Libro de Operacion y Mantenimiento PDF

February 2012
BI006752
Operation and
Maintenance
Manual
MD6240 and MD6290
Rotary Blasthole Drill
412450 Rev. 06
SAFETY.CAT.COM
PARTS ORDERING AND PRODUCT SUPPORT
Use only genuine Cat® parts in the maintenance, rebuild or repair of these machines. The manufacturer
shall have no liability as to any unauthorized modification of machines or parts. The manufacturer is also
not obligated or liable for any machines or parts that have been improperly handled; that have not been
operated, maintained or repaired according to furnished manuals or other written instructions, and that
have been operated with other than genuine Cat parts or authorized OEM components.
IDENTIFICATION OF THE MACHINE

Always furnish the Model Number and Serial Number when ordering parts. This information is found
on the machine nameplate.
PART NUMBER AND DESCRIPTION

In addition to the Model and Serial Number, always give the part number and description of each part
ordered. If there is any doubt as to the correct part number and description, furnish a dimensional
sketch or return the part to be replaced, transportation charges prepaid. Your cooperation in furnishing
as much information as possible will assist us in filling your orders correctly and in the shortest possible
time.
SHIPMENT
Unless otherwise instructed, all shipments will be made via motor freight collect, freight forwarder or
UPS prepaid and charged on our invoice. Shipments cannot be made on open account until your credit
has been approved by our accounting department.
PARTS ORDERING
In North America Telephone 1-800-854-9030
or Telefax 1-800-582-6570
Telephone (903) 786-2981
Telefax (903) 786-6407
PRODUCT SERVICE AND WARRANTY

In North America Telephone 1-800-258-0009
Telephone (903) 786-2981
Telefax (903) 786-6408
Caterpillar Global Mining LLC

Mining Products Division
3501 S. FM Hwy 1417, Denison, TX 75020
Mining.cat.com
© 2012 Caterpillar All Rights Reserved. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,”
the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of
Caterpillar and may not be used without permission.
Printed in U.S.A.
Safety Information
This safety alert symbol indicates important safety messages in this manual.
When you see this symbol, carefully read the message that follows and be alert to
the possibility of personal injury or property damage.
Before Starting Engine, Study Operator’s Manual

* Read and understand the warnings and cautions shown in Section 2
* Practice All Safety Precautions
* Make Pre-Operations Check
* Learn Controls Before Operating
It is Owner/Operator’s responsibility to understand and follow manufacturer’s in-
structions on machine operation and maintenance, and to observe pertinent safety
precautions, laws and regulations.
California Proposition 65 Warnings

The following warning applies to equipment supplied with lead-acid batteries:
Battery posts, terminals and related accessories contain lead and lead compounds,
chemicals known to the State of California to cause cancer and reproductive harm.
Wash hands after handling.
The following warning applies to equipment supplied with diesel powered engines:
Diesel engine exhaust and some of its constituents are known to the State of Cali-
fornia to cause cancer, birth defects, and other reproductive harm.
Drill Model : ___________________________________
Drill Serial No. : ________________________________
Date Delivered : ________________________________
Dealer : _______________________________________
Customer : ____________________________________
Rev. 06
B1006752 02/15/2012
Introduction i
Product Description
Rotary blasthole drills are designed for blasthole drilling purposes only. DO NOT
use these machine for any other purpose than blasthole drilling. Any other use
could result in personal injury, property damage and will void the warranty.
These machines are crawler mounted drill rigs, consisting of two (2) major assemblies:
1. Rotary Drill Assembly

2. Excavator Type Undercarriage (Crawlers)
The rotary drill assembly is made up of the engine package, compressor package, hydraulic system,
rotary drive, pulldown and hoisting system and drill pipe handling mechanism.
The crawlers are powered by two (2) hydrostatic motors. Each crawler has its own independent, vari-
able and reversible speed control, and is equipped with 33.5 inch (85 cm) wide triple cleated grousers.
Manual Contents
This manual is furnished to acquaint operators with the machine specifications, safety and operating
procedures, machine controls and daily maintenance activites.
This manual should be considered a permanent part of the machine and must re-
NOTE
main with the machine at all times.
The instructions in this manual are not intended to cover all details about these machines, nor do
they intend to provide for every possible contingency that may be encountered in connection with the daily
operation or maintenance of these machines.
Continuing improvement and advancement of product design might have caused changes to your
machine which are not included in this manual.
Periodic additions or revisions may be made to this manual. The right is reserved to make changes
at any time without notice and without obligation. Should further information be desired or should particu-
lar problems arise which are not covered sufficiently in this manual, the matter should be referred to the
manufacturer.
ii Introduction
Contents
MACHINE SPECIFICATIONS .............................................................SECTION 1
SAFETY ..............................................................................................SECTION 2
OPERATOR CONTROLS ...................................................................SECTION 3
OPERATING INSTRUCTIONS ...........................................................SECTION 4
DRILLING PRACTICES ......................................................................SECTION 5
MACHINE TRANSPORT ..................................................................SECTION 6
OPTIONS AND ACCESSORIES.........................................................SECTION 7
LUBRICATION AND PREVENTATIVE MAINTENANCE ....................SECTION 8
Introduction iii
Notes
iv Introduction
Section 1
Machine Specifications
\Machine Specifications 1-1

MD6290 Specifications
Pull-down/Hoisting Capacity Cooler Assembly

Rated pull-down capacity Up to 22,680 kg (50,000 lb); Radiator-CAC-Oil Cooler Assembly
optional 27,216 kg (60,000 lb) for Cat C15
Rated hoist capacity Up to 21,364 kg (47,100 lb) (Tier III) 540 hp, single, front-end mounted
Feed rate 0-42.9 m/min (0-141 fpm) Air-finned, three-core, radiator/aftercooling/hydraulic side-by-side
Retract rate 0-44.8 m/min (0-147 fpm) compressor–stacked, CAC-stacked
Pull-down cylinder stroke 513.08 cm (202 in) for 30 ft configuration Cooler height 139.70 cm (55 in)
Head travel (30 foot config) 1,026.16 cm (404 in) Cooler width 269.24 cm (106 in)
Pull-down cylinder stroke 589.28 cm (232 in) for 35 ft configuration Fan 121.92 cm (48 in) diameter; 10 blades
Head travel (35 foot config) 1,178.56 cm (464 in) Fan speed 1,525 rpm
Pull-down cylinder stroke 624.84 cm (246 in) for 11 m configuration Fan guard Welded
Head travel (11 m config) 1,249.68 cm (492 in) Engine radiator

Top tank Sealed top tank, pressure cap,
Type Hydraulic overflow tube and sight glass
Number of cylinders 1 Coolant connections 63.5 mm (2.5 in) top tank;
Cylinder bore 17.78 cm diameter (7 in) 88.9 mm (3.5 in) bottom tank
Cylinder rod 12.70 cm diameter (5 in) Compressor oil core hose connection 63.5 mm (2.5 in) O-ring boss
Cable type 1 in DYFORM 8 Hydraulic oil cooler

Hose connections 41.28 mm (1.625 in) O-ring boss
Nominal line tension 5 to 1 factor against working
Air-to-air cooler 114.30 mm (4.5 in) O.D.
Cable sheaves (cylinder) 40.64 cm OD (16 in) Standard ambient rating 52˚ C (125˚ F)
Cable sheaves (top and bottom) 55.88 cm OD (22 in)
Sheave pins 5.08 cm (2 in) diameter with roller bearing Radiator-CAC-Oil Cooler Assembly
Sheave guards Standard at bottom plate
for Cat C27
(Tier II) 800 hp, single, front-end mounted
Adjustable head guide shoes Steel with replaceable Nylatron
Air-finned, four-core, radiator/hydraulic side-by-side compressor
CAC–stacked
Rotary Drive System Cooler width 289.56 cm (114 in) dual fan
Rotation speed 0-220 rpm Cooler height 165.01 cm (65 in) dual fan
Torque 12,880 Nm max (0-9,500 ft-lb) Fan 116.84 cm (46 in) diameter, two fans, 16 blades
Horsepower capacity 138.7 kW (186 hp) Fan speed 1,700 rpm
Gearbox Casting design Fan guard Welded
Main thrust bearing Taper roller Engine radiator
Lubrication Oil flooded Top tank Sealed deaeriation tank, pressure cap,
overflow tube and sight glass
Gearing Spur
Standard ambient rating 52˚ C (125˚ F)
Ratio 16:04 to 1
Drive motor See Hydraulic System
Performance ratings are based on 100% efficiency and on engineering

specifications and calculations in accordance with accepted industry
standards. These capacities will vary with drilling conditions. All
specifications are subject to change without notice.
1-2 Machine Specifications

Cooler Assembly Compressor

Radiator-CAC-Oil Cooler Assembly Compressor (Standard)
for Cummins QXR-15 Type Oil-flooded, single-stage screw
Tier III; 485 hp or 535 hp, single, front-end mounted
Discharge air flow (sea level) 29.7 m 3/min (1,050 cfm)
Air-finned, three-core, radiator/aftercooling/hydraulic side-by-side
Max operating pressure 8.6 bar (125 psi)
compressor–stacked, CAC-stacked
Air cleaner
Cooler height 139.70 cm (55 in)
Type Dry-type with safety element/STG 16
Cooler width 269.24 cm (106 in)
Oil cooling Air-to-oil cooler, thermostatically controlled
Fan 121.92 cm (48 in) diameter; 10 blades
Oil separation Vertical barrier element, pre-separation
Fan speed 1,525 rpm
in 136 l (36 gal) (T-tank)
Fan guard Welded
Oil filtration 12 micron replaceable element
Engine radiator
Drive Direct coupled to engine flywheel
Top tank Sealed-top tank, pressure cap,
overflow tube and sight glass Controls Automatic with safety shut-down
Coolant connections 63.5 mm (2.5 in) top tank; Air shut-off Hydraulic cylinder-operated from operator’s seat
88.9 mm (3.5 in) bottom tank
Compressor oil core hose connection 63.5 mm O-ring boss (2.5 in)
Compressor (Optional)
Type Oil-flooded, single-stage screw
Hydraulic oil cooler
Hose connections 41.28 mm O-ring boss (1.625 in) Discharge air flow (sea level) 35.4 m 3/min (1,250 cfm)
Air-to-air cooler 114.3 mm (4.5 in) O.D. Max operating pressure 8.6 bar (125 psi)
Air cleaner
Radiator-Coolant-Oil Cooler Assembly Type Dry type with safety element/STG16
for QSK-19
Tier I; 750 hp, single, front-end mounted
Type Oil-flooded, single-stage screw
Air-finned, three-core, radiator/hydraulic side-by-side compressor-
stacked Discharge air flow (sea level) 48.1 m 3/min (1,700 cfm)
Cooler width 258.10 cm (101.625 in) single fan Max operating pressure 6.9 bar (100 psi)
Cooler height 154.94 cm (61 in) single fan Air cleaner
Fan 121.92 cm (48 in) diam, 10 blades Type Dry-type with safety element/SRG 20
Fan speed 1,525 rpm Compressor (Optional)

Fan guard Welded Type (high-pressure) Oil-flooded, two-stage screw
Engine radiator Discharge air flow (sea level) 32.6 m 3/min (1,150 cfm)
Top tank Sealed deaeriation tank, pressure cap, 38.2 m 3/min (1,350 cfm)
overflow tube and sight glass 42.5 m 3/min (1,500 cfm)
Standard ambient rating 52˚ C (125˚ F) Max operating pressure 10.3/24.1 bar (150/350 psi)
Radiator-CAC-Oil Cooler Assembly Air cleaner
for QSK-19 Type Dry-type with safety element/SRG 20
Tier II; 760 hp, single, front-end mounted
Air-finned, four-core, radiator/hydraulic side-by-side compressor
CAC–stacked
Cooler width 289.56 cm (114 in) dual fan
Cooler height 165.10 cm (65 in) dual fan
Fan 116.84 cm (46 in) diameter, two fans, 16 blades
Fan speed 1,700 rpm
Fan guard Welded
Engine radiator
Top tank Sealed deaeriation tank, pressure cap,
overflow tube and sight glass

Engine Engine (cont.)

