC Mechanical Systems Manual Optional Equipment
Section 20
Optional Equipment
This section describes the optional equipment as listed inTable 20-1.
Option Subsection
Auxiliary Air System

n t Subsection 20.1
Hydraulic Boarding Ladders

Y e Subsection 20.2
m
NL uip ion
Top Off Systems Subsection 20.3
Jib Crane
O q t Subsection 20.4
A L f E ra
Table 20-1: Optional Equipment
I o p e
ER ce O
t
AT nan en
20.1 Auxiliary Air System
M te m
The drill may feature an on-board auxiliary air compressor and dryer. The purpose of this system is to provide com-
E n i p
pressed air for general use. The auxiliary air system is not used in any drill functions.
C a q i u
N
The auxiliary air system includes a Sullair ES6-10 rotary screw compressor, a desiccant air dryer, and a 30-gallon
E
air reservoir (see Figure 20-1).
r M E
R fo o r
F E E f
E S S E
Refer to the manuals provided with this equipment for service and repair information. Repair
R U U
parts are listed in the LinkOne Parts Manual.
T T
O
N NO
O
D DO

Sec20Options.fm -20.1- Section 20, Version 00 - 07/12
Optional Equipment 320XPC-UDC Mechanical Systems Manual
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p R60833D1
C a q u
E N M E
Figure 20-1: Auxiliary Air Compressor (Option)
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

Section 20, Version 00 - 07/12 -20.2- Sec20Options.fm
20.2 Boarding Ladders

Refer to Figure 20-2. The drill may feature one or two optional hydraulically operated boarding ladder(s).
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
BD1248a01
E E f f
E F S E
R U U S Figure 20-2: Typical Boarding Ladder (Right Rear Shown)
T T
O
N NO
O
D DO

20.2.1 Boarding Ladder Hydraulic Control (VB6)
Drills that are equipped with a boarding ladder are also equipped with an additional valve bank (VB6) which is
located in the machinery house near the hydraulic tank (see Figure 20-3). Hydraulic oil is supplied to VB6 from the
low pressure pump.
n t VB6
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
BD1246a01
Figure 20-3: Ladder Hydraulic Control (VB6) Location

20.2.2 Boarding Ladder Circuits
Refer to Figure 20-4. Each boarding ladder circuit actuates a double-acting hydraulic cylinder to raise and lower
the boarding ladder. A solenoid-operated directional valve is used to control the pressurized oil flow for raising and
lowering the ladder.
VALVE BANK 6
RIGHT FRONT
n t RIGHT REAR
BOARDING STAIR
e
BOARDING STAIR
Y m
B B
NL uip ion
RFLRS RRLRS
1.26.1.2 1.26.1.4
P A P A
T B RFLLS T B RRLLS
O q t
1.26.1.3 1.26.1.5
A A
L f E ra
1.5 1.5
GPM GPM
5.7 73
A
5.7
L/MIN
e
L/MIN
I o
600 PSI
p
600 PSI
41.3 BAR
R ce O
72 41.3 BAR
E
600 71 600
t
AT nan en
PSI PSI
41.3 41.3
BAR 32 BAR
T602 T603 T604
T601
M te m
.05Ø .05Ø
70
E n i p
500 500
i
FROM LOW PRESSURE PUMP PSI PSI 56
34.5 69 34.5
u
PRESSURE COMPENSATED
C a q
BAR BAR
AT 1500 PSI, 103 BAR
N
0-5 GPM
M E
0-19 L/MIN P1
E r
X P2
R fo o r X T2
E E f
T1
F
B1 A1 B2 A2
E
TO LOW PRESSURE
E S
RETURN FILTER
R U U S
T T T606 T607
O
T605 T608
N NO
68 68 68 68
1.50",38.1 mm Ø BASE
1.50",38.1 mm Ø BASE
O
74 .62",15.8 mm Ø ROD 57 RFLPS 57
D DO
.62",15.8 mm Ø ROD 74
6.50",165.1 mm STROKE RRLPS
1.18.10.3 6.50",165.1 mm STROKE
1.18.11.2
DOWN UP DOWN UP
RIGHT FRONT RIGHT REAR

R63361_07 STAIR CYLINDER STAIR CYLINDER
Figure 20-4: Boarding Ladder Circuits

20.2.3 Boarding Ladder Remote Control
Refer to Figure 20-5. Each boarding ladder can be controlled by either a switch on the operator’s console in the
cab or by a remote joystick-type switch near the ladder. Move the joystick handle up to raise the ladder or down to
lower the ladder.
n t
Y e
m
NL uip ion
O q t
A L f E ra
I e
BD1246a01
R ce O o p
E t
Figure 20-5: Ladder Remote Control
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

20.3 Lubricant Replenishment Systems
20.3.1 Top Off Systems
01
02
n t
Y e
m
NL uip ion
O q t
A L f E ra R60376a
e
03 04
I
R ce O o p
E t
AT nan en
M te m
E i n i p
C a q u
E N M E
R60376c
R o r o r R60376
LEGEND
E E f f 03. Filter Panel
F E
01. Oil Top Off system / Start Control 04. Solenoid Controlled Diverter Valves
E S S
02. 80 Gallon (303 Liters) Reservoir
R U U
T T Figure 20-6: Filter Panel
O
N NO
20.3.1.1 General
O
D DO
The top off tank is an option on all P&H drills. It is intended to ease the filling duties of the compressor lubricating oil
(T-tank) reservoir and the hydraulic system oil reservoir. Two major advantages become available when using this
system.
• The oil from the top off tank(s) is filtered before it is added to the system reservoirs.
• By having this mounted on the drill, the reservoir levels can be topped off when needed without the need of
a lube truck visit.
P&H offers two models of top off tanks: a single 80 gallon (303 liter) tank and a dual 80 gallon (303 liter) tank. Cus-
tomers that use the same fluid in the compressor and hydraulic systems would order the single tank. Customers
using different fluids in the compressor lubrication and hydraulic systems would order the dual tank.

The dual tank has two vertical 80 gallon (303 liter) tanks (01 and 02, Figure 20-7) for a total of 160 gallons (606
liters) and two separate pumping systems (01 and 02, Figure 20-8). The single tank system is similar to the dual
tank system except it only has one tank and one pumping system.
20.3.1.2 Dual Tank Oil Top Off System
03 04
LEGEND
t
01. Hydraulic Oil Tank
n
02. Compressor Oil Tank
e
03. Hydraulic Oil Tank Breather/Fill Cap
Y m
06 04. Compressor Oil Tank Breather/Fill Cap
NL uip ion
05 05. Hydraulic Oil Pump Start Pushbutton
06. Compressor Oil Pump Start Pushbutton
O q t
07. Valve #1
08. Valve #2
L f E ra
08
09. Valve #3
I A o p e
10. Valve #4
ER ce O
t
AT nan en
07 PRIMARY SECONDARY
FILTER FILTER
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
S
10
R U U
FILTER FILTER
T T
O
N NO
O
D DO 01
BD1155b01
02
Figure 20-7: Dual Top Off Tank

LEGEND 01
01. Hydraulic Oil Pumping System
02. Compressor Oil Pumping System 11
02
03. Oil Pump Pushbutton Station (Typical)
04. Oil Pump (Typical)
05. Primary Filter (Typical)
06. Secondary Filter (Typical) 03
07. Valve #1
08. Valve #2
t
09. Valve #3
n
10. Valve #4
e
11. Low level Switch (Typical)
Y
08
m
NL uip ion
O q t
A L f E ra
I o e
07
p
PRIMARY SECONDARY
R ce O
FILTER FILTER
E t
AT nan en
M te m
E i n i p
C a q u
N M E
10
E r r
09
R o
PRIMARY SECONDARY
f o
FILTER FILTER
FE E f
E S S E
R U U
T T 04 05 06
O
N NO
BD1155e01
O
D DO Figure 20-8: Dual Top Off Tank Pumping System
Refer to Figure 20-8. Filtering is accomplished during use as oil is pumped through a 12-micron primary filter (05)
followed by a 3-micron secondary filter (06). Both filters are of the spin on canister type and replacement intervals
can be monitored by viewing the filter’s two gauges during pumping. When the differential pressure between the
two gauges is greater than 20 psi (1.4bar), the filter needs to be changed.
Each pump is protected by a low level switch (11, Figure 20-8) that stops the pump when the
tank is near empty.