Engine (Standard) Engine (Optional)
Manufacturer Caterpillar ® Manufacturer Cummins
Model C15 electronic (Tier III) Model QSX-15 (Tier III) electronic
Rated horsepower 403 kW (540 hp) Rated horsepower 362 kW (485 hp) or 399 kW (535 hp)
Full load 2,100 rpm Full load 2,100 rpm
Starting system 24 V DC Starting system 24 V DC
Safety shut-down system Energized to run Safety shut-down system Energized to run
Air cleaner Air cleaner
Type Dry-type with safety element Type Dry type with safety element
Model STG 16 Model SRG 20
Batteries Two (2) 8-D Batteries Four (4) 8-D
Muffler 127 mm (5.0 in) inlet and outlet Muffler 127 mm (5.0 in) inlet and outlet
Muffler guard 10 ga. for personal protection Muffler guard 10 ga. for personal protection
Jacket water cooling/CAC Radiator Jacket water cooling/CAC Radiator
Standard ambient rating 52˚ C (125˚ F) Fuel tank 1,382 l (365 gal)
Fuel tank 1,382 l (365 gal) optional tank 1,071 l (283 gal)
(optional tank) 1,071 l (283 gal) Turbo and manifold covers Blankets and/or exhaust wrap
Turbo and manifold covers Blankets and/or exhaust wrap Engine (Optional)
Engine (Optional) Manufacturer Cummins
Manufacturer Caterpillar Model QSK-19 (Tier I) electronic
Model C27 electronic (Tier II) Rated horsepower 559 kW (750 hp)
Rated horsepower 597 kW (800 hp) Full load 2,100 rpm
Full load 2,100 rpm Starting system 24 V DC
Starting system 24 V DC Safety shut-down system Energized to run
Safety shut-down system Energized to run Air cleaner
Air cleaner Type Dry-type with safety element
Type Dry-type with safety element Model SRG 20
Model SRG 20 Batteries Four (4) 8-D
Batteries Four (4) 8-D Muffler 127 mm (5.0 in) inlet and outlet
Muffler 127 mm (5.0 in) inlet and outlet Muffler guard 10 ga. for personal protection
Muffler guard 10 ga. for personal protection Jacket water cooling (Two pump, two loop) Radiator
Jacket water cooling/CAC Radiator Fuel tank 1,382 l (365 gal)
Fuel tank 1,382 l (365 gal) optional tank 1,071 l (283 gal)
(optional tank) 1,071 l (283 gal) Turbo and manifold covers Blankets and/or exhaust wrap
Turbo and manifold covers Blankets and/or exhaust wrap

Engine (cont.) Operator’s Cab

Engine (Optional) Location To the right from the mast
if facing rear deck from the rear end
Manufacturer Cummins
Type Shock-mounted; two-man,
Model QSK-19 electronic (Tier II)
integrated FOPS certified
Rated horsepower 566 kW (760 hp)
Length at floor 198.12 cm (78 in)
Full load 2,100 rpm
Width at floor 151.76 cm (59.75 in)
Starting system 24 V DC
Floor area 3 m 2 (32.40 ft 2)
Safety shut-down system Energized to run
Height inside 194.51 cm (76.50 in)
Air cleaner
Construction 12 ga. steel welded to formed
Type Dry-type with safety element 12 ga. channel and angle supports
Model SRG 20 Windows .64 cm (0.25 in) tinted safety glass in rubber mounting
Batteries Four (4) 8-D Number of windows 10
Muffler 127 mm (5 in) inlet and outlet Number of doors 2 with windows (included in above)
Muffler guard 10 ga. for personal protection Left door to work deck Swing-type HD hinge
Jacket water cooling/CAC Radiator Right door Swing-type HD hinge
Fuel tank 1,382 l (365 gal) Operator’s seat One swivel-type with armrests,
optional tank 1,071 l (283 gal) headrest and retractable seat belt
Turbo and manifold covers Blankets and/or exhaust wrap Helper’s seat Fixed folding jump seat
Insulation, wall and ceiling 2.54 cm (1 in) thermal
Mast Insulation, floor .95 cm (0.375) in closed-cell foam
Construction ASTM 500 grade B rectangular tubing, welding with .318 cm (0.125 in) pyramid vinyl surface
Main chord size Front 20.32 cm (8 in) x 10.16 cm (4 in) Door latches Heavy-duty latches with lockable handles
x 0.64 cm (0.25 in); Sound levels 82 dB(A) or less
Rear 10.16 cm (4 in) x 10.16 cm (4 in)
Air conditioner, heater, pressurizer Wall-mounted
x 1.27 cm (0.5 in)
Other Window wipers and washers
Pivot and raising area Rectangular tubing “A” frame;
reinforced in high-stress areas
Hydraulic lines Pressure-rated steel hydraulic tubing
Operator’s Controls
Hose rack Sheet steel trough for moving hoses Location Console at front and side cab wall,
placed 45˚ to the deck
Table hole diameter 27.90 cm (11.0 in) diameter
deck hole for guide bushing Standard Engine Controls
Mast-Elevating Cylinders Coolant temperature/high temperature shut-off, oil pressure, (low
pressure shut-off), auto shut-down bypass, start button, stop button,
Number of cylinders 2
tachometer, throttle control, engine hourmeter, fuel level, voltmeter
Cylinder bore 19.78 cm (7.0 in) diameter
Standard Compressor Controls
Cylinder rod 8.89 cm (3.5 in) diameter
Compressor temperature, air pressure gauge, air shut-off control
Cylinder stroke 96.52 cm (38 in)
(electric) (high air temperature)
Lift capacity each cylinder 47,990 kg (105,800 lb)
Cylinder connection pins 45 mm (1.75 in) diameter

Operator’s Controls (cont.) Mainframe

Standard Drilling Controls Main rails 20.32 cm (8 in) x 40.64 cm (16 in) x 1.27 cm (0.5 in)
ASTM 500 grade B
Leveling jack controls (hydraulic)
Rectangular tubing heavily cross-braced and reinforced
HOBO/Break-out wrench control (electric)
at high-stress areas
Mast elevation control (hydraulic)
Construction Electric welded
Pull-down control (electric over hydraulic)
Jacks, mast pivot and deck Welded integrally to mainframe
Pull-down pressure control (pilot hydraulic)
Toolbox Lockable door, below front deck
Rotation control (electric over hydraulic)
Machine deck Access both sides
Propel controls (electric over hydraulic)
Hand rails 4.80 cm (1.9 in) diameter x 1.22 m (48 in) high
Carousel in/out control (electric)
Tow hooks Welded, two (2) front
Carousel indexing control (electric)
Carousel lock (electric)
Mast lock (electric)
Leveling Jacks
Number 4
Dust/water injection (electric)
Location 2 front; 2 rear
Dust curtain (electric)
Cylinder bore 13.97 cm (5.5 in)
Deck wrench control (electric)
Cylinder rod diameter 7.62 cm (3 in)
Level indicator (bubble)
Cylinder stroke 121.92 cm (48 in) 152.40 cm (60 in)
On/off light switch (electric)
optional front and rear
Drill hourmeter (gauge)
Lift capacity 29,620 kg (65,300 lb) each
Wiper/washer controls (electric)
Pad connection Link pad
Optional
Pad diameter 60.96 cm (24 in)
Filter indicators for engine and compressor intake, filter indicators for
Safety check valves Internal at each cylinder
hydraulic fluid system, indicator lights for interlocks, water injection
flow control, rotary torque control, rotary head rpm gauge and heating Inner extension boot 21.90 cm (8.625 in) OD 0.81 cm (.322 in) wall
systems control
Drill Table & Work Deck

Undercarriage Table height off ground 132.08 cm (52 in)
Type Excavator type Deck floor material Non-skid sheet metal
Pad width 750 mm (29.5 in) Drill deck length 266.06 cm (104.75 in)
Pad type Triple grouser Drill deck width 257.81 cm (101.5 in)
Rollers Sealed, oil-flooded Drill deck area 6.86 m 2 (73.8 ft 2)
Number of rollers on each side 10 Hand rails 48 mm x 1.22 m (1.9 in diameter x 48 in height)
Upper track chain support Two (2) carrier rollers Dust Curtain
Rock guards/chain guides Standard full-length guards (Optional Hydraulic Lifters, Front and Rear)
Overall length 508.00 cm (200 in) (variable with adjustment) Material 6.4 mm (0.25 in) rubber nylon reinforced
Width over tracks 391.16 cm (154 in) Enclosed area 4.2 m 2 (45.14 ft 2)
Final drive Independent hydrostatic, 2-speed motors Split for excess Front and rear with 30.50 cm (12 in) overlap
Drive horsepower per track Maximum 152 kW (204 hp) Dust deflector Natural rubber seal,
1.27 cm (0.5 in) thick, 35.56 cm (14 in) diameter
Brakes Spring set, hydraulic release
Location Directly below table bushing
Brake release Automatic
Tram speed max 3.14 km/h (1.95 mph)
Gradeability mast down 66% Hydraulic System
Rear axle 20.32 cm (8 in) solid Left Track/Rotation
Front Three-point oscillating type Type Axial piston, variable volume
Track adjustment means Hydraulic with grease gun Max flow 283 l/min (75 gpm)
Track drive disconnect Standard (Manual) Pressure rating 413.7 bar (6,000 psi)

Hydraulic System (cont.) Accessories, Tools & Handling

Right Track Equipment
Type Axial piston, variable volume Note: 4-pod carousel for 9.14 m (30 ft) and 10.67 m (35 ft) mast,
2-pod carousel for 11 meter mast
Max flow 283 l/min (75 gpm)
Pressure rating 413.7 bar (6,000 psi) Drill Pipe (optional)
Diameter Customer specification, 11.43-17.78 cm (4.5 in-7.0 in)
Accessory Circuit Pump/Hoist/Pull-down
Wall thickness 1.91 cm (0.75 in)
Type Axial piston, variable volume
Length 9.14 m (30 ft); Optional 10.67 m (35 ft)
Max flow 283 l/min (75 gpm)
Diameter Wall Thickness Thread Pipe Length
Pressure rating 344.7 bar (5,000 psi)
11.43 cm (4.5 in) 1.91 cm (0.75 in) 3 Beco 9.14 m (30 ft)
Fan Circuit Pump(s)
Type Gear
12.70 cm (5 in) 1.91 cm (0.75 in) 3.5 Beco 9.14 m (30 ft)
Max flow 216 l/min (57 gpm) single fan;
246 l/min (65 gpm) dual fan 12.70 cm (5 in) 1.91 cm (0.75 in) 3.5 Beco 10.67 m (35 ft)
Pressure rating 206.8 bar (3,000 psi) 13.97 cm (5.5 in) 1.91 cm (0.75 in) 4 Beco 9.14 m (30 ft)
Track Drive Motors 13.97 cm (5.5 in) 1.91 cm (0.75 in) 4 Beco 10.67 m (35 ft)
(2)–Two-speed 107/125 cc 15.24 cm (6 in) 1.91 cm (0.75 in) 4.5 Beco 9.14 m (30 ft)
Type Bent axis fixed volume 15.24 cm (6 in) 1.91 cm (0.75 in) 4.5 Beco 10.67 m (35 ft)
Pressure rating 413.7 bar (6,000 psi) 16.51 cm (6.5 in) 1.91 cm (0.75 in) 4.5 Beco 9.14 m (30 ft)
16.51 cm (6.5 in) 1.91 cm (0.75 in) 4.5 Beco 10.67 m (35 ft)
Rotation Drive Motor
Type Axial piston var. 9.76 cubic inch displacement
Pressure rating 344.7 bar continuous (5,000 psi);
413.7 bar intermittent (6,000 psi) Top Adapter Sub
Fan Drive Motor(s) Diameter Depends on pipe diameter
Single fan: 1 Dual fan: 2 Length 71.12 cm (28 in)
Type Piston Top thread 13.97 cm (5.5 in) API Reg.
Pressure rating 413.7 bar continuous (6,000 psi) Bottom thread Depends on pipe diameter
Pump Drive Gearbox Bit Sub

Type l3 pad Diameter Depends on pipe diameter
Drive Rubber coupler/drive shaft to front of engine Length 76.20 cm (30 in) for 30 and 35 ft mast,
152.40 cm (60 in) for 11 m mast
Filtration
Top thread Depends on pipe diameter
All filters have indicators and bypass
Bottom thread Depends on pipe diameter
Loop 12 micron 2 per loop (optional)
Table bushing One (1) piece insert standard,
Charge 3 micron 1 per loop
Optional: roller bushing or two-piece
Main return 12 micron absolute
Deck Wrench
Case return 12 micron absolute
Location Drill deck
Wrench plate 7.62 cm (3 in) T1- Steel
Oil-Cooling System (Hydraulic Tank) Wrench positioning Hydraulic cylinder
Reservoir 644 l (170 gal) with sight and temperature gauge
Impact means Stationary jaw
Reservoir pressure Atmospheric, filtered breather
HOBO Break-Out Wrench
Reservoir refill system 871 l (230 gal) through return filter
Location Outside mast, under pipe rack
Lubrication Support Pivot
Centralized manual (optional auto lubrication) Wrench type Patented HOBO (Hydraulically Operated Break-Out)
Power Hydraulic Cylinders

Accessories, Tools and Handling

Equipment (cont.)
Pipe Rack
Type Carousel, with stationary pods and breaker plates
Size of drill pipe/capacity 11.43 cm to 17.78 cm (4.5 in to 7 in)/
9.14 m (30 ft) and 10.67 m (35 ft) mast 4 pipes
Size of drill pipe/capacity 11.43 cm to 17.78 cm (4.5 in to 7 in)/
11 m (36 ft 1 in) mast 2 pipes
Length of drill pipe 9.14 m (30 ft); optional 10.67 m (35 ft)
Pipe rack swing Hydraulic cylinders (2)
Pipe rack index Hydraulic motor through chain drive
Location Outside mast
Winch–Mounted on the mast

Rating 3,629 kg (8,000 lb)
Cable size 12.7 mm (0.5 in)

Safety hook Swivel-type positive lock
Performance ratings are based on 100% efficiency, and on engineering specifications and calculations in accordance
with accepted industry standards. These capacities will vary with drilling conditions. All specifications are subject to
change without notice or obligation.

Pull-Down/Hoisting Capacity Cooler Assembly

Rated pull-down capacity Up to 22,680 kg (50,000 lb) For Cat C27 or CumminsQST-30 ®
Rated hoist capacity Up to 22,680 kg (50,000 lb)
Engines–Split Coolers
Air-finned, three- or four-core, radiator/hydraulic stacked, compressor
Feed rate 0-38.1 m/min (0-125 fpm)
separate
Retract rate 0-38.1 m/min (0-125 fpm)
Radiator/hydraulic cooler height/width 147.32 cm (58 in)/
Pull-down cylinder stroke (12 meter) 726.94 cm (286.2 in) 147.32 cm (58 in)
Head travel (12 meter) 1,453.89 cm (572.4 in) Compressor cooler width 187.88 cm (72 in)/162.56 cm (64 in)
Pull-down cylinder stroke (15 meter) 880.11 cm (346.5 in) Fan 121.92 cm (48 in) diam. one fan per cooler, 10 blades
Head travel (15 meter) 1,760.22 cm (693.0 in) Fan speed Maximum 1,525 rpm
Type Hydraulic Fan guard Welded
Number of cylinders 1 (stationary rod, moving barrel) Engine radiator, top tank Sealed deaeriation tank, pressure cap,
Cylinder bore 16.51 cm (6.5 in) diameter overflow tube and sight glass
Cylinder rod 10.16 cm (4 in) diameter Standard ambient rating 52˚ C (125˚ F)
Cable type 1 in DYFORM 8 Compressor

Nominal line tension 5 to 1 factor against working Compressor (Standard)
Cable sheaves (cylinder) 40.64 cm (16 in) OD Type Oil-flooded, single-stage screw
Cable sheaves (top and bottom) 50.80 cm (20 in) OD Discharge air flow (sea level) 48.1 m 3/min (1,700 cfm)
Sheave pins 5.10 cm (2 in) diameter with roller bearing Max operating pressure 6.9 bar (100 psi)
Sheave guards Standard at bottom plate Air cleaner
Adjustable head guide shoes Steel with replaceable Nylatron Type Dry-type with safety element
Automatic cable tensioning system Hydraulic cylinder, Model SRG 20
powered by fan circuit
Oil cooling Air-to-oil cooler, thermostatically controlled
Oil separation Vertical barrier element, pre-separation
Rotary Drive System in 189 l (50 gal) horizontal sump (T-tank)
Rotation speed 0-220 rpm Oil filtration 12 micron replaceable element
Torque 12,880 Nm max (0-9,500 ft-lb) Drive Direct coupled to engine flywheel
Horsepower capacity 138.7 kW (186 hp) Controls Automatic with safety shut-down
Gearbox Casting design Air shut-off Hydraulic cylinder-operated from operator’s seat
Main thrust bearing Taper roller Compressor (Optional)

Lubrication Oil-flooded Type (high pressure) Oil-flooded, two-stage screw
Gearing Spur Discharge air flow (sea level) 32.6 m 3/min (1,150 cfm);
Ratio 16:04 to 1 38.2 m 3/min (1,350 cfm);
Drive motor See Hydraulic 42.5 m 3/min (1,500 cfm)
Performance ratings are based on 100% efficiency and on engineering Max operating pressure 10.3/24.1 bar (150/350 psi)
specifications and calculations in accordance with accepted industry Air cleaner Dry-type with safety element/SRG 29
standards. These capacities will vary with drilling conditions. All
specifications are subject to change without notice.
Type (high pressure) Oil-flooded, two-stage screw
Discharge air flow (sea level) 32.6 m 3/min (1,150 cfm);
38.2 m 3/min (1,350 cfm);
42.5 m 3/min (1,500 cfm)
Max operating pressure 10.3/24.1/34.5 bar (150/350/500 psi)
Air cleaner Dry-type with safety element/SRG 29

Engine Engine (cont.)

Engine (Standard) Engine (Optional)
Manufacturer Caterpillar ® Manufacturer Cummins
Model C27 Tier II Model QST-30 (Tier II)
Rated horsepower 597 kW (800 hp) Rated horsepower 671 kW (900 hp) or 783 kW (1,050 hp)
Full load 2,100 rpm Full load 2,100 rpm
Starting system 24 V DC Starting system 24 V DC
Safety shut-down system Energized to run Safety shut-down system Energized to run
Air cleaner Air cleaner
Type Dry-type with safety element Type Dry-type with safety element
Model SRG 20 Model SRG 29
Batteries Four (4) 8-D Batteries Four (4) 8-D
Muffler 127 mm (5 in) inlet and outlet Muffler 127 mm (5 in) inlet and outlet
Muffler guard 10 ga. for personal protection Muffler guard 10 ga. for personal protection
Jacket water cooling/CAC Radiator Jacket water cooling/CAC Radiator
Fuel tank 1,325 l (350 gal), optional tank 1,571 l (415 gal) Fuel tank 1,325 l (350 gal), optional tank 1,571 l (415 gal)
Turbo and manifold covers Blankets and/or exhaust wrap Turbo and manifold covers Blankets and/or exhaust wrap
Engine (Optional)
Manufacturer Cummins Mast
Model QST-30 (Tier I) Construction ASTM 500 grade B rectangular tubing, welding
Rated horsepower 634 kW (850 hp) or 783 kW (1,050 hp) Main cord size Front 20.3 cm x 10.1 cm x 0.6 cm (8 in x 4 in x 0.25 in);
Full load 2,100 rpm Rear 10.1 cm x 10.1 cm x 1.2 cm (4 in x 4 in x 0.5 in)
Starting system 24 V DC Pivot and raising area Rectangular tubing “A” frame;
reinforced in high-stress areas
Safety shut-down system Energized to run
Hydraulic lines Pressure-rated steel hydraulic tubing
Air cleaner
Hose rack Sheet steel trough for moving hoses
Type Dry-type with safety element
Table hole diameter 27.9 cm (11 in) diameter deck hole
Model SRG 29
for guide bushing
Batteries Four (4) 8-D
Muffler 127 mm (5 in) inlet and outlet
Mast-Elevating Cylinders
Muffler guard 10 ga. for personal protection
Number of cylinders 2
Jacket water cooling Radiator
Cylinder bore 20.32 cm (8 in) diameter
Fuel tank 1,325 l (350 gal), optional tank 1,571 l (415 gal)
Cylinder rod 10.16 cm (4 in) diameter
Turbo and manifold covers Blankets and/or exhaust wrap
Cylinder stroke 108.2 cm (42.6 in)
Lift capacity each cylinder 56,728 kg (125,065 lb) at 2,500 psi
Cylinder connections pins 5.71 cm (2.25 in) diameter

Undercarriage Operator’s Controls

Type Excavator type Location Console at front and side cab wall, placed 45˚ to the deck
Pad width 750 mm (29.5 in) Standard Engine Controls

Pad type Triple grouser Coolant temperature/high temperature shut-off, oil pressure, (low
Rollers Sealed, oil flooded pressure shut-off), auto shut-down bypass, start button, stop button,
tachometer, throttle control, engine hourmeter, fuel level, voltmeter
Number of lower rollers on each side 12
Upper track chain support Two (2) carrier rollers
Standard Compressor Controls
Compressor temperature, air pressure gauge, air shut-off control
Rock guards/chain guides Standard full-length guards
(electric) (high air temperature)
Overall length 570.48 cm (224.6 in)
Standard Drilling Controls
Width over tracks 391.16 cm (154 in)
Leveling jacks controls (hydraulic)
Final drive Independent hydrostatic motors
HOBO/Break-out wrench control (electric)
Drive horsepower per track Maximum 152 kW (204 hp)
Mast elevation control (hydraulic)
Brakes Spring set, hydraulic release
Pull-down control (electric over hydraulic)
Brake release Automatic
Pull-down pressure control (pilot hydraulic)
Tram speed max 2.0 km/h (1.25 mph)
Rotation control (electric over hydraulic)
Gradeability mast down 66%
Propel controls (electric over hydraulic)
Rear axle 20.32 cm (8 in) solid
Carousel in/out control (electric)
Front Three-point oscillating type
Carousel indexing control (electric)
Track adjustment means Hydraulic with grease gun
Carousel lock (electric)
Track drive disconnect Standard (manual)
Mast lock (electric)
Dust/water injection (electric)
Operator’s Cab
Dust curtain (electric)
Location To the right from the mast
Deck wrench control (electric)
if facing rear deck from the rear end
Level indicator (bubble)
Type Shock-mounted; two-man, integrated FOPS certified
On/off light switch (electric)
Length at floor 198.12 cm (78 in)
Drill hourmeter (gauge)
Width at floor 151.76 cm (59.75 in)
2 2 Wiper/washer controls (electric)
Floor area 3 m (32.4 ft )
Height inside 194.31 cm (76.5 in) Optional
Construction 12 ga. steel welded to formed 12 ga. channel Filter indicators for engine and compressor intake, filter indicators for
and angle supports hydraulic fluid system, indicator lights for interlocks, water injection
flow control, rotary torque control, rotary head rpm gauge and heating
Windows 0.6 cm (0.25 in) tinted safety glass in rubber mounting
systems control
Number of windows 10
Number of doors 2 with windows (included in above)
Left door to work deck Swing-type HD hinge
Right door Swing-type HD hinge
Operator’s seat One swivel-type with armrests,
headrest and retractable seat belt
Helper’s seat Fixed folding jump seat
Insulation, wall and ceiling 2.5 cm (1 in) thermal
Insulation, floor 0.9 cm (0.375 in) closed cell foam with
0.3 cm (0.125 in) pyramid vinyl surface
Door latches Heavy-duty latches with lockable handles
Sound levels 82 dB(A) or less
Air conditioner/heater/pressurize Wall-mounted
Other Window wipers and washers