Operation
Operation of the top off system consists of two modes:
• Filling the top off system tank(s).
• Dispensing oil from the top off tank(s) to either the hydraulic reservoir or the compressor T-Tank.
Filling the Top Off System Tank(s)
The top off system tank(s) can be filled by two different methods:
METHOD 1
n t
Y e
m
NL uip ion
Remove the breather/fill cap (03 or 04, Figure 20-7). Pour the new oil into the tank through the fill neck.
O q t
METHOD 2
L f E ra
This method uses the top off tank pump in suction mode to pump oil from pails or drums to fill the top off tank.
A
I o p e
ER ce O
t
AT nan en
This procedure discusses filling the compressor oil using the appropriate portions of the dual
M te m
top off tank system. The hydraulic oil tank can be filled using a similar procedure, but using
p
valves #3 and #4 (09 and 10) as shown on Figure 20-8 and the appropriate pushbutton switch.
E
C a q i n u i
1. Position the three-way valves #1 (06) and #2 (07) as shown in Figure 20-9. Valve #1 opens the port between
N M E
the pump and suction tube. Valve #2 closes the port (08) to the compressor T-Tank and directs the oil being
E r r
pumped into the compressor oil top off tank.
R
E E fo f o
2. Place the suction tube (09) in the oil pail or drum.
E F S E
S
3. Push and hold the compressor oil pump pushbutton (02) to start the pump. Oil will be drawn from the pail or
R U U
drum (03), pass though the filters (04 and 05) and begin filling the compressor oil top off tank with clean oil.
T T
O
4. Watch the sight gauge (11) and continue pumping until the oil is at desired level. Release the pushbutton.
N NO
5. Place suction tube into hose tray (09) to drain.
O
D DO

LEGEND 01
01. Compressor Oil Pumping System
02. Oil Pump Pushbutton Station
03. Oil Pump
04. Primary Filter
05. Secondary Filter
06. Valve #1 02
07. Valve #2
08. Fixed Hose To Compressor T-Tank
t
09. Suction Hose
n
10. Hose Tray 03 04
e
08
11. Oil Level Sight Gauge
Y m
NL uip ion
O q t
07
L f E ra
A
FILTER FILTER
05
I o p e
ER ce O 10
t
AT nan en 11
M te m
09
E i n i p
C a q u
E N M E
r
PRIMARY SECONDARY
r
FILTER FILTER
R
E E fo f o
E F S E BD1155d01
R U U S
T T Figure 20-9: Filling Compressor Oil Dual Top Off Tank
O
N NO
Dispensing Oil to Either the Hydraulic Tank or Compressor T-Tank.
O
D DO
This procedure discusses dispensing oil to the compressor T-Tank using the appropriate por-
tions of the dual top off tank system. Oil can be dispensed to the hydraulic oil tank using a simi-
lar procedure, but using valves #3 and #4 (09 and 10) as shown on Figure 20-8 and the
appropriate pushbutton switch.
1. Position the three-way valves #1 (06) and #2 (07) as shown in Figure 20-10. Valve #1 opens the port between
the top off tank compressor oil reservoir and pump it through both filters to valve #2. Valve #2 opens the port
(08) to the compressor T-Tank and passes clean oil to the compressor T-Tank

2. Note the oil level gauge on the T-Tank. Push and hold the compressor oil remote fill pushbutton (located next
to the T-Tank). As an alternative, have an assistant press and hold the pushbutton switch (02) while you
observe the T-Tank oil level.
3. Watch the sight gauge and continue pumping until the T-Tank oil is at the desired level. Then release the push-
button.
If dispensing stops, the oil level in the top off tank may be too low and caused the pump to stop.
Fill the appropriate top off tank to resume dispensing.
n t
Y e
m
LEGEND
NL uip ion
O q t
01. Compressor Oil Pumping System 01
L f E ra
02. Oil Pump Pushbutton Station
A
03. Oil Pump
04. Primary Filter
I o p e
R ce O
05. Secondary Filter
E
06. Valve #1
t
AT nan en
07. Valve #2 02
08. To Compressor T-Tank
M te m
09. Compressor Top Off Tank Oil Level Gauge
03 04 08
E i n i p
C a q u
E N M E
R o r o r 06 07
E E f f
PRIMARY SECONDARY
F
FILTER FILTER
E
05
E
R U U S S
T T
O
N NO
09
O
D DO PRIMARY
FILTER
SECONDARY
FILTER
BD1155f01
Figure 20-10: Dispensing Oil to Compressor T-Tank

20.3.2 Wiggins Quick Fill System
02 03 04
06
t
05
e n
Y m
NL uip ion
O q t
01
A L f E ra
I o p e
ER ce O
t
AT nan en
F8101_a01
LEGEND
M te m
E n p
01. T-tank Oil Fill Port 04. Hydraulic Tank Fill Port
02. Left Hand Platform
C a q
03. Right Hand Platform i u i 05. Grease Tank Fill Port
E N M E
R o r o r Figure 20-11: Wiggins Quick Fill Ports
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO

20.4 Jib Crane

The drill may feature an optional deck-mounted jib crane. The jib crane includes an electric hoist (Figure 20-12).
Refer to the manual provided with this equipment for service and repair information. Repair
parts are listed in the LinkOne Parts Manual. A PDF copy of the manual (Series62Q.pdf) for the
hoist is included on the 320XPC distribution CD.
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
BD1245a01
Figure 20-12: Jib Crane (Option)

320XPC Mechanical Systems Manual General Maintenance
Appendix A
General Maintenance
A.1 Removal – General

The following general rules apply to removal of most major components.
n t
1. Always make sure that all controls are in the OFF position. Main and emergency power switches must be
e
opened and locked in the open (OFF) positions. Place warning signs on these switches so that others do not
Y m
NL uip ion
turn on the power while you are working on the machine.
O q t
A L f E ra
I e
Unexpected machine operation could result in death or severe personal injury. Warning
R ce O o p
signs must always be removed by the person who placed them - never by anyone else.
E t
AT nan en
2. Lifting heavy components with inadequate hoisting apparatus can injure personnel and/or damage equipment.
Use suitable rigging and hoisting equipment to stabilize and lift heavy objects.
M te m
3. Before performing any work on any system, consider the effect that the work may have on the system. Be sure
E i n i p
that the machinery will not move as a result of the work being performed. Be sure the system is not under pres-
C a q u
sure. Be sure electrical power is disconnected.
E N M E
R o r o r
E E
A.2 Disassembly – General
f f
E F S E
S
1. Disassemble only what is required for specific repairs.
R U U
T T
2. Never use a torch to assist in removing parts unless the parts to be heated are already damaged beyond
O
repair, or the instructions recommend the use of heat for disassembly. Excessive heat may damage the part
N NO
beyond repair.
O
D DO
3. Never use more force than necessary to dismantle an assembly. In most cases, a great deal of force is not
required.
4. Handle parts carefully to prevent nicks or other damage while the parts are removed from the machine.
5. Tag all electrical leads and hydraulic lines before disconnecting them to ensure proper reconnections.
A.3 Inspection, Cleaning And Repair – General