Mainframe Hydraulic System

Main rails 20.32 cm x 40.64 cm x 1.27 cm (8 in x 16 in x 0.5 in) Left Track/Rotation
ASTM 500 grade B
Type Closed-loop, axial piston, variable volume
Rectangular tubing heavily cross-braced
and reinforced at high-stress areas Max flow 283 l/min (75 gpm)
Construction Electric welded Pressure rating 413.7 bar (6,000 psi)
Jacks, mast pivot and deck Welded integrally to main frame Right Track/Pull-down/Hoist
Toolbox Lockable door, below front deck Type Closed-loop, axial piston, variable volume
Machine deck Access both sides Max flow 283 l/min (75 gpm)
Hand rails 4.80 cm (1.9 in) diameter x 1.22 m (48 in) high Pressure rating 413.7 bar (6,000 psi)
Tow hooks Welded, two (2) front Fan/Accessory Circuit
Mast rests Between front jacks, and additional mast rests Type Open loop, axial piston, variable volume
off front end of frame
Max flow 273 l/min (72 gpm) dual fan (one per cooler)
Leveling Jacks Pressure rating 206.8 bar (3,000 psi
Number 4
Track Drive Motors (2)-Single Speed 107cc
Location 2 front; 2 rear
Type Bent-axis fixed volume
Cylinder bore 13.97 cm (5.5 in)
Pressure rating 413.7 bar (6,000 psi)
Cylinder rod diameter 7.62 cm (3 in)
Rotation Drive Motor
Cylinder stroke 152.40 cm (60 in)
Type Axial piston var. 9.76 cubic inch displacement
Lift capacity 29,620 kg (65,300 lb) each
Pressure rating 344.7 bar continuous (5,000 psi);
Pad connection Link pad 413.7 bar intermittent (6,000 psi)
Pad diameter 60.96 cm (24 in)
Fan Drive Motor(s)-Single Fan
Safety check valves Internal at each cylinder
Fan drive motor(s) Single fan: 1
Inner extension boot 21.90 cm (8.625 in) OD, 0.81 cm (0.322 in) wall
Type Piston
Pressure rating 413.7 bar continues (6,000 psi)
Drill Table & Work Deck Pump Drive Gearbox
Table height off ground 152.08 cm (52 in) Type 3 pad
Deck floor material Non-skid sheet metal Drive Rubber coupler/drive shaft to front of engine
Drill deck length 266.06 cm (104.75 in)
Filtration
Drill deck width 257.81 cm (101.5 in)
All filters have indicators and bypass
Drill deck area 6.8 m 2 (73.8 ft 2)
Loop 12 micron 2 per loop (optional)
Hand rails 4.8 cm (1.9 in) diameter x 121.9 cm (48 in) high
Charge 3 micron 1 per loop
Dust Curtain (Optional Hydraulic Lifters, Main return 12 micron absolute
Front and Rear)
Case return 12 micron
Material 6.4 mm (0.25 in) rubber nylon reinforced
Enclosed area 4.2 m 2 (45.14 ft 2)
Split for excess Front and rear with 30.50 cm (12 in) overlap
Dust deflector Natural rubber seal, 1.27 cm (0.5 in) thick,
35.56 cm (14 in) diam.
Location Directly below table bushing

Lubrication Accessories, Tools & Handling

Centralized manual (optional auto lubrication) Equipment (cont.)
Top Adapter Sub
Oil Cooling System (Hydraulic Tank) Diameter Depends on pipe diameter
Reservoir 643 l (170 gal) with sight and temperature gauge Length 71.12 cm (28 in)
Reservoir pressure Atmospheric, filtered breather Top thread 13.97 cm (5.5 in) API Reg.
Reservoir refill system 871 l (230 gal) through return filter Bottom thread Depends on pipe diameter
Bit Sub
Accessories, Tools & Handling Diameter Depends on pipe diameter
Equipment Length Up to 342.90 cm (135 in)
Drill Pipe (Optional, Price-Adder) Top thread Depends on pipe diameter

12 meter mast arrangement Bottom thread Depends on pipe diameter
Diameter Customer specification 11.43-17.78 cm (4.5-7.0 in)
Wall thickness 1.91 cm (0.75 in) Table bushing One (1) piece insert, roller deck bushing or two-piece
Length 10.67 m (35 ft) Deck Wrench
Threads Depends on pipe diameter
Diameter Wall Thickness Thread Pipe Length Location Drill deck
11.43 cm (4.5 in) 1.91 cm (0.75 in) 3 Beco 10.67 m (35 ft) Wrench plate 7.6 cm (3 in) T1- Steel
Wrench positioning Hydraulic cylinder
Impact means Stationary jaw
16.51 cm (6.5 in) 1.91 cm (0.75 in) 4.5 Beco 10.67 m (35 ft) HOBO Break-Out Wrench
17.78 cm (7 in) 1.91 cm (0.75 in) 4.5 Beco 10.67 m (35 ft) Location Outside mast, under pipe rack
15 meter mast arrangement Support Pivot
Diameter Customer specification 11.43-17.78 cm (4.5-7.7 in)
Wall thickness 1.91 cm (0.75 in) Wrench type Patented HOBO (Hydraulically Operated Break-Out)
Length 7.62 m (25 ft) Power Hydraulic cylinders
Threads Depends on pipe diameter
Diameter Wall Thickness Thread Pipe Length Carousel
11.43 cm (4.5 in) 1.91 cm (0.75 in) 3 Beco 7.62 m (25 ft) Type Carousel, with stationary pods and breaker plates
Size of drill pipe/capacity 11.43-17.78 cm (4.5-7 in)
12 meter mast arrangement (4 pod)
16.51 cm (6.5 in) 1.91 cm (0.75 in) 4.5 Beco 7.62 m (25 ft) 15 meter mast arrangement (2 pod)
17.78 cm (7 in) 1.91 cm (0.75 in) 4.5 Beco 7.62 m (25 ft) Length of drill pipe 10.67 m (35 ft) for 12 meter mast,
7.62 m (25 ft) for 15 meter mast
Pipe rack swing Hydraulic cylinders (2 )
Pipe rack index Hydraulic motor through chain drive
Location Outside mast
Mounting Upper, lower pillow-block bearing
Winch
Rating 3,629 kg (8,000 lb)
Cable size 12.70 mm (0.5 in)
Safety hook Swivel-type positive lock

MD6290 Component Locator
FRONT OF MACHINE
COMPRESSOR OIL COOLER
ENGINE RADIATOR HYDRAULIC OIL COOLER
ENGINE AIR FILTER COMP. AIR CLEANER
RH FRONT JACK
LH FRONT JACK
COMPRESSOR AIR/OIL SEPARATOR
MAST ACCESS LADDER
AIR COMPRESSOR
FUEL TANK
DIESEL ENGINE
MUFFLER FUEL FILL
DRIVELINE
PUMP DRIVE
RETURN FILTERS
DUST COLLECTOR
HYDRAULIC OIL RESERVOIR

CHARGE FILTERS
(LOOP FILTERS OPTIONAL) MAIN ELECTRIC CABINENT
PRESSURE/VACUUM FILTER
MAST ELEVATING CYLINDERS
RH REAR JACK
LH REAR JACK
WINDOW WASHER BOTTLE
PIPE CAROUSEL
OPERATOR’S CAB
IN DECK PLENUM CHAMBER
A/C CONDENSER
IN DECK TOOL BOX
CRANE (OPT)
DRILLING PLATFORM CRANE CONTROLS (OPT)

VIEWING HATCH

TOP MAST SHEAVE
ROTARY DRIVE
CAROUSEL
BATTERY BOX
TRACK FINAL DRIVE
CRAWLER
HYDRAULIC OIL FILL PUMP
LIGHTS
DUST CURTAINS
A/C/ UNIT

FRONT OF MACHINE
MAST REST
WATER TANKS
BOLTED UNDER DECK
AIR/OIL RECEIVER TANK
LEFT FRONT JACK
COMPRESSOR RIGHT FRONT JACK

AIR CLEANER
ENGINE AIR CLEANER
OIL INJECTION TANK

AIR COMPRESSOR
FRONT FUEL TANK
ENGINE MUFFLER
ENGINE COOLER
COMPRESSOR OIL COOLER
ENGINE
BATTERY BOX
CENTRAL LUBE
SYSTEM PUMP
REAR FUEL TANK

FLEX DRIVE COUPLING
(COVER REMOVED)
PUMP DRIVE GEARBOX HYDRAULIC FILL

HAND PUMP
FUEL TANKS MAIN RETURN FILTER
BOLTED UNDER DECK
CASE DRAIN FILTER
MAIN HYDRAULIC PUMPS HYDRAULIC TANK
DRILL STEM THREAD

LUBRICATOR
RIGHT REAR JACK
LEFT REAR JACK
DRILLING PLATFORM
OPERATOR’S CAB
Due to the variety of drill options and requirements, each drill may vary from the configurations shown.

TOP SHEAVES
ROTARY DRIVE
GEARBOX
TRAVELING SHEAVES
FINAL DRIVE
MAST CARRIER ROLLERS
TRACK ROLLERS
CRAWLER ASSEMBLY
HYDRAULIC FILL
HAND PUMP TENSIONER
IDLER
MAST ELEVATING
CYLINDERS FRONT IDLER
BOTTOM SHEAVES

MD6290 Dimensions
SKF ROTARY BLASTHOLE DRILLS
Based on MD6290 with 11M mast arrangement

\Machine Specifications
Based on MD6240 with 12M and 15M mast arrangement
MD6240 Dimensions
1-19
Transient Stability Limits
Maximum Wind Speed = 75 MPH (120.8 Km/h) at which time drilling must be stopped, mast
lowered and machine shut down.
BE SURE to observe if any overhead power lines arein the area. Contact with
overhead high voltage power lines can cause severe injury or death. Follow
the maximum safe distance requirements in Section 2 of this manual.
21°
9° 12°
25°
18° 18°
NOTE The values contained here are given only as guidelines, and are not intended as
a recommendation for safe operation. Safe operation is dependent on operator
experience and judgement, ground conditions and proper preparation of ground
surfaces, and accelerations due to sudden change of direction or speed of
movement, either from operator input or ground conditions on which machines
are operating.
Machines are typically much more stable operating with the mast down anytime
a machine is operating on rough ground conditions, significant slopes, or there
is any doubt about the machine stability or its ability to be operated safely in the
conditions in question.

Line of Sight Limits
17°
Defines the Operator’s general
line of sight when in the seated
9°
position.
52°
13°
°
30
°
10
6°
7° 23° 23°
) 8°
5
2
1 TRAMMING
7
2
)
0
$ 25° 31°
& 17°
+ 14°
,
9°
1
(
52°
66°
13°
27°
°
30
°
10
6°
7° 23° 23°
8°
DRILLING

Safety Stand Placement
Support (Jack Stand) Guidelines for Rotary Drills
MD6240 AND MD6290

IF DURING MAINTENANCE MACHINE
REQUIRES ADDITIONAL SAFETY SUPPORTS,
PLACE SUPPORTS (JACK STANDS) AS CLOSE TO
LEVELING JACKS AS POSSIBLE. THESE AREAS
SUPPORT THE MACHINE DURING DRILLING OPERATIONS.
NEVER SUPPORT THE MACHINE BY PLACING

SUPPORTS UNDER MEMBERS OF THE REAR DECK
OR COOLER SUPPORT DECK. THESE AREAS ARE
NOT STRUCTURALLY ROBUST AND ARE NOT INTENDED
TO SUPPORT THE ENTIRE MACHINE WEIGHT.

Section 2
Safety
Maximum Wind Speed = 75 MPH (120.8 Km/h) at which time drilling must be
stopped, mast lowered and machine shutdown.
Safety 2-1
Hazard Classification
The Rotary Blasthole Drill is a heavy moving machine with a mast which raises vertically for drilling.
Like all moving objects and reach extending devices, there are potential hazards associated with its use.
These hazards will be minimized if the machine is properly operated, inspected and maintained. Operator's
must read this manual and have been trained to use the machine in an appropriate and safe manner.
Non-English speaking persons must have an interpreter explain all safety and operating procedures in this
manual. Should any questions arise concerning the maintenance or operation of the machine contact the
manufacturer at 1-800-258-0009.
Safety Alert Symbol

The safety alert symbol is used to alert you to potential personal injury hazards. Obey all safety messages
that follow this symbol to avoid possible injury or death.
Safety Alert Symbol
Hazard Classification
A multi-tier hazard classification system is used to communicate potential personal injury hazards. The
following signal words used with the safety alert symbol indicate a specific level of severity of the potential
hazard. All are used as attention-getting devices on decals and labels fixed to the machine to assist in
potential hazard recognition and prevention.
Indicates an imminently hazardous situation which, if not avoided, will result in

death or serious injury.
Red
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
Orange
Indicates a potentially hazardous situation which, if not avoided, may result in

minor or moderate injury.
Yellow
Indicates a potentially hazardous situation which, if not avoided, may result in

property or equipment damage.
Blue
2-2 Safety
Overview of Potential Hazards
Potential Hazard Prevention

Crush Hazard. Falling objects Do not exceed hoist capacity &
can cause severe injury or stay away from lifted loads. (3500
death. lbs./1587 kg.) Do not use dam-
aged cable.
Crush Hazard. Falling pipe car- Place carousel against lower

ousel can cause severe injury stops before servicing hydraulic
or death. circuit. Purge air from circuit after
servicing carousel circuit.
Entanglement Hazard. Death Keep clear of rotating drivelines.