The following general recommendations should be followed during routine cleaning, inspection and repair of most
machine components.
Copyright © 2008 P&H Mining Equipment, Inc. Knowledge and Development - Peak Services
AppendixA.fm -A.1- Appendix A, Version 01 - 04/08
General Maintenance 320XPC Mechanical Systems Manual
Gasoline, naphtha, and other highly flammable fluids will burn if ignited, and may
explode if the fumes are ignited in a confined space, resulting in burns, severe bodily
injury and/or death. Do not use these materials to clean, or for any other maintenance
procedure. If necessary, use Toluol, Perchloroethylene, or other approved solvent.
1. Clean all parts thoroughly using kerosene, diesel oil, or a suitable commercial solvent. Never use a hot alkaline
solution on finished parts or bearings.
t
2. Dry metal parts (except bearings) using low-pressure compressed air. Do not spin-dry bearings.
3. Inspect all gears as described under Subtopic A.5.7.

e n
Y m
NL uip ion
4. Inspect all bushings for wear, scoring or galling and replace when required.
O q t
5. If possible, replace all oil seals and O-rings, regardless of the reason for removal, even if no damage is appar-
L f E ra
ent.
I A o p e
6. If possible, replace all gaskets. Be sure the new gasket is of the same material and thickness as the discarded
gasket.
ER ce O
t
AT nan en
7. Inspect all anti-friction bearings as described under Subtopic A.5.1.
M te m
E i n i p
C a q u
A.4 Assembly
E N M E
r
The following general rules apply to assembly of any component.
R fo o r
E E f
1. When torque values are specified, be sure to use a torque wrench and tighten to the specified torque value. If
F E
a tightening sequence is specified, follow the sequence. If none is given, tighten evenly and alternately around
E S S
the bolt circle.
R U U
T T
2. Always pre-pack anti-friction bearings with suitable bearing grease before installation.
O
N NO
3. Install all bearings as instructed under Subtopic A.5.1.
O
4. Inspect all grease passages to be sure they are open and clean.
D DO
5. Smooth all nicks, burrs, or galled spots on shafts, bores, pins, gears and bushings. Pay particular attention to
oil seal seating areas to ensure that shaft irregularities do not lead to seal wear and lubrication leaks.
6. Check the fit of keys in keyways. Shaft keyways have an interference fit which should not be altered.
Knowledge and Development - Peak Services Copyright © 2008 P&H Mining Equipment, Inc.
Appendix A, Version 01 - 04/08 -A.2- AppendixA.fm
A.5 Maintenance Of Specific Components
A.5.1 Bearings
A.5.1.1 Removal
Most bearings are removed by means of a bearing puller or driver. In either case, the puller or driver should contact
only the inner bearing race to prevent damage to the bearing. Inspection and repair. Inspect all bearings for wear,
binding, excessive play, distorted races and roller wear or damage. Always replace worn or damaged bearings.
n t
Y e
Some organizations make it a practice to replace all bearings in crucial applications whether or
m
NL uip ion
not damage is apparent. The cost of the part is often minor in comparison with the cost of redo-
ing the job should the part fail.
O q t
L f E ra
A.5.1.2 Installation
I A o p e
Prepack all anti-friction bearings with a good grade of bearing grease before installation. Many bearings require an
R ce O
interference fit between the inner race and the shaft on which the inner race is mounted. To obtain the required
E t
interference fit, the bearing must be heated, the shaft must be cooled, or a combination of both methods may be
AT nan en
necessary. It is usually easiest to heat the bearing, and this is the method most commonly used. Use an oven, a
bearing heater, or an oil bath for heating a bearing; do not use a torch. Once the bearing has been properly heated,
M te m
it must be pressed into position on the shaft in one smooth and continuous operation. Do not allow the bearing to
E n i p
stop short of it's final position, since it will quickly “freeze” on the shaft and will then have to be removed and
C a q i u
reheated before it can be properly installed.
E N M E
R o r o r
E E f f
F
Never use hot alkaline solutions on bearings (or other finished parts) because the alka-
E S E
line solutions will score or damage finished surfaces.
S
R U U
T T
N O O
N
Never spin dry bearings with compressed air since this will damage the bearings.
O
D DO
A.5.2 Couplings
Power transmission couplings are the usual means of connecting coaxial shafts so that one shaft can drive the
other. For example, they may be used to connect an electric motor to a pump shaft or to connect two pieces of
shafting together to obtain a longer shaft extension.
Couplings are manufactured in many types, styles and sizes. However, they can be classified into two groups:
Rigid couplings (sometimes called solid couplings) and flexible couplings. Each is discussed below.
A.5.2.1 Rigid (Solid) Couplings
These couplings connect shaft ends together rigidly, making the shafts so connected into a single continuous
entity. They are generally used when true alignment and a solid coupling are required, as with line shafting. Solid
couplings are self-supporting and automatically align the shafts to which they are attached when the coupling
halves on the shaft ends are connected. Solid couplings require the following for good service:
1. Coupling halves must be interference fits on shafts
2. After installation, all surfaces of the coupling must be checked for runout and surfaces found to be running out
must be machined true. Checking of surfaces for runout is especially necessary if the coupling halves are
assembled by driving or bumping rather than pressing.
Rigid couplings should not be used to connect shafts of independent units which must be aligned at assembly.
t
A.5.2.2 Flexible Couplings
e n
Flexible couplings are used to connect two independently supported coaxial shafts so one can drive the other. For
Y m
example, prime movers such as internal combustion engines and electric motors are usually connected to gear
NL uip ion
reducers and pumps by means of flexible couplings.
O q t
For this type of application, the flexible coupling is used because it is practically impossible to obtain perfect align-
L f E ra
ment of the adjacent shafts. Also, there is usually wear occurring in the connected components and their shaft
A
bearings, as well as movement from temperature changes and external forces such as vibration.
I o p e
R ce O
Therefore, to enable coaxial shafts to operate satisfactorily with slight misalignment, flexible couplings, depending
E t
on the design, may allow one or more of the following misalignments:
Angular Misalignment
AT nan en
Parallel Misalignment
M te m
E i n i p
C a q u
Axial Movement (End Float)
E N M E
Torsional Movement (Twisting)
R o r o r
f f
Most flexible couplings are made up of three basic parts: two hubs mounted on the shaft ends to be connected,
FE E
and a flexing element that transmits power from one hub to the other. Most flexible couplings fall into one of the fol-
E
lowing categories:
S S E
R U U
Chain Couplings
T T
O
N NO
A chain coupling is one having two sprockets with hubs for attachment to the shafts, connected by a length of dou-
ble chain having links which mesh with the sprocket teeth. This type of coupling normally requires lubrication.
O
D DO
Gear Couplings
Gear couplings are made up of meshing internal and external gears or splines. Flexibility results from both the fit of
the teeth and the special shaping of the teeth that permits them to pivot in relation to each other. This type of cou-
pling normally requires lubrication.
Jaw and Slider Couplings
These couplings usually have two hubs which attach to the shafts. The hubs are connected by a sliding member
which provides flexibility. The slider is connected to the hubs by jaws, keys, or splines. These couplings usually
require lubrication.
Resilient Element Couplings
This is a very common type of coupling. The most commonly used resilient flexible materials are metal and rubber
(or synthetic substitute). These couplings allow angular and parallel misalignment and end float. Those using rub-
ber elements have more torsional flexibility than most other types of couplings. Most of these couplings do not
need lubrication, except the ones using flexible metal elements.
A.5.3 Alignment
In preparing to align a coupling, it must be determined which unit is to be adjusted - the “driving” or the “driven” unit.
Common practice is to position, level and secure the driven unit as required and then adjust the “driver” to align
t
with it. The driven unit must be set with its shaft centerline slightly higher than the driver to allow for alignment
n
shims.
Y e
m
NL uip ion
Coupling alignment consists of bringing the centerlines of two coaxial shafts into alignment, rather than aligning the
surfaces of the coupling. For example: If the coupling hub surfaces do not run true with the shaft centerline, align-
ment of the untrue surfaces will result in misalignment of the shaft centerlines. True running surfaces are therefore
O q t
a vital requirement if the alignment procedures that follow are to be successful.
A L f E ra
I e
There are two kinds of shaft misalignment: Angular Misalignment and Parallel Misalignment.
R ce O o p
E
Note that misalignment of the shaft centerlines may occur in any plane within a full circle. Angular misalignment
t
AT nan en
may be a tilt up, down, or to the side of one shaft in respect to the other. Parallel misalignment may be one shaft
high, low, or to the side of the other. The usual method of correcting alignment is to check and adjust in the vertical
and horizontal planes as illustrated in Figure A-4.
M te m
E i n i p
To align centerlines of coaxial shafts in both the vertical and horizontal planes requires four distinct operations: An
C a q u
angular and parallel alignment in the vertical plane and the same in the horizontal plane.
E N M E
r
To do an alignment properly requires an organized procedure. Since adjustments are usually made by inserting
R o r
shims at low support points, an important first step is to check the foundation of the unit to ensure that no rocking
f o
E E f
motion exists. If rocking does exist, eliminate it by shimming before proceeding. Tools best suited for coupling
F E
alignment are the straight edge, feeler gauge, and taper gauge. The taper gauge is just what it implies, a tapered
E S S
piece of straight metal which allows direct reading instead of the “trial and error” type of reading obtained by a
R U U
feeler gauge.
T T
Two methods of coupling alignment are commonly used: the straightedge-feeler gauge method and the dial indica-
O
N NO
tor method. Each method will be illustrated using specific measurements as examples after the following general
explanation. In both methods, four alignments are performed in a specific order, although the final two steps are
O
combined into one in the numbered procedure below.
D DO
Only when adjustments are performed in the correct order can a succeeding adjustment be per-
formed without disturbing prior settings.
A.5.3.1 Vertical Face Alignment
To adjust vertical face alignment, it is necessary to tilt the unit as required. First, measure the gap at the top and
bottom of the coupling; then, shim as required to align these faces.
The easiest way to determine the amount of shims required is as follows:
The tilt required at the coupling face is the same as the angle of change at the base of the unit. Therefore the shim
thickness required is proportional to the misalignment.
As an example, the misalignment at the coupling faces is 0.006" in 5 inches. Therefore, each five inches of base
must be tilted 0.006" to correct misalignment. Since the base length is 10 inches, the shim thickness required is
twice 0.006" or 0.012".
A rule for shim thickness selection is: Shim thickness is as many times greater than the mis-
alignment as the base length is greater than the coupling diameter.
n t
e
A.5.3.2 Vertical Height Alignment
Y m
NL uip ion
Measure the height difference from the coupling hub base to the shaft centerline. Then raise the lower unit as
required without changing its angular position. This adjustment corrects parallel misalignment in the vertical plane.
O q t
L f E ra
A.5.3.3 Horizontal Face and OD Alignment
I A o p e
R ce O
When the units are properly aligned vertically, shimming is complete. Then move the unit as required to align the
E
coupling hub faces and O.D's at the sides of the coupling.
T GaugenMethod t
A na en
A.5.4 Coupling Alignment - Straightedge-Feeler
Align the coupling as follows:

M te m
E i n i p
C a q u
1. Using feeler gauges, measure the width of the gap at top and bottom between the coupling faces.
E N M E
r r
2. Assume the gap at the top is 0.160 and at the bottom is 0.152. This equals 0.008" misalignment in 5 inches
R fo o
(the diameter of the coupling). Base length is 12 inches. Therefore, shim thickness required is about 2.112
E E f
times 0.008" or about 0.020". A shim placed under the low end of the driver will tilt it into approximate angular
F E
alignment with the driven unit.
E
R U U S S
3. Using a straightedge and feeler gauges, measure the height difference between driver and driven unit height at
T T
the OD of Figure A-8. Straight Edge Feeler Gauge Alignment the coupling halves. Then, place shims at all
O
driver support points equal in thickness to the measured height difference.
N NO
4. Finally, use a straightedge to check alignment of O.D's at the sides of the coupling. Using a feeler gauge,
O O
check the gap between coupling hub faces at the sides of the coupling. Adjust the driver as necessary to align
D D
the O.D's and to set the gap equal at the sides.
A.5.5 Coupling Alignment - Dial Indicator Method
A dial indicator can be used in two ways to check coupling alignment. They are:
1. Attached to one shaft or coupling half while contacting the second hub or shaft while both shafts are rotating,
or
2. Attached to one shaft or coupling half while contacting the second hub or shaft while one shaft is rotating.
The ideal method is the first, dial indicating while both shafts are rotating. In this method, when the indicator is
rotated its tip will proceed in a circle which is concentric with the shaft bearings. The mating unit shaft should also
be rotated, since the point contacted by the indicator tip will also describe a true circle. When these two circles
coincide (zero runout on the indicator) the shafts will be in alignment in the plane being measured. The reason this
method is ideal is that coupling surface runout does not affect the accuracy of shaft alignment. In other words, it is
possible by this method to accurately align shafts in spite of coupling surfaces that are not running true to each
other. However, in some cases, the above method is not possible. In such cases, it becomes necessary to use the
method of attaching the dial indicator to one shaft or coupling half while contacting the second hub or shaft while
one shaft is rotating. Refer to Figure A-9 and proceed as follows:
A.5.5.1 Vertical Face Alignment
Attach the indicator to the shaft or coupling half of the driver. Place the indicator tip in contact with the face of the
t
coupling half on the driven unit. Rotate the shafts of both units together and note the total indicator readings (T.I.R.)
n
at top and bottom. T.I.R. is a measure of vertical angular misalignment. Place shims (calculate the amount as pre-
e
viously described) under the driver at the low end to bring it into vertical alignment with the driven unit.
Y m
NL uip ion
A.5.5.2 Vertical Height Alignment
O q t
Place the indicator tip in contact with the outside surface of the driven unit coupling half. Rotate shafts of both units.
L f E ra
Note the indicator readings at top and bottom. The height difference between the units is one-half of the T.I.R.
I A e
Place shims at all driver support points equal to one-half total indicator runout.
R ce O o p
E
A.5.5.3 Horizontal Face Alignment
t
AT nan en
Place the indicator tip in contact with the face of the driven unit coupling half. Move the driver as necessary to
obtain zero reading on the indicator.
M te m
A.5.5.4 OD Alignment
E i n i p
C a q u
N M E
Place the indicator in contact with the OD surface of the driven unit coupling half. Move the driver as necessary to
E r
obtain zero reading on the indicator. Repeat steps 3 and 4 as necessary to obtain zero readings on both face and
R fo o r
OD surfaces at the sides of the coupling. Do not disturb shims during horizontal alignment adjustments.
FE E f
E
A.5.6 Sheaves
E
R U U S S
1. Inspect sheaves to see that belts or wire rope have not worn grooves into the sheaves. Replace sheaves when
T T
wear grooves appear since grooves will cause rapid and dangerous belt or rope damage.
O
N NO
2. Make sure the belt or wire rope is correctly sized for the sheave on which it is being used. If there is any doubt,
check your operating and/or maintenance manual to determine the proper size for the application.
A.5.7 GearsO
D DO
Some of the basic terms associated with gears are defined under the topic “Terminology”. Some of the defects for
which gears should be inspected are defined under “Inspection”.
TERMINOLOGY.
ADDENDUM. The addendum is the distance a gear tooth extends above the pitch circle (or circular pitch).
BACKLASH. Backlash is the difference between the thickness of a tooth and the width of the gap between the two
gear teeth on it's mating gear. Backlash is necessary to compensate for variations in spacing and form of the gear
teeth, to provide space for lubricant, and to allow expansion of the teeth when their temperature increases during
operation.
BOTTOM LAND. The bottom land is the surface at the bottom between adjacent gear teeth.
CIRCULAR PITCH. Circular pitch is the distance along the pitch circle or pitch line between the corresponding pro-
files of adjacent teeth.
CIRCULAR THICKNESS OF TOOTH. The circular thickness of a tooth is the length of the arc between the two
sides of a gear tooth as measured along the pitch circle unless otherwise specified.
CLEARANCE. Clearance is the radial distance between the working depth circle and the root circle.
n t
e
DEDENDUM. The dedendum is the depth of the tooth space below the pitch circle or pitch line; the radial distance
Y m
between the pitch circle and the root circle.
NL uip ion
FACE WIDTH. The face width is the length of a gear tooth in the plane parallel to the shaft centerline (the axial
O q t
plane).
A L f E ra
FILLET CURVE. The fillet curve is the concave portion of the tooth profile where it joins the bottom land.
I o p e
ER ce O
PITCH CIRCLE. Pitch circle is the curve of intersection of a pitch surface of revolution and a plane of rotation. It is
the imaginary circle that rolls without slipping with a pitch circle of a mating gear.
t
AT nan en
ROOT CIRCLE. The root circle is tangent to the bottom of the tooth space when viewed in a cross section.
M te m
E p
TOOTH PROFILE. Tooth profile is one side of a gear tooth in a cross section between the outside circle and the
root circle.
C a q i n u i
N M E
WORKING DEPTH. The working depth is the depth of engagement of two gears; the sum of the operating adden-
E
dum.
R o r o r
E E f f
TOP LAND. The top land is the surface of the top of the gear tooth.
E F S E
S
WHOLE DEPTH. The whole depth is the distance from the top land to the bottom land.
R U U
A.6 Gear Tooth O
T T
N
Wear
N O
O
D DO
A.6.1 Inspection
All gearing should be inspected for signs of wear or damage. If any of the problems illustrated and discussed below
are found, the problem should be corrected and, if necessary, the gear or gear set should be replaced as soon as
possible.
A.6.2 Gear Wear
Gear wear is usually caused by abrasion, corrosion or lubrication failure. Each is discussed below:
If a damaged or worn pinion or gear must be replaced always replace the mating gear or pinion.
Do not run a new pinion or gear with a worn mating part as rapid failure of the parts will result.
1. Abrasion. Abrasive wear is typified by a lapped appearance, radial scratch markings or grooving of the tooth
contact surfaces and is generally caused by foreign material in the lubricating oil.
2. Corrosion. Corrosive wear is a deterioration of the tooth surface caused by chemical action. It often results
from active ingredients in the lubricating oil such as acid, moisture or extreme pressure additives. Lubricants
t
can also be contaminated by atmospheric chemicals, or chemicals or other materials (such as salt water)
n
which somehow leak into the lubricant supply.
Y e
m
3. Lubricant Failure. Lubricant failure results in allowing metal-to-metal contact of gear teeth. This causes over-
NL uip ion
heating, which produces alternate welding and tearing of the metal, thus removing metal from the tooth sur-
faces. This is called “scoring”. The most common cause of this problem is localized overheating of the teeth at
O q t
the point at which they mesh, causing breakdown of the lubricant film. Another similar condition called “frost-
L f E ra
ing” is a form of scoring typified by micropitting under thin lubricant film conditions.
A.6.3 Surface Fatigue