or serious injury can result from Switch off engine before perform-
contact with rotating drivelines. ing service. Do not operate with
guard removed.
Entanglement Hazard. Rotat- Keep away from fan and belt

ing parts can cause personal when engine is running. Stop
injury. engine before servicing.
Crush Hazard. Falling mast can Purge air from circuit after servic-
cause severe injury or death. ing mast raising cylinder(s).
Burn Hazard. Hot pressurized Allow to cool before opening.

fluid can cause severe burns.
Safety 2-3

Fall Hazard. Death or serious Do not climb raised mast. Lower
injury may result from climbing mast completely to service.
raised mast.
Improper operation or mainte- Read and understand operator's

nance can result in serious injury manual and all safety signs before
or death. using or maintaining machine.
If you do not understand the in-

formation in the manuals, consult
your supervisor, the owner or the
manufacturer.
Electrocution Hazard. Death Maintain required clearance.
or serious injury can result from
contacting electric power lines. Always contact the electric power
line owner. The electric power
shall be disconnected or the pow-
er lines moved or insulated before
machine operations begin.
Crush / Fall Hazard. Riding Do not ride rotary head. Lower
rotary head can cause severe mast completely to service.
injury or death.
Flying Object & Spray Hazard. Shut off live air at source, and re-
Death or serious injury can relieve all pressure before removing
sult from release of pressurized filler plug.
liquids.
Entanglement Hazard. Rotating Do not operate with guard re-

parts can cause severe injury. moved. Keep all guards in
place.
Crush Hazard. Falling rotary Purge air from circuit after servic-
head can cause severe injury ing feed cylinder(s).
or death.
2-4 Safety

Explosion / Burn Hazard. Can Keep all open flames and sparks
cause death, burns or blindness away. Wear personal protective
due to ignition of explosive gases equipment, including face shield,
or contact with corrosive acid. gloves and long sleeve shirt.
READ MANUALS
Read all manuals prior to opera-
tion.
DO NOT OPERATE equipment if

you do not understand the infor-
mation in the manuals.
Consult your supervisor, the

owner or the manufacturer.
Explosion Hazard. Combustible Do not spray "High Energy" start-

gas can cause severe injury or ing aid into compressor air inlet or
death. engine grid heaters.
Fall Hazard. Death or serious Use the access system provided

injury can result from falling. when servicing the machine.
Crush Hazard. Standing on Keep clear of moving stairway.

stairway when raising or lower-
ing can cause severe injury or
death.
Electrical Shock Hazard. Can Disconnect battery prior to electrical system service
cause severe injury or death. work or any welding to avoid electrical shock and ma-
chine damage. Refer to service operator manual.
Safety 2-5
Safety Guidelines
Before Operation
• Do study this manual and fully understand the controls.
• Do be sure all safety guards are securely in place and all access doors are closed and locked.
• Do wear safety helmet, glasses and hearing protection when operating or working on machine.
• Do be sure all personnel are clear of the machine and work area before starting the engine or oper-
ating machine.
• Do be sure drill area is clear of all obstructions before operating and know the size limitations of the
machine.
• Do attach safety chain when using towbar.
• Do Not operate machine with:
• A hydraulic leak
• Broken or damaged electrical wiring
• Damaged hydraulic hoses or fittings
Operation
• Do provide sufficient ventilation when running the engine in an enclosed area. Exhaust gasses
contain carbon monoxide, a deadly poison, which is colorless and odorless.
• Do make sure the drill pipe is secured in the loader before raising or lowering the mast, if your
machine is equipped with a drill pipe loader.
• Do make sure the mast lock pins are engaged in the mast base before starting drilling operations.
• Do examine the surface before drilling to determine the possible presence of unfired explosives.
• Do use PPE (personal protection equipment) appropriate for the conditions you are working in; e.g.
safety helmet, safety glasses, hearing protection, gloves, respirator.
• Do Not wear jewelry or loose fitting clothing when working on machinery. Keep clothing, hands
and hair clear of moving parts.
• Do Not drill into or near a "bootleg" hole or any hole that may contain explosives.
• Do Not use the machine for any other purpose than what it was designed for. This machine is de-
signed for rotary blasthole drilling operations only.
• Do Not travel on steep inclines soft or unstable ground or close to unsupported excavations.
• Do Not move machine if drill is in a potentially unstable position.
After Operation
Normal Shut Down
1. Be sure machine is on solid level ground. Lower jacks, so the jack pads just touch the ground, but
do not lift machine up.
2. Be sure all controls are in the OFF or NEUTRAL position.
3. Allow engine to idle for a minimum of five (5) minutes before stopping.
4. Turn the ignition key to OFF position.
5. Check machine for any unusual conditions.
6. Report any defects to your immediate supervisor.
2-6 Safety
Safety Guidelines
Maintenance
• Do be sure two people are present when performing service work, both being fully trained on the
safety issues. One person shall supervise from the operator's position and have immediate access
to an emergency stop in all situations. Visual, audible or verbal communication signals must be
established and understood by both persons.
• Do be sure each person is adequately trained to perform service and maintenance procedures.
• Do place a warning tag on starting controls to alert personnel that someone is working on the ma-
chine and disconnect battery before making repairs or adjustments to machine.
• Do be sure you have adequate lighting when performing service work at night.
• Do relieve pressure on hydraulic or pneumatic systems before loosening connections or parts.
• Do be sure machine and components are well supported before servicing or replacing parts.
• Do maintain a metal-to-metal contact between the fill nozzle and fuel tank when filling the fuel tank.
This will prevent sparks and the possibility of an explosion.
• Do Not hammer bit or drill pipe. Use only proper tools to make repair or adjustments.
• Do Not weld or grind near oil lines.
• Do Not attempt to remove radiator cap when engine is hot or has overheated.
• Do Not smoke or use an open flame near batteries, when servicing the batteries. Batteries can
give off hydrogen which is a highly explosive gas.
• Do Not leave tools or other loose objects on the engine, drive mechanisms or drilling platform.
They could be thrown by this equipment with a powerful force.
Equipment Transfer
• If all or part of the equipment is shipped to a new destination, always include a complete instruction
manual or a copy of the following topics from the operator's manual:
• Safety Section
• Operation Instructions including:
• Pre-Start Checks
• Start-up
• After Start Checks
• Shutdown Procedure Clearances from High Voltage Lines
• Propelling Machine Line Voltage Minimum Clearance
0 to 50 kv 10 ft (3 m)
50 to 200 kv 15 ft (4.6 m)
200 to 350 kv 20 ft (6.1 m)
350 to 500 kv 25 ft (7.6 m)
500 to 750 kv 35 ft (10.7 m)
750 to 1000 kv 45 ft (13.7 m)
Table 2-1
Safety 2-7
Safety Sign List
Refer to Figures 2-1 and 2-2 for locations

Item Description Part No. Qty.
1 WARNING - Falling Objects (Winch) 429414 1
2 WARNING - Falling Objects (Carousel) 429448 2
3 WARNING - Rotating Shaft 429406 2
4 WARNING - Entanglement 428893 5
5 WARNING - Falling Mast 429418 2
6 WARNING - Hot Pressurized Fluid 429449 1
7 WARNING - Climbing Raised Mast 429404 2
8 WARNING - Modification or Alteration 429445 1
9 WARNING - Hazardous Voltage 429437 1
10 WARNING - Riding Rotary Head 429420 1
11 WARNING - Flying Objects & Spray 429141 1
12 WARNING - Rotating Parts 429431 2
13 WARNING - Falling Rotary Head 429426 2
14 WARNING - Combustible Gas (Batteries) 429439 2
15 WARNING - Combustible Gas (Ether) 429444 1
(ref. 429469)
Safety Sign Maintenance

Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap
and water to clean safety signs. Do not use solvent-based cleaners as they may damage the safety sign
material.
2-8 Safety
Safety Sign Locator
Fig. 2-1
Safety 2-9
Safety Sign Locator
Fig. 2-2
2-10 Safety
Safety Signs
WARNING WARNING
Entanglement
Hazard
Rotating parts can
cause personal injury.
3500 lbs/
1587 kg
Do not exceed hoist Keep away from fan

capacity & stay away and belt when engine
Crush Hazard
from lifted loads. is running. Stop engine
(3500 lbs./1587 kg.) before servicing.
Falling objects can cause
severe injury or death. Do not use damaged 428893
cable. 429414
428893
429414
WARNING WARNING
Crush Hazard
Purge air from circuit
Place carousel against after servicing mast
Crush Hazard Falling mast can cause
lower stops before raising cylinder(s).
severe injury or death.
servicing hydraulic circuit.
Falling pipe carousel can Purge air from circuit after
cause severe injury or death. servicing carousel circuit. 429418
429448
429418
429448
WARNING
WARNING
Entanglement Hazard Keep clear of rotating drivelines.

Switch off engine before performing
Death or serious injury
service. Do not operate with guard
can result from contact
removed. Burn Hazard
with rotating drivelines.
429406
Allow to cool before
Hot pressurized fluid can opening.
429406 cause severe burns.
429449
429449
Safety 2-11
Safety Signs
WARNING DANGER
Maintain required clearance.

Line voltage Required clearance
Electrocution Hazard
Death or serious injury can result from contacting 0 to 50 kv 10 ft (3 m)
electric power lines. 50 to 200 kv 15 ft (4.6 m)
Fall Hazard 200 to 350 kv 20 ft (6.1 m)
Always contact the electric power line owner.
Death or serious injury The electric power shall be disconnected or the 350 to 500 kv 25 ft (7.6 m)
may result from climbing power lines moved or insulated before machine 500 to 750 kv 35 ft (10.7 m)
raised mast. operations begin.
429437 750 to 1000 kv 45 ft (13.7 m)
429437
WARNING
Do not climb raised
mast. Lower mast
completely to
service.
429404
429404
Crush / Fall Hazard
Do not ride rotary head.
Riding rotary head can Lower mast completely
cause severe injury or to service.
death.
429420
429420
WARNING
WARNING
Flying Object & Spray Hazard
Improper operation or Read and understand Death or serious injury can
maintenance can result operator's manual and all result from release of
in serious injury or safety signs before using
death. or maintaining machine. pressurized liquids.
If you do not understand
the information in the Shut off live air at source, and
manuals, consult your
supervisor, the owner or
relieve all pressure before
the manufacturer. removing filler plug.
429445
429141
429445
429141
2-12 Safety
Safety Signs
WARNING WARNING
Explosion / Burn Hazard
Can cause death, burns or blindness due to
Entanglement Hazard ignition of explosive gases or contact with
corrosive acid.
Rotating parts can cause
severe injury.
Keep all open flames and sparks away. Wear

personal protective equipment, including face
shield, gloves and long sleeve shirt.
READ MANUALS
Do not operate with Read all manuals prior to operation.
guard removed. DO NOT OPERATE equipment if you do not
Keep all guards in place. understand the information in the manuals.
Consult your supervisor, the owner or the
429431 manufacturer.
429431 429439
429439
WARNING WARNING
Crush Hazard
Purge air from circuit Explosion Hazard
Do not spray "High Energy"
after servicing feed
Falling rotary head can starting aid into
cylinder(s). Combustible gas can
cause severe injury or compressor air inlet
cause severe injury
death. or engine grid heaters.
or death.
429426 429444
429426 429444
Safety 2-13
Safety Signs (International)
429740
Flying Object & Spray Hazard (429740)
429720
Explosion/Burn Hazard (429720) Fall Hazard–Mast (429712)
T104915
Fall Hazard (T104915)
429713
Explosion Hazard–Ether (429713)
429705
Entanglement Hazard (429705)
2-14 Safety
3500 lbs/
1587 kg
429718
429721
Crush Hazard–Carousel (429718)
Crush Hazard–Winch (429721)
429715 429719
Crush Hazard–Mast (429715) Crush Hazard–Rotary Head (429719)
Safety 2-15
429709
Electrocution Hazard (429719)
429722
Modification or Alter Hazard (429722)

429717
Burn Hazard–Pressurized Fluids (429717)
429714
Crush/Fall Hazard–Rotary Head (429714)
429710
429738
2-16 Safety
Section 3
Operator Controls
Operator Controls 3-1

Graphic Symbol Legend
The following is a listing of the graphic symbols found on the cab control consoles and their basic descrip-
tion. The control functions are described in detail following the symbol descriptions.
Drill Functions
HOBO Swing HOBO Lock Deck Wrench
Auto Pulldown Holdback Hoist Pulldown
Winch Drill Pipe Support Oil Injection
Pipe Rack Swing Pipe Rack Rotate Pipe Rack Lock
Thread Lube Mast Lock Dust Curtain/Blower
ON
OFF
Main Air Drill/Propel Dust/Water
Mast Lower/Raise Front Jack–UP/DOWN Left Rear/Right Rear Jack–Up/Down
3-2 Operator Controls

Graphic Symbol Legend
Drill Functions
Rotation/Left Track Pressure Pulldown Pressure Drilling Air Pressure
Hydraulic System Pressure Rotation–Forward/Reverse Pulldown Pressure–Increase/Decrease
Water Injection–Increase/Decrease
Operator Controls and Indicators
Compressor Discharge Temperature Engine Coolant Temperature Engine Oil Pressure
Fuel Level Battery Charge Engine Hourmeter
Engine Tachometer Engine Start Drill Hourmeter
Ether Injection Engine Stop Ignition–On/Off
Throttle–Fast/Slow

Operator Control Panel (standard)
Fig. 3-1 Operator Control Panel
NOTE "PUSH" LEVER - Move lever AWAY FROM OPERATOR

"PULL" LEVER - Move lever TOWARDS OPERATOR
NOTE Options are used along with or in place of standard equipment on some machines.
Although every effort has been made to be as complete and thorough as pos-
sible in the following pages, not every photo and item described herein may be
used on each machine and your machine may have different controls than those
shown. Consult with manufacturer if unsure about any function or control prior to
use.
1. Level Indicator
Indicates when the machine is level.
2. Throttle
Used to control the engine speed. Minimum engine speed is 1300 RPM, Maximum speed is 2100
RPM.
3. Jack Levers
Used for lowering and raising the jacks to level the machine. Pull the levers to lower the jacks.
Push the levers to raise the jacks.
3a. Right Rear Jack
3b. Front Jacks
3c. Left Rear Jack

4. Mast Lever
Controls the lowering and raising of the mast.
• Pull lever to raise mast.
• Push lever to lower mast.
DO NOT raise mast close to power lines. See Section 1 for Clearances from High
Voltage Lines.
5. Propel Levers - Hydraulic pilot operated

Control the speed and the direction of the tracks.
• Push levers to propel forward (radiator end).
• Pull levers to propel in reverse (cab end).
5a. Right Track Lever
5b. Left Track Lever
6. Rotation Lever - Hydraulic pilot operated
Controls rotary head speed and direction.
• Push lever for forward rotation.
• Pull lever for reverse rotation.
7. Hoist/Pulldown System Lever - Hydraulic pilot operated
Controls the raising and lowering of the rotary head.
• Push lever to raise the rotary head.
• Pull lever to lower the rotary head.
8. Engine Diagnostic Lamp
Light flashes to indicate engine fault.
Refer to engine manual for fault codes and remedy.
9. Remote Pulldown Relief
Controls the pressure to the feed system to increase or decrease the weight on bit.
• Turn control clockwise to increase pressure.
• Turn counterclockwise to decrease pressure.
9a. Holdback System Pressure Control
This valve is used on high pressure machines using down the hole hammers and is used in con-
junction with the Holdback System Switch (see switch panel detail) which activates the solenoid
valve. Normally this valve is wide open (all the way out, counterclockwise) when drilling begins. As
pipe sections are added, the weight on the bit increases. To avoid too much pressure on the bit turn
valve IN (clockwise) to increase oil restriction from pulldown cylinder to tank.
• Turn control clockwise to decrease pressure on bit.
• Turn counterclockwise to increase pressure on bit.
10. Compressor Start-Run Valve–not shown (cold weather option)
Low Pressure Machines:
When starting machine, valve should be in the "Start" position so compressor is unloaded or in low
pressure mode. When machine is warmed up, turn valve to "Run" position.
High Pressure Machines:
When starting machine, valve should be in the "Low" position. When machine is warmed up, turn
valve to "High" position.
NOTE Machines without cold weather package do not use this valve.

Fig. 3-2 Instrument Panel

11. Main Circuit Breaker Panel
Pull to disconnect, push to reset breakers.
11a. Circuit Breaker Panel
For Air Conditioner and Heater.
12. Light Switches
Used to turn on and off outside drill and cab interior lights.
13. Compressor Air Filter Indicator
Shows RED when filter element needs to be changed. Indicates differential pressure across filter
element.
14. Engine Air Filter Indicator
Shows RED when filter element needs to be changed. Indicates differential pressure across filter
element.
15. Ignition
The ignition key is used to turn the electrical power ON/OFF.
(a) Turn key ON to supply electrical power.
(b) Turn key OFF to stop engine.
16. Starter
The Start button is used to start the engine.
(a) Press Start button to start the engine.
(b) Release button once engine is running.
17. Ether Injection (optional)
Aids in starting cold engine.
(a) Press for 3 seconds.
(b) Release to discharge.
(c) Wait 3 seconds to start engine.
18. Drill Hourmeter
Meter records actual drilling hours.
19. Engine Hourmeter
Meter records total engine hours.
20. Engine Oil Pressure
Gauge indicates engine oil pressure.
21. Engine Tachometer
Gauge indicates engine revolutions per minute.
22. Engine Coolant Temperature
Gauge indicates the temperature of the engine coolant.
23. Compressor Discharge Temperature
Gauge indicates the temperature of the compressor discharge air.
24. Fuel Level
Gauge indicates fuel level in tank.
25. Voltage
Gauge indicates voltage output of the electrical charging system.
Operator Control Panel (optional)
Fig. 3-3 Optional Control Panel
Fig. 3-4 Water Injection Pump Motor Flow

Control
Controls hydraulic flow to water pump motor.
Turn clockwise to increase flow.
1. Auto Lube Controller

Controls auto lube system. Refer to Section 7 of this manual for operator's manual.
2. Drill Depth Meter
Monitors drilling depth. Refer to Section 7 of this manual for operator's manual.
3. Tram Interlock Light
Light ON, indicates drill pipe is still in hole. Machine will not tram until pipe is out of hole.
4. Test Switch
Turn switch ON to check filter indicator lights.
5. Filter Indicator Lights
Light ON, indicates that particular filter needs to be changed. Monitors the following fluid filters:
Loop, Charge, Main Return, Case Drain, and Compressor Oil Filter.\
6. Caterpillar EMS (Engine Monitoring System) Panel
An electronic monitoring system that displays various engine parameters. Each time the engine is
started, the EMS undergoes an automatic self-test. This panel replaces the engine hour meter, en-
gine oil pressure gauge, engine tachometer, engine coolant temperature gauge and voltage gauge.
7. Caterpillar EMS Scroll Switch
Move switch up or down to scroll through menus on EMS panel.
8. Horn Button
Push button to sound horn.
9. Jack Retract Light
Light ON, indicates jacks are fully retracted.
10. Oil Injection Light
Light ON, indicates oil injection pump is running.
11. Compressor Low Oil Pressure Light
Light ON indicates low oil pressure at compressor bearings.
12. Rotary Torque Control
Turn knob clockwise to increase rotary torque.
13. Hydraulic Oil Temperature Gauge
o
Monitors temperature of oil in hydraulic tank. Oil temperature in tank should not be above 180 F
o
(82 C) during normal operation.

Cat EMS Panel
Engine Monitoring System (EMS) The main gauge module has ten indicators (two
rows offi ve) that are used to display the system
Display diagnostics. A digital LCD readout displays the
parameters that are monitored. When metric values
Overview are displayed, the units of measurement are
also displayed. When US values are displayed,
the units of measurement are not displayed. For
example, if metric values are being displayed, the
readout would be “35 kPa”. If US values are being
displayed, the readout would be “5”. (The unit of
measurement “psi” is NOT displayed.)
The following parameters are monitored:
• Auxiliary pressure
• Auxiliary temperature
• Battery voltage
• Coolant temperature
• Engine hours
• Engine load (percent)
g00746960
Illustration 53 • Engine oil pressure
The EMS display is used to display various engine • Engine speed
parameters. The EMS display supports backlighting
in order to provide excellent visibility in various light • Fuel pressure
conditions.
• Fuel rate
The engine ECM processes the operating
parameters and diagnostic information before • Fuel temperature
sending this information to the EMS display via the
CAT data link. The main gauge module displays • Inlet air temperature
the information that is received from the ECM. Only
two wires are required from the ECM to the display • Turbocharger outlet pressure (boost)
for communication of all of the engine operating
parameters. The quad gauge module has graduated warning
zones that display information in an analog format.
The EMS display incorporates three individual The quad gauge module displays the following
gauge modules which can be installed in various information:
locations in order to enhance operation. One main
gauge module is required for each desired operator • Battery voltage
station. The tachometer module and the quad
gauge module are optional. These optional modules • Coolant temperature
will NOT operate without being connected to a main
gauge module. • Engine oil pressure
The following information describes the function • Fuel pressure
and the requirements for installation of each gauge
module: The tachometer module displays engine speed
(rpm) on an analog gauge.

Fig. 3-5 Instrument Panel with optional Murphy Fig. 3-6 Cummins Engine Panel
Power View display.
14. Murphy Power View (optional)

The "power view" system is an option in place of the engine hourmeter. It monitors several engine
functions, including: RPM, Engine Hours, Coolant Temperature, Oil Pressure, Fuel Consumption,
Throttle Position, and Engine Service Codes.
Aids in starting cold engine.
16. Engine Pre-Lube Switch
Prior to starting engine, place switch in the START position (toward operator). With ignition switch
ON, push Engine Start Button, this activates the engine pre-lube system. You will hear the pre-lube
pump running, when it stops, the engine starter will activate. After engine starts, flip switch to RUN
position (ISC).
17. Engine Fault Code Switch
Turn switch ON (towards operator) to activate fault code signals from amber light (80).
18. Engine Throttle Switch
This is a 3-position switch. Position switch all the way DOWN (toward operator) for LOW IDLE,
MIDDLE position for MEDIUM IDLE, UP for HIGH IDLE.
19. Engine Protection Light (Green)
Light comes on at start-up to indicated engine systems are normal.
20. Engine Fault Code Light (Amber)
When light is on, it indicates there is a fault in the engine system.
21. Engine Stop Light (Red)
Flashes in a sequence to indicate fault codes. The engine fault codes are listed in the engine
operator/maintenance manual. The fault codes can also be accessed using the Power View (14)
display.

System Pressure Gauge Panel
Fig. 3-7 System Pressure Gauge Panel

System Pressure Gauge Panel
26. Rotation / Left Track Pressure
Maximum pressure 5000 PSI (344.7 bar). Avoid stalling the rotary head for extended
periods.
Gauge indicates hydraulic pressure required to rotate the drill string and when in propel mode, indi-
cates pressure to left track motor.
27. Pulldown Pressure
Maximum pressure 2600 PSI (179 bar). Higher pressures may cause the machine to
tip.
Gauge indicates hydraulic pressure at feed cylinder.

28. Hydraulic System Pressure
Indicates auxiliary pump pressure.
29. Drilling Air Pressure
Gauge indicates the air pressure in the drilling air line.
When the drilling air is turned OFF, there should be zero pressure on this gauge.

Switch Panel (standard)
HOLD BACK
HOBO CLAMP THREAD LUBE
HOBO SWING OIL INJECTION
POSITIONER DUST CURTAIN
DUST/WATER MAST LOCK
PIPE RACK SWING PIPE RACK LOCK
AUX. PUMP MAIN AIR
FAST PULLDOWN AUTO TOOL
AUTO PULLDOWN DRILL/PROPEL
WINCH PIPE RACK INDEX
Fig. 3-8 Switch Panel

Switch Panel (standard)
30. Hydraulically Operated Break-Out Wrench (HOBO) - Swing

The break-out wrench is used to undo tight thread connections. This switch is used to swing the
break-out wrench into or away from the drill pipe.
• Push and hold switch up to swing break-out wrench out.
• Push and hold switch down to swing break-out wrench in.
31. Hydraulically Operated Break-Out Wrench (HOBO) - Clamp
The break-out wrench is used to undo tight thread connections. This switch is used to clamp and
unclamp the break-out wrench and to turn the wrench.
• Push and hold switch right to disengage (open) break-out and unclamp wrench.
• Push and hold switch left to clamp wrench and engage (close) break-out.
32. Drill Pipe Loader - Interlock
This switch is connected to a proximity switch in the mast. If the pipe rack moves off its stop inside
the mast the proximity switch will activate and stop the pulldown, rotation and auto feed. This is to
prevent the rotary head from hitting the pipe rack. When this happens, use the pipe loader swing
switch (40) to swing pipe rack back against stop, then drilling can resume. When adding drill pipe
however, use pulldown and rotation with the pipe loader out. To do this, place the switch in the
OVERRIDE position (towards the UNLOCK symbol). This will allow the rotation and pulldown func-
tions to work when the pipe loader is out.
33. Drill Stem Thread Lube
• Push and hold switch down to activate grease pump to lubricate drill pipe threads.
34. Air Line Lubricator
• Push switch down to activate lubricator pump to provide lubrication for "In The Hole Hammers"
used on high pressure machines.
35. Water Injection / Dust Collector
This switch is used to engage the water injection or dust collector systems to control drilling dust.
• Push switch up to engage water injection system.
• Push switch down to engage dust collector system.
36. Drill Pipe Support
The drill pipe support is used to support the drill pipe in the center of the mast when using the drill
pipe loader for multiple pass drilling.
• Push and hold switch up to engage drill pipe support.
• Push and hold switch down to disengage drill pipe support.
37. Dust Curtain
Switch is used to raise or lower the dust curtain at the rear of the machine.
• Push and hold switch up to lift dust curtain.
• Push and hold switch down to lower dust curtain.