I A o p e
ER ce O
t
AT nan en
Surface fatigue of gear teeth is divided into three primary categories. They are:
1. Pitting. Pitting occurs when the endurance limit of the tooth material is exceeded. The usual causes are over-
loading or excessive shock.
M te m
E i n i p
C a q u
2. Spalling. Spalling is similar to pitting except that the pits are usually larger, very irregular in shape and quite
N M E
shallow. Spalling is usually caused by high contact stress levels. The edges of the initial spalled areas break
E r
away rapidly and larger irregular voids are formed. These voids often join together and form still larger voids.
R fo o r
E E f
3. Case Crushing. Case crushing is a subsurface fatigue failure which occurs when the endurance level of the
F E
tooth material is dramatically exceeded. Severe shock loading is the most likely cause of case crushing.
E
R U U
A.6.3.1 Plastic Flow S S
T T
O
Plastic flow consists of deformation of tooth surfaces caused by high contact stresses as the gear teeth mesh.
N NO
There are two basic types of plastic flow. They are:
O
D DO
1. Cold Flow. Cold flow is the cold-working deformation of tooth surfaces caused by high contact stresses and the
rolling and sliding action of the meshing teeth. The dents and battered appearance of the surfaces are a result
of dynamic loading due to operation while the tooth profiles are being damaged by a combination of cold-work-
ing and wear.
2. Rippling. Rippling is generally caused by high contact stresses under cyclical operation. This has a tendency to
roll and knead the contact surfaces, resulting in the rippling of the immediate surface.
A.6.3.2 Gear Backlash
Gear backlash is the play between teeth which prevents the gears from binding while in motion. It is built into the
gearset during manufacture. In terms of tooth dimensions, it is the amount by which the width of the tooth spaces
exceeds the thickness of the mating gear teeth. Backlash can also be described as the distance, measured along
the pitch line, that a gear will move when engaged with another gear that remains motionless.
Normally, there must be some backlash present in gear drives to provide running clearance and room for lubricant.
Without backlash, gear binding will result in heat generation, noise, abnormal wear, and possible failure of the
gearset.
Backlash is built into standard gears by cutting the gear teeth thinner by 50% of the backlash desired in the set.
When two gears made in this manner are mated, at proper center-to-center distance, their two 50% allowances
combine to give 100% of the backlash desired by the designer.
On non-reversing drives, or where load is applied in only one direction, the increase in backlash that results from
tooth wear does not adversely affect operation. However, on reversing drives and drives where timing is critical,
excessive backlash cannot be tolerated.
n t
The following illustration and chart can be used as a rule of thumb to obtain the approximate backlash for a pair of
e
gears operating at standard center distance. See Figure A-12. This chart should only be used when the manufac-
Y m
turer's recommendations can not be obtained. If any discrepancy between the chart and manufacturer's recom-
NL uip ion
mendations exists, the manufacturer's instructions take precedence.
O q t
In general, check backlash as follows:
1. Hold one gear motionless.