Switch Panel
38. Mast Lock

Switch UNLOCKS or LOCKS mast in the vertical or angle drilling positions.
• Push and hold switch left to unlock (retract) mast pins.
• Push and hold switch right to lock (engage) mast pins into mast.
BE SURE to visually check to see that the mast lock pins are fully engaged in the
holes in the mast before drilling. Also be sure pins are fully retracted from holes
before lowering mast.
39. Used for Optional Functions

40. Drill Pipe Loader - Swing
This switch is used to swing the drill pipe loader out from and into the center of the mast when
adding and retracting drill pipe and for storing the drill pipe loader when propelling or lowering the
mast.
41. Drill Pipe Loader - Rotate
This switch is used to rotate the drill pipe loader left or right to the next position.
• Push and hold switch left to rotate drill pipe loader left.
• Push and hold switch right to rotate drill pipe loader right.
42. Drill Pipe Loader - Lock
This switch is used to lock or unlock the drill pipe loader so the loader can be indexed left or right to
the next position.
• Push and hold switch down to lock pin IN.
• Push and hold switch up to move pin OUT.
43. Drilling Air
Turns the air ON/OFF for drilling procedures.
• Push switch up to turn drilling air ON.
• Push switch down to turn drilling air OFF.
44. Pulldown System (Auto Feed)
The pulldown system switch engages and disengages the pulldown for drilling operations.
• Push switch up to disengage pulldown.
• Push switch down to engage pulldown.
DO NOT engage this switch on unless you are actually drilling. Once drilling is fin-
ished, this switch must be disengaged
45. Fast Down

Push switch down to activate "fast down". Use this feature to increase speed of rotary head coming
down the mast.
46. Winch
• Push and hold switch up to raise winch hook.
• Push and hold switch down to lower winch hook.

Switch Panel
47. Tool (Deck) Wrench

Switch retracts or extends the deck wrench to hold the drill pipe when breaking thread joints or
when multiple pass drilling is required.
• Push and hold switch up to retract tool wrench.
• Push and hold switch down to engage tool wrench.
48. Drill / Propel Switch
Engages the drill controls or propel system.
• Push switch up to engage the propel system.
• Push switch down to engage the drilling controls.
Drill mode must be selected if not propelling the machine or when the machine is
unattended. Drill mode engages the propel brakes.
49. TRAM High/Low Switch

• Push switch UP for LOW SPEED tram
• Push switch DOWN for HIGH SPEED tram.
50. Holdback System
Push switch down to activate the holdback system solenoid valve. This switch is used in conjunc-
tion with the Holdback Pressure Control Valve (53).
51. Auxiliary Pump
This switch activates the auxiliary pump, which provides power for the drill set-up and tooling func-
tions, i.e. winch, breakout wrench, deck wrench, pipe positioner and pipe rack.
• Switch down - Pump loaded
• Switch up - Pump unloaded
52. Remote Pulldown Relief
Controls the pressure to the feed system to increase or decrease the weight on bit.
• Turn control clockwise to increase pressure.
• Turn counterclockwise to decrease pressure.
53. Holdback System Pressure Control
This valve is used on high pressure machines using down the hole hammers and is used in con-
junction with the Holdback System Switch (50) which activates the solenoid valve. Normally this
valve is wide open (all the way out, counterclockwise) when drilling begins. As pipe sections are
added, the weight on the bit increases. To avoid too much pressure on the bit turn valve IN (clock-
wise) to increase oil restriction from pulldown cylinder to tank.
• Turn control clockwise to decrease pressure on the bit.
• Turn counterclockwise to increase pressure on bit.

Lights, Circuit Breakers
ADDITIONAL DRILL CAB ROTATING

LIGHTS LIGHTS LIGHTS BEACON
FRONT CAB BEACON

LIGHTS LIGHTS
ADDITIONAL ECM IGN-24V WIPERS

LIGHTS
CIRCUIT
BREAKERS
DRILL LIGHTS MAIN POWER
CONTROL
PANEL
12 VOLT HEATER &

DRILL LIGHTS NOTE: Not all switches and circuit breakers are used on every
machine. See parts manual for specific switches and breakers.
PULL TO PUSH
DISCONNECT TO RESET
STARTER
Fig. 3-9 Control Panel - Left Side
Fig. 3-10 Control Panel - Right Side

1. 10 AMP Circuit Breaker - Air Conditioner
2. 15 AMP Circuit Breaker - Heater

Remote Mounted Cameras
There are two remotely mounted cameras on the machine that allow the operator greater visibility while
tramming. The cameras are switched on by a toggle switch on the cab circuit breaker panel.
The cameras can be positioned for best view but as a minimum should optimize the operator's visibility to
the front and far left side of the machine.
The display is located in the cab so that the operator has full view of the display when the machine is being
trammed. Only one camera is able to be viewed at a time.
9 8
Fig. 3-11 Camera Display Controls
1. POWER LED–indicates that the monitor has power

2. DAY/NIGHT SENSOR–senses available light and adjusts
monitor brightness accordingly
3. MENU BUTTON–initiates display of onscreen user controls
for image contrast, brightness and speaker volume
4. + BUTTON– UP button-increases the value for setup menu
items, such as volume
5. - BUTTON–DOWN button-decreases the value for setup
menu items, such as volume
6. POWER/CAM SELECT BUTTON–when pressed and held
for one second, turns the monitor ON or OFF; when pressed
briefly, switches image input
7. NORMAL/MIRROR SWITCH–switches image display to
Normal or Reverse (as it would appear in a rear-view mirror)
8. MONITOR CABLE–receives power and camera images
from the control box
9. BRACKET SLOT–accepts the adjustable mounting bracket
Heater/AC/Pressurizer
Fig. 3-12 Heater/Air Conditioner Unit
1. Heater - A/C Temperature Control

Controls temperature of A/C or heat.
2. OFF - Heat - A/C Switch
Selects OFF, HEAT, or A/C.
3. Fan Switch (3 position)
Selects fan speed, LOW - MEDIUM - HIGH Condenser/Dryer
4. Vent Control
Selects FRESH AIR or RECIRCULATION
Pressurizer w/Air Filter

Backpack Combo

AC/Heater
Cab Heater Fault Isolation

Check out the heater as follows:
a. Check blower motor by operating console switch, checking all three positions and observing blower
operation. Check for tripped circuit breaker and reset if tripped. Check for possible shorts in wiring
or loose connections.
b. Check for heating by first allowing diesel engine to warm up thoroughly, then turning on blower and
assuring that the circulated air is warm.
c. If heater fails to heat, check cutoff valves at plumbing connections to engine to be sure they are
turned on, then check the heater plumbing.
Fig. 3-13 Heater Connections and Cutoff Valves (Cat.

C15)
1. Water Outlet to Heater
2. Water Inlet from Heater

Air Conditioner
Maintenance and Servicing Schedule

Although the systems are of heavy duty, industrial design, they still need maintenance and service. They
will not run indefinitely and the warranty is conditional upon these services being carried out.
Daily Weekly Monthly Every 3 Every 6 Yearly

Service Service Service Months Months Service
Check for Cleanliness of Fresh Air and
Return Air Filters. X X X X X X
Check Compressor Clutch:

1. Fixing screws & bracket
2. Clutch electrical connections X X X X X
3. Belt tension and wear
Check for Cleanliness of Condensing
Coil. X X X X
Clean Condenser Fan Motor With Dry

Compressed Air. X X X X
Check for Correct Setting of Thermo-

X X X X
stat.
Check Refrigeration and Water Lines
for Damaged Lines X X X X
Check Condensing Coil:

1. Refrigerant connections against leak-
age X X X
2. Fixing bolts and screws
Check Condenser Fan Motor
1. Seal on motor shaft
2. Fixing clamps and screws X X X
3. Inspect motor brushes for wear
4. Electrical Connections
Check Condenser Fan
1. For damage
2. For securing screws X X X
3. For excessive noise
Check Compressor
1. Refrigerant piping and connections
2. Electrical connections X X X
3. Check securing screws & bolts
4. Welds on mounting bracket

Air Conditioner

Check Liquid Receiver/Drier

1. Refrigerant lines & connections
2. Securing bolts
3. For possible need of replacement X X X
4. For refrigerant leakage
5. Sight glass during operation
Check High Pressure & Low Pressure
Controls
1. For correct setting X X X
2. Securing screws tightness
3. Electrical connections
Check Securing Fasteners on Fresh Air
and Return Air Filters X X X
Check Evaporator Coil

1. For cleanliness
2. For refrigerant leakage X X X
3. For tightness of securing screws
Check Evaporator Fan Motor
1. For tightness of securing screws X X X
2. For electrical connections
Check Evaporator Blower
1. For tightness
2. For damaged blades X X X
3. For excessive noise during operation
Check Against Refrigerant Leakage of
the Thermal Expansion Valve X X X
Check Electrical Connections of Ther-

mostat X X X
Check Control Switch

1. Electrical connections X X X
2. Operation
Check Heater Control Valve

1. For water leakage
2. Tightness of securing screws X X X
3. Operation
Check for Damage and Cleanliness of
Louvers X X X

Air Conditioner

Check Condensate Drip Tray

1. For cleanliness X X X
2. For drain pipe blockage
Check Securing Screws & Bolts for

Tightness on Main Frame & Panels X X X
Check for Leakage of Refrigeration

and Water Lines X X X
Check Evaporator Pressure Regulator

1. For leakage X X X
2. Evaporator pressure setting
Check Fresh Air Fan Motor

1. For excessive noise during operation
2. Brushes for wear x X X
3. For electrical connections
4. For tightness of securing screws
Inspect Motor Brushes for Wear on
Evaporator Fan Motor x x

Air Conditioner
DO NOT brush fins of coil with wire brush or irreparable damage will occur. If fins are
bent, use a correct coil fin comb to realign them.
Servicing
Condenser Coil - When the cover is removed the condenser coil is exposed, and thus readily available
for examination and cleaning. If cleaning is required, wash with low pressure water in the reverse
direction to air flow.
Condenser Fan Motor - Inspection of the motor is carried out by lifting the cover and removing the
motor from its mounting bracket. The brushes are accessible by removing the brush cover screws.
Inspect brushes for wear and replace if necessary. The motor case should be cleaned using only
moisture free compressed air.
Condenser Fan Blade - If any part appears to be damaged or worn excessively, DO NOT REPAIR, but
replace the fan blade.
Compressor - The compressor is equipped with either pad type or Rotalock suction and discharge
service valves mounted on the cylinder head. The pad type valves and the Rotalock valves are not
interchangeable.
Oil Charge - The system is charged with a R-134a compatible oil.
Compressor Oil Level - It is not necessary to frequently check or change the compressor oil. However,
it may be necessary to replenish or replace the compressor oil in the following cases:
1. Whenever the compressor, evaporator, condenser or receiver-drier is replaced.
2. Whenever the refrigerant has leaked from the system.
3. Whenever the refrigerant is suddenly released from the cooling cycle.
4. Whenever any oil-related problems occur in the cooling cycle.
Follow the component manufacturer's recommended procedures for repairs or replacements to
the system.