A L f E ra
I o p e
R ce O
2. Turn the mating gear until it contacts the motionless gear.
E t
AT nan en
3. Install a dial indicator touching the gear which can be moved on the side toward which it can be moved and
turn the gear as far as it will go.
M te m
E p
4. Read the total backlash on the dial indicator. Note that feeler gauges can often be used in place of a dial indi-
C a q i n u i
cator. The space which constitutes backlash is illustrated in Figure A-12. Backlash must be held within the lim-
its specified by the manufacturer or rapid gear wear will result.
E N M E
A.6.4 Shafts
R o r o r
E E f f
F
All shafts should be inspected for nicks, burrs, and wear ridges prior to reinstallation. Smooth defective areas using
E S E
crocus cloth, India Stone or a very fine file. It is particularly important that shaft seal surfaces (surfaces on which
S
R U U
seal lips fit) be smooth to prevent seal lip wear, which will cause lubricant leaks. Keyways must be free of nicks and
burrs.
T T
O
N NO
O
D DO
320XPC Mechanical Systems Manual General Hydraulic System Maintenance
Appendix B
General Hydraulic
System Maintenance
B.1 General
n t
e
Maintenance of individual hydraulic system components such as motors, pumps or valves is included in the system
Y
of which the component is a part. For example, maintenance and repair of the propel motor is covered under Pro-
m
NL uip ion
pel System. The purpose of this section is to discuss maintenance of hydraulic systems in general.
O q t
This section includes general procedures to be followed in the event of hydraulic component failure, preventive
L f E ra
maintenance, bleeding procedures, flushing procedures, and recognition of trouble symptoms.
I A o p e
B.2 General Maintenance Rules
ER ce O
t
AT nan en
The following points should be kept in mind when working on the hydraulic system or any components of the sys-
tem:
M te m
E i n i p
C a q u
E N M E
R o r o r
Pressurized fluid escaping from a hydraulic system can penetrate the skin causing seri-
f f
ous injury. Always relieve pressure by connecting a microbore hose from the appropri-
F E E
ate test port to the tank test port before disconnecting hydraulic lines. Tighten all
E S E
connections before reapplying pressure. Keep hands and body away from pinholes and
S
R U U
nozzles which eject fluid under high pressure. Use a piece of paper to search for leaks.
T T
Do not use your hands. If any fluid is injected into the skin, it must be surgically removed
within a few hours by a medical doctor or gangrene can result.
O
N NO
1. All systems are designed to operate within minimum and maximum pressure limits. A pressure relief (unload-
O
D DO
ing) valve is included in nearly all systems to limit maximum pressures to levels for which the system is
designed.
! WARNING
The setting of a pressure relief or unloading valve must never be increased in an attempt
to “get more out of the system”. This could cause the system to operate at a pressure
level for which it was not designed and equipment damage and/or personnel injury or
death could result.
2. Because internal leaks waste the power of the system, working parts are designed for extremely close fits.
Because of the necessary close fits, even very small amounts of dirt or foreign material can cause wear or
damage to components, which will, in turn, cause faulty operation of the system. Every precaution must be
AppendixB.fm -B.1- Appendix B, Version 01 - 04/08
General Hydraulic System Maintenance 320XPC Mechanical Systems Manual
taken to assure absolute cleanliness of hydraulic oil. This includes dirt, chips from failed parts of the system, as
well as contaminants such as water or other fluids which are incompatible with the fluid in the system.
3. To ensure cleanliness of the system oil, samples should be drawn from the reservoir every 6 month (more
often, if problems are experienced). Each sample should be taken by an approved sampling procedure (e.g.
IS0 Standard 4021) and analyzed by a qualified lubrication specialist to determine whether it is suitable for fur-
ther use. The interval between normal hydraulic fluid replacements depends on operating conditions and on
successfully keeping contaminants out of the system.
4. Whenever there is a hydraulic system component failure that gives reason to believe that there are metal parti-
cles or other foreign materials in the system, drain and flush the entire system, clean strainer baskets and
replace filter cartridges. A complete change of hydraulic oil must be made under these circumstances.
n t
Y e
m
NL uip ion
Flushing the hydraulic system is time consuming and expensive. Therefore, it should be done
O q t
only when necessary. However, avoiding a flush when there is clear evidence of a contami-
L f E ra
nated system will prove to be a false economy in the long run.
I A o p e
5. Whenever the hydraulic system is drained, check the magnetic drain plugs for metal particles. If metal particles
R ce O
are present, flush the system and add a new charge of oil.
E t
AT nan en
6. Never change the type of oil used in the system without first checking that the replacement oil is acceptable for
use in the system.
M te m
E n i p
7. All containers and funnels used in handling hydraulic oil must be very clean. Use a funnel with a 200 mesh
C a q i u
screen for filling the hydraulic oil reservoir and fill the reservoir only through the filler opening. The use of cloth
N
to strain the oil is not acceptable because this will allow lint to enter the system.
E r M E
r
8. When removing any hydraulic component, be sure to cap and tag all hydraulic lines involved. Always plug the
R fo f o
ports of the removed components.
E E
E F S E
9. All hydraulic components must be disassembled and assembled in spotlessly clean surroundings. During dis-
R U U S
assembly, pay particular attention to the identification of parts to ensure correct reassembly. Clean all metal
parts in a clean mineral oil solvent. Be sure to clean all internal passages. After the parts have dried, lay them
T T
on a clean lint-free surface for inspection.
O
N NO
10. Replacement of all O-rings, back-up rings and seals is recommended when overhauling any component. Lubri-
cate all parts with hydraulic oil before reassembly. Use small amounts of petroleum jelly to hold O-rings in place
O
D DO
during reassembly.
11. Replace all lost hydraulic oil after completing installation of repaired components. Always maintain a sufficient
quantity of clean hydraulic fluid of the proper type and viscosity in the reservoir.
12. Bleed air from the system after components have been removed from the system or when it is suspected that
air has entered the system.
13. Keep all hydraulic connections tight. A loose connection in a hydraulic line will permit the oil to leak out or air to
be drawn into the system. Air in the system can cause damage to components as well as noisy or erratic sys-
tem operation.
14. Change filter elements and clean strainers when necessary.
Appendix B, Version 01 - 04/08 -B.2- AppendixB.fm
B.2.1 Correct Tightening of Hydraulic Connections
The following procedures are recommended to ensure that system hydraulic connections are correctly made and
to minimize the probability of system leaks.
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
Figure B-1: Tightening SAE Flare Connections
n t
Y e
m
NL uip ion
O q t
A L f E ra
I e
Table B-1: Pipe Thread Leaks
R ce O o p
E
B.2.2 Pipe Thread Connections
t
AT nan en
Pipe thread connections tend to leak more at high pressure than any other style of connection. National pipe threads (NPT)
leak much more than do the dry seal thread (NPTF) types. However, either will leak if under-tightened or over-tightened. Use
M te m
a good pipe thread sealant on NPT threads of the male connection, but do not use sealant on the first two threads. This will pre-
E n i p
vent the sealant from entering the system. Always apply sealant on male threads - never apply sealant to female threads. The
C a q i u
most probable causes and remedies for pipe thread leaks are listed in Table B-1.
B.2.3 SAE Flare Connections

E N M E
R o r o r
f f
Most leaks from this type of connection are due to lack of tightening and human error. It is impossible to tell if the nut has been
E E
tightened by simply looking at the connection. Figure B-1 shows one method of tightening this type of connection. If the joint
F E(O-ring Seal)
still leaks after it has been correctly tightened, refer to Table B-2 for possible remedies.
R U U S
B.2.4 SAE StraightEThread Connection
S
T T
O
This type of connection leaks most often because the jam nut and washer are not properly installed before assem-
N NO
bly of the fitting. As a result, there is not enough room for the O-ring to seat when it is squeezed and the washer
cannot seat properly on the face of the O-ring boss (View A, Figure B-2). The compressed rubber between the
O
D DO
washer and the boss face will cold flow out of compression and the fitting will loosen and leak. Leakage from
straight thread connectors may be indicated by any of the following:
1. Fittings loosen after short service.
2. O-rings leak after short or long service.
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o e
Figure B-2: Incorrect O Ring Installation
R ce O p
E t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO Table B-2: Flare Connection Leakage
O
D DO
3. Instant leakage upon start-up. To stop leakage from straight thread connectors, proceed as follows (see Figure
B-3):
A. Back the jam nut and washer (View A, Figure B-3) to the end of the smooth portion of the fitting.
B. Lubricate the O-ring.
C. Thread the fitting into the port, finger tight.
D. Back the fitting out (no more than one turn) to align the fitting for attachment of the mating hose or tube.
E. Tighten the jam nut to achieve the O-ring seal as illustrated in View B, Figure B-33.
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
Figure B-3: Correct O Ring Installation
t
B.2.5 Split Flange Connections
AT nan en
M te m
E n i p
Table B-3 lists probable causes and remedies for split-flange connection leaks. To install a split flange connection,
C a q i
refer to Figure B-4 and proceed as follows:
u
E N M E
1. Thoroughly clean the sealing surfaces and the flanges.
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
D DOO
Figure B-4: Split Flange Tightening Sequence
2. Lubricate and install the proper O-ring in the fitting groove.
3. Align the fitting with the port and assemble the flanges over the fitting.
4. Snug the bolts in the sequence shown in Figure B-4 to 113 of the torque value obtained from Table B-4. Be
sure the flanges remain square with the fitting and bolt surface.
5. Torque the bolts diagonally to 213 of the final torque value from Table B-4.
6. Torque the bolts diagonally to the final torque value in Table B-4.
n t
Y e
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NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
F
Table B-3: Split Flange Leakage
E S S E
R U U
T T
O
N NO
O
D DO
B.2.6 Flat Face O-ring Seal Connections
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f Table B-4: Split Flange Torque Values
E F S E
S
Flat face O-ring seal connections allow installation or replacement of connecting parts without mating piping. O-ring
R U U
failure is the primary cause of leaks in this type of fitting. Contamination, improper fluid, or improper installation of
T T
the O-ring or fitting may cause premature failure of the O-ring. To install a flat face O-ring seal fitting, proceed as
O
follows:
N NO
1. Be sure the fitting sealing surfaces are clean and free of defects. See Figure B-5.
O
D DO
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
Figure B-5: Flat-face O Ring Seal Connection
E i n i p
C a q u
2. Inspect the O-ring. It must be free of defects.
E N M E
3. Lubricate the O-ring and install it in the groove. Use petroleum jelly to hold the O-ring in place.
R o r o r
E E f f
4. Assemble the fitting and hand tighten while pressing the joint together. This will ensure that the O-ring remains
F
in proper position.
E S S E
R U Systems
5. Tighten the connection to the torque value specified in Table B-5.
B.2.7 Troubleshooting Hydraulic U

T T
O
N NO
Probably the greatest aid to troubleshooting is knowledge of the system. Every component has a purpose in the
O
system. The construction and operating characteristics of each component should be understood.
D DO
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o e
Table B-5: Flat-face Seal Torque Values
p
ER ce O
t
B.2.8 Developing Systematic Procedures
AT nan en
To troubleshoot a system effectively, develop a logical sequence of looking for the cause of the problem, using
M te m
some or all of the following techniques:
E i n i p
C a q u
1. Ask the operator how the machine performed when it started to fail or if there was anything unusual happening
N
prior to the machine failure.
E r M E
R r
2. If the machine is operative, check to see what gauge or other indications are normal and which are out of nor-
mal limits.
E E fo f o
E F S E
3. Visually inspect the machine for oil leaks and loose connections.
R U U S
4. Examine filters and all lines, checking for heat, loose connections and collapsed hoses.
T Symptoms
T
O
B.2.9 Recognizing Trouble
N N O
O
The following symptoms are signs of trouble:
D DO
B.2.9.1 Excessive Heat
A misaligned pump places an excessive load on bearings and can be readily identified by the heat generated. A
warmer than normal return line may indicate that the system is operating at the unloading valve setting. Low vis-
cosity hydraulic oil will increase the internal leakage of components, resulting in a heat rise. Cavitation and slip-
page in a pump will also generate excessive heat.
B.2.9.2 Excessive Noise
Wear, misalignment, cavitation or air in the oil will cause noise. Contaminated oil can cause an unloading valve to
stick or chatter. Excessive noise may be the result of dirty filters or fluid, high fluid viscosity, excessive drive speed,
low reservoir level or loose intake lines, which would allow air to enter the system.
320XPC Mechanical Systems Manual Component Weight Tables
Appendix C
Component Weight Tables
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
AppendixC.fm -C.1- Appendix D, Version 00 - 05/09
Component Weight Tables 320XPC Mechanical Systems Manual
Weight
Component Part Number Pounds Kilograms
Lower Final Assy * 100J6626F5 38,161 17,346

• Equalizer Axle R11405F1 3,680 1,673
• Equalizer Axle Mount 18N2599D1 347 158
• Equalizer Axle Pivot Pin 19P861D1 128 58
• Main Axle R41246D2 6,410 2,914
• Main Axle Mount (each) R33987F1 989 450
• Crawler Assy (each and without shoes) R6575F7 (RH) or F8 (LH) 12,847 5,840
•• Crawler Frame
•• Planetary Transmission
n
53r176D2 t
R6570D3 (RH) or D4 (LH) 7,560
2,800
3,436
1,273
••• Propel Motor **
Y e
41U100D2 200 91
m
NL uip ion
•• Drive Tumbler R54640D2 1,000 455
36" Crawler Shoe (each) 5004012 290 132
O q t
L f E ra
LH Platform Assy R57590F1 15,750 7,159
A
• Weldment w/grating R57096D2 7,924 3,602
I o e
• HV Switch Cabinet Assy R60404F1 244 111
R ce O p
• Oil Cooler (empty) R58736F1 1,900 864
E
• T-tank Assy (empty) R55420F2 4,873 2,215
t
AT nan en
•• T-tank Oil Separator Cover R10591D1 393 179
•• T-tank Oil Separator - Inner Element R63585D1 360 164
•• T-tank Oil Separator - Outer Element 5010588 560 255
M te m
• Muffler 27Q762D1 185 84
E p
• Butterfly Valve R51305D2 193 88
• Water Tank (empty)
C a q i n u i R61180F1 3,520 1,600
N M E
Rear Deck Assy R57543F1 13,776 6,262
E r
• Weldment R57163D1 12,695 5,770
R fo
• A/C Mounting Bracket
o r R63463D1 317 144
E E f
10 " Rear Leveling Jack Cylinder Assy R57579F1 4,300 1,955
F
• Jack Cylinder R55005D1 - est weight 1,000 455
• Jack Spud
E
• Jack Cap
S S E 5002036
R37239D1
855
267
389
121
R U U
Rear Deck Assy w/Leveling Jacks 18,076 8,216
T T
O
Rotary Carriage Assy R54410F4 29,175 13,261
N NO
• Rotary Gearcase Assy R10678F2 8,833 4,015
• Pulldown Gearcase Assy 916J204F1 10,900 4,955
O
D DO
Mast Assy
• Mast Final Assy
• Weldment
R14102F8
R53818D2
900
31,700
409
14,409
• Safety Sling Assy - Upper R35131F1 800 364
• Safety Sling Assy - Lower R27427F3 775 352
Mast Assy w/o Rotary Carriage Assy 34,175 15,534
Mast Assy w/Rotary Carriage Assy R53818D2 63,350 28,795
* Weight does not include crawler shoes.

** Estimated weight.
Figure C-1: 320XPC Component Weights (Sheet 1 of 3)
Appendix D, Version 00 - 05/09 -C.2- AppendixC.fm
320XPC Mechanical Systems Manual Component Weight Tables
Weight
Mast Support Assy R58192F1 12,700 5,773

• Pivot Pin R63367D1 103 47
• Hoist Cylinder R24281D1 600 273
• Auxiliary Winch 23U52D1 740 336
Bit Breakout Wrench - 15" Bit 5003178 130 59
Bottom Plate
n t
R57094D1 4,327 1,967
Y e
m
Pipe Rack Assy 100J6766 3,342 1,519
NL uip ion
• Weldment 16J1647D1 2,170 986
• Upper Arm R10364D1 246 112
O q t
• Lower Arm 6N612D1 326 148
L f E ra
• Cylinder - Lower R10271D1 230 105
Back Brace Assy

I A o p e
R57829F1 1,955 889
R ce O
• Brace - Lower 5004271 417 190
E
• Brace - Upper 5006144 642 292
t
AT nan en
• Brace - Collar 5006143 437 199
Operator Cab R57302F1 6,030 2,741
M te m
E n i p
Air Conditioner R59320D1 750 341
RH Platform
C a q i u R58768F2 5,305 2,411
• Ladder Assy
E N M E
R50340D1 200 91
r r
• House Section R58078F1 2,683 1,220
R fo o
• Catwalk R57364D1 1,896 862
FE E f
• Folding Ladder (Rear) 5201319 273 124
E S
RH Rear Platform
S E R57895F1 1,574 715
R U U
Optional Top-off Tank Filter Panel - Single R34574D1 437 199
T T
Optional Top-off Tank Filter Panel - Dual R34573D1 - est weight 900 409
O
N NO
Main Frame Assy R59383F1 30,409 13,822
O
D DO
8" Front Leveling Jack Assy
• Jack Cylinder
• Jack Spud
R57352F1
R17564D2
303006
3,600
640
736
1,636
291
335
• Jack Cap R63531D2 405 184
• Jack Casing 14J1906 1,939 881
10" Front Leveling Jack Assy (each) R65392 5,779 2,627

• Jack Cylinder R55005D1 640 291
• Jack Spud 5002036 855 389
• Jack Cap R65390D2 428 195
• Jack Casing R65335D1 1,610 732
AppendixC.fm -C.3- Appendix D, Version 00 - 05/09
Component Weight Tables 320XPC Mechanical Systems Manual
Weight
Mast Support Assy R57583F1 3,545 1,611

• Dynavane Filter Assy 49R20D2 480 218
Pressurizer Motor/Fan 49R20D2 310 141
Transformer R59275D1 7,300 3,318
t
Optional 10KW Heater w/Wall Mount R63966 313 142
Optional Auxiliary Compressor

e n
R60833 - est weight 700 318
Y m
NL uip ion
Optional Soft Start Transformer R60670D1 4,700 2,136
O q t
Optional Soft Start Vacuum Switch Cabinet R60688F1 450 205
L f E ra
HV Cabinet R60836F1 1,165 530
Main Control Cabinet (MCC)

I A o p e R58946F1 1,490 677
DC Drives Cabinet
ER ce O R58386F1 1,895 861
t
AT nan en
Grease Tank & Panel Assy R57525D1 300 136
M te m
Hydraulic Tank Assy R58307F1 1,770 805
E i n i p
u
Power Unit Assy R57827F2 15,500 7,045
NC a q
• Base Weldment R59793D2 1,144 520
M E
• Main Drive Motor - 1000 HP EBM1720F1A 4,300 1,955
E r
• Air Compressor - Sullair 3850 CFM R47474D2 4,400 2,000
R fo o r
• Pump Drive Transmission (PDT) R52932D1 1,576 716
E E f
• Main (Propel) Pump R57532D1 219 100
F
• Air Filter Assy w/Frame 46U63 420 191
E S S
Power Unit Assy
E R57827F3, F4, F6 12,415 5,643
R U U
• Base Weldment R59793D2 1,144 520
T T
• Air Compressor - GD 51U165D1 or D4 3,800 1,727
O
N NO
• Air Filter Assy 46Z534D1 100 45
O
D DO
Power Unit Assy
• Base Weldment
R57827F5
R59793D2
11,665
1,144
5,302
520
• Air Compressor - GD 3600 CFM 51U165D4 3,800 1,727
• Air Filter Assy 46Z534D1 100 45
Jack Shoe 30" GH188995 475 216

Jack Shoe 50" - Front Jack R56353D1 920 418
Jack Shoe 50" - Rear Jack R56352D1 838 381
Appendix D, Version 00 - 05/09 -C.4- AppendixC.fm
INTENTIONALLY BLANK
n t
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NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
n t
Y e
m
NL uip ion
O q t
A L f E ra
I o p e
ER ce O
t
AT nan en
M te m
E i n i p
C a q u
E N M E
R o r o r
E E f f
E F S E
R U U S
T T
O
N NO
O
D DO
All designs, specifications and components of the equipment described above are subject to change at the manufacturer’s sole discretion at any time
without advance notice. Data and descriptions published herein are informational in nature and shall not be construed to warrant the service or the
suitability of the equipment for any particular purpose as performance may vary with the conditions encountered. The only warranty applicable is our
standard written warranty for this equipment or service.
P&H, Centurion, PreVail, Optima, TripRite and Delta are trademarks of Joy Global Inc. or one of its affiliates. joyglobal.com
© 2012 P&H Mining Equipment Inc. All rights reserved.

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320XPC Mechanical Manual

Copyright © 2012 P&H Mining Equipment, Inc. Peak Services

Peak Services Copyright © 2012 P&H Mining Equipment, Inc.

Model 320XPC Mechanical Systems Manual Visual Table of Contents

Copyright © 2012 P&H Mining Equipment, Inc. Peak Services

Peak Services Copyright © 2012 P&H Mining Equipment, Inc.

SECTION 1, Blasthole Drill Safety

2.2.1 General . . . . . . . . . . . . . . .E . . . . . . . . i.p

2.2.2 Drill Description . . . . . . .C . . . . . . .a. . . . . . . .u

2.2.3 Power Unit . . . . . . . . N . . . . . . .M. . . . . . . . . .q. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

SECTION 3, Preventive Maintenance

Copyright © 2012 P&H Mining Equipment, Inc. Peak Services

Table of Contents (Continued)

Peak Services Copyright © 2012 P&H Mining Equipment, Inc.

Table of Contents (Continued)

SECTION 4, Cable Reel

Copyright © 2012 P&H Mining Equipment, Inc. Peak Services

Table of Contents (Continued)

SECTION 6, Power Unit

6.2 Power Unit Maintenance . . . N . . . . . . . . . . . . . . . . .q. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.2.1 Main Drive Motor E

SECTION 8, Water Injection System

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Table of Contents (Continued)

SECTION 9, Hydraulic System

SECTION 11, Leveling System

Copyright © 2012 P&H Mining Equipment, Inc. Peak Services

Table of Contents (Continued)

SECTION 12, Lubrication

SECTION 13, Mast

Peak Services Copyright © 2012 P&H Mining Equipment, Inc.

Table of Contents (Continued)

SECTION 14, Hoist/Pulldown Machinery

15.1.2 RotaryE Drill PipeS

SECTION 16, Pipe Handling Equipment

Copyright © 2012 P&H Mining Equipment, Inc. Peak Services

Table of Contents (Continued)

T T And Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2

Peak Services Copyright © 2012 P&H Mining Equipment, Inc.

Table of Contents (Continued)

19.1.1 Installation . . . . . . . . . . . . . . . . . . . .T .......n

19.1.4 NORMAL OPERATION . .E . . . . . . . . . t. . . . . . .p

19.2.4 CheckingF FastenersEand Fittings E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.10

Copyright © 2012 P&H Mining Equipment, Inc. Peak Services

Table of Contents (Continued)

B.1 General . . . . . . . . . . . . . . . . . . . . .E . . . . . . . . i.p

Peak Services Copyright © 2012 P&H Mining Equipment, Inc.

SECTION 1, Blasthole Drill Safety

SECTION 3, Preventive Maintenance

SECTION 4, Cable Reel

Copyright © 2012 P&H Mining Equipment, Inc. Peak Services

List of Figures (Continued)

Figure 6-2: Main Drive Motor. . . . . . . . . . . . . . . . . . . .R . . . . . . .e . . . . . . .O

Figure 6-5: Pump Drive Flexible Coupling.M

Figure 6-6: Coupling Hub Removal . . .E . . . . . . . . . t. . . . . . .p

Figure 7-4: MainR UFlow Diagram. U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

Figure 7-5: T-tank andT

SECTION 8, Water Injection System

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List of Figures (Continued)

SECTION 9, Hydraulic System

Copyright © 2012 P&H Mining Equipment, Inc. Peak Services

List of Figures (Continued)