Air Conditioner
Servicing (cont.)
Changing Compressor:
1. Connect pressure gauge to suction gauge port on suction service valve stem one to two turns
clockwise. If gauge shows a pressure above zero gauge pressure and compressor can be oper-
ated, close suction service valve and operate compressor until compressor suction pressure is
reduced to approximately 2 psig.
2. Stop compressor and immediately close discharge service valve by turning clockwise.
3. Remove suction and discharge service valves from compressor.
4. Remove mounting bolts from compressor and remove compressor from engine.
5. Remove clutch.
6. Check to see that new replacement compressor:
a. Is of the same model and bill of material or an approved replacement for the one being re-
moved.
b. Oil level meets compressor manufacturer's specifications.
7. Install clutch removed from defective compressor with "non-Rok" key in place after checking to see
that the clutch has no objectionable imperfections in it. Tighten hexhead bolt in end of shaft.
Carefully lower, do not drop, clutch or compressor shaft. In most instances it is a
NOTE
good idea to replace clutch assembly as well.
8. Mount compressor using specified torque for mounting bolts, making sure that belts are properly
aligned and tightened to recommend belt tension (120 pounds for new belts, 100 pounds for used
belts).
9. Securing service valves to compressor:
a. If valves are of the flat pad type, check to see that valve mounting surfaces on both valves and
cylinder head are clean, free of nicks, gaskets and foreign material. Using new mounting gasket
mount valves to compressor and tighten mounting bolts.
b. If valves are of the Rotalock type, check to see that valve mounting surfaces on both valves
and compressor are clean and that o-ring valve mounting gasket is properly positioned and in good
condition. If deformed, broken or split, replace with new gasket. Properly align valve to cylinder
head and tighten Rotalock nuts.
c. Special care should be used so that no dirt or foreign material enters compressor during instal-
lation. The new replacement compressor should not be left unsealed to the atmosphere longer
than is absolutely necessary for preparation and actual installation. In no case should compressor
be open to atmosphere for more than five minutes.

Air Conditioner
Servicing (cont.)
Changing Compressor (continued):
10. With service valves in closed position, connect vacuum pump to discharge and suction gauge
ports of service valves and evacuate to 500 microns Hg. Stop vacuum pump and close lines to
compressor.
11. Open suction service valve until a minimum pressure of 50 psig in crankshaft is reached. Close
service valve, purge pump until a vacuum of 500 microns Hg is again reached. Open and backside
discharge service valve by turning counterclockwise, which closes discharge gauge port.
12. Open suction service valve. Charge system with refrigerant to specified limits through suction
service valve gauge port. Operate system for 5 minutes at fast idle, check for leaks. No leaks are
permissible.
13. Seal off discharge and suction connection ports of defective compressor.
Seal Assembly Replacement Procedure (Optional, HG 1000 Only):

Parts required: Seal Assembly Kit. This assembly includes front seal plate, seal nose and spring
assembly, o-ring for front plate and when required, a seal plate retainer and dust shield.
1. Remove compressor from engine in accordance with procedure under "Changing Compressor,"
Items 1 thru 4, inclusive. Place compressor on bench with shaft in up position.
2. Remove hex nut from end of crankshaft and remove flywheel or clutch by use of a 5/8-11 bolt. Do
not tap on shaft or clutch.
3. Wash or clean seal plate and adjoining surfaces of all dirt and foreign material.
4. Remove shaft key.
If the compressor being repaired has a dust shield, carefully remove it to avoid
NOTE
marring the shaft and discard.
5. Remove seal plate assembly by removing the six bolts in plate and gently pry plate loose, being
careful not to scratch, mar, or nick crankcase mating surface or edges.
6. Remove carbon nose and spring assembly from shaft by a seal puller. When pulling the seal assembly
from the shaft, do not scratch crankshaft. If rubber seal around shaft does not come out with carbon
nose and spring assembly, remove same with long nose pliers, pulling on edge of grommet.
7. Remove all gasket material, dirt and foreign material from crankcase mating surface to seal plate,
exposed crankshaft, and adjacent surfaces.
8. Coat exposed surface of crankshaft with clean refrigeration oil. Dip bellows seal assembly and shaft
seal washer in clean refrigeration oil. Place bellows seal assembly over shaft with end for holding
shaft seal washer going on last. With hand, push bellows seal assembly on shaft to a position beyond
taper of shaft. Do not push into seal cavity.

Air Conditioner
Servicing (cont.)
Seal Assembly Replacement Procedure (continued):
9. Assemble shaft seal washer in bellows seal assembly, assuring before doing so to see that bellow
seal assembly and notches in washer line up with the tabs in bellow seal assembly. Cover exposed
surface of shaft seal washer with clean refrigeration oil.
10. Insert new o-ring in crankcase groove on mating surface for seal plate.
11. Place new front seal plate or seal plate and retainer over the shaft. Properly line up mounting holes
with seal and seal plate. When aligned, place plate and seal assembly up against crankcase. Insert
the six capscrews and screw in squarely and evenly. Tighten capscrews in a circular sequence to a
torque of 6–7.5 ft-lb.
12. Rotate shaft by hand 15 to 20 revolutions to seat seal. Clean off excess oil.
13. Install the key. Replace the clutch and tighten the clutch mounting bolt.
NOTE In general, it is more cost effective to replace the compressor.
Liquid Receiver/Drier - In the event that the system is contaminated, or has lost all its charge, or is
down for extensive maintenance, the receiver/drier should be replaced. It is a low cost item and
provides a great deal of protection. If the system has lost its charge completely, replacement should
be effected immediately prior to final leak testing and charging. This prevents contaminants being
drawn into the desiccant and thereby decreasing its capacity.
NOTE If the system is charged, the refrigerant MUST be recovered into a refrigerant
recovery device.
High Pressure and Low Pressure Controls - Follow Maintenance Schedule. If found faulty, replace
completely. Do not attempt to repair any part. Connection is via access ports so minimal refrigerant
is lost.
Filters - Clean regularly as per Maintenance Schedule with low pressure water or clean compressed air.
Replace if found that they cannot be cleaned.

Air Conditioner
Servicing (Cont.)
DO NOT brush fins of coil with wire brush or irreparable damage will occur. If fins are
bent, use a correct coil fin comb to realign them.
Evaporator Coil - Follow Maintenance Schedule. If found that the coil needs cleaning, wash with low
pressure, ambient temperature water. Ensure that a baffle is used to prevent any water from being
washed into the cabin through the return air plenum. Some detergent may be misted on to assist
cleaning.
Setting of TX Valve Superheat & Evaporator Pressure Regulators - The purpose of these devices in
the air conditioning unit are as follows:
TX Valve - Thermostatic Expansion (TX) Valve - This device has high pressure liquid refrigerant enter-
ing and passing through a very small orifice thereby causing a drop in pressure. This lower pres-
sure refrigerant has some 'flash gas' in it, therefore its volume for a given mass increases, and as
the same amount of mass is being fed to the evaporator its velocity through the distributor increas-
es, which causes a further pressure drop and more liquid 'evaporation'. This refrigerant then enters
the evaporator coil at a much lower pressure and as heat is taken up through the heat exchange
surface, evaporation continues, thereby cooling the air and changing the state of the refrigerant
from a high density liquid to a low density gas.
Complete evaporation of the liquid must take place prior to the refrigerant leaving the heat ex-
change coil, as liquid refrigerant at the compressor will cause damage. Refrigerant is incompress-
ible and flushes out bearings. Refrigerant vapor leaving the evaporator coil should be 'superheat-
ed'. At the point where the temperature of the refrigerant corresponds to the saturated pressure,
the condition is said to be saturated. If the temperature is higher than saturated pressure, the
condition is said to be superheated.
Normally around 10 - 11oF (6oC) is considered favorable.
If it is too high, as is the case in an undercharged system, the system loses capacity as the amount
of energy to superheat gas is no where near as much as to change the state of the refrigerant from
a liquid to a gas. Suction pressures will be low, suction line warmer than normal.
If it is too low, suction pressures will be higher, but coil temperature will also be high, so heat
transfer will not be as effective. If it is 'flooding back', the line will be sweaty all the way back to the
compressor and the compressor could be noisy.

Air Conditioner
Servicing (Cont.)
Setting of TX Valve Superheat & Evaporator Pressure Regulators (continued)
The following table has been provided for your convenience:
SUCTION PRESSURE SATURATED 10oF

TEMPERATURE SUPERHEAT
psi kPa oF oC oF oC
28.4 196 30 -1 40 5
30.0 207 32 0 42 6
31.7 219 34 1 44 7
33.4 230 36 2 46 8
35.1 242 38 3 48 9
36.9 254 40 5 50 11
How to set - Ensure that coils and filters are clean and system fully charged. Run through normal
checks and ensure pressures, etc., are within expected levels and no blockages in supply line to
TX valve.
Check that the bulb or coil is securely and cleanly clamped to the suction line.
Fit a thermometer probe to the suction line adjacent to the bulb or coil.
Connect up pressure gauge at the EPR port.
Operate the unit under a stable load and calculate the superheat, then adjust the TX valve slowly.
After adjustment, please allow time for the system to stabilize as 'hunting' will occur for some time.
Evaporator Pressure Regulator - This device modulates according to pressure in the evaporator. Its
purpose is to keep pressure, and therefore temperature, above a set figure to prevent ice build-
ing-up on the coil, and water in the heating circuit from freezing and possible rupture of the water
pipes.
If the pressure falls, it will restrict the flow, therefore the evaporator pressure and temperature rise,
but the suction pressure to the compressor falls. Operation is reversed if pressure rises.
In normal air conditioning applications, it should be set at 28-30 psi.
How to Set - Once the TX valve has been adjusted to correct superheat the EPR valve can be adjusted
by screwing the adjusting screw beneath the knurled cap. The Lp gauge line is left in position.

Air Conditioner
Troubleshooting
I. System Produces No Cooling

CAUSE INDICATIONS REMEDY
Fuse blown or circuit breaker tripped Electrical components will not operate. Replace fuse or reset circuit breaker.
Broken or disconnected electrical wire Electrical components will not operate. Check all terminals for loose connec-
tions; check wiring for hidden breaks.
Broken or disconnected ground wire Electrical components will not operate. Check ground wire to see if loose, bro-
ken, or disconnected.
Clutch coil burned out or disconnected Compressor clutch inoperative. Check current flow to clutch; replace if
inoperative.
Electric switch contacts in pressure Compressor clutch inoperative. Replace low pressure or high pressure
switches burned excessively, or clutch switches or clutch relay.
relay not working
Blower motor disconnected or burned Blower motor inoperative. Check current flow to blower motor;
out repair or replace if inoperative.
Mechanical:
Loose or broken drive belt Visual inspection. Replace drive belts and/or tighten to
specifications.
Compressor partially or completely Compressor pulley slips on belt or will Remove compressor for service or
frozen not turn when clutch is engaged. replacement.
Compressor reed valves inoperative Only slight variations of both gauge Service or replace compressor reed
readings at any engine speed. valves.
Expansion valve stuck in open position Head pressure normal, suction pressure Replace expansion valve.
high evaporator flooding.
Refrigeration:
Broken refrigeration line Complete loss of refrigerant. Examine all lines for evidence of break-
age by stress or rubbing wear.
Safety valve Complete or partial refrigerant loss. Examine valve on drier.
Leak in system No pressure on high and low gauges Evacuate system, apply static charge
(applies to any system having complete leak test system, & repair leak as neces-
loss of refrigerant). sary.
Compressor shaft seal leaking Clutch and front of compressor oily; Replace compressor shaft seal.
system low or out of refrigerant.
Clogged screen or screens in receiver High gauge normal or may read high. Repair as necessary.
dehydrator or expansion valve; plugged Low gauge usually shows vacuum or
hose or coil very low pressure reading. Frosting usu-
ally occurs at point of blockage.

Air Conditioner
Troubleshooting
II. System Will Not Produce Sufficient Cooling

Electrical:
Blower motor sluggish in operation Small displacement of air from dis- Remove blower motor for service or
charge duct; blower motor possibly replacement.
noisy.
Mechanical:
Compressor clutch slipping Visual inspection. Remove clutch assembly for service or
replacement.
Obstructed blower discharge passage Blower operates at high speed but air Examine entire discharge passage
displacement very small. for kinks, waddings or failure to open
passage during installation. Correct as
necessary.
Clogged air intake filter Insufficient air displacement by blower. Replace air filter screens and service, or
replace if necessary.
Insufficient air circulation over condens- Insufficient cooling at discharge outlet; Clean condenser.
er coils; fins clogged with dirt or bugs. excessive high pressure gauge reading.
Evaporator clogged Fins clogged with lint, dust, or coated Remove cover and clean with
with cigarette tars. compressed air. Use cleaning solvent to
remove cigarette tars.
Evaporator pressure regulator defective High pressure gauge readings normal; Repair or adjust as necessary.
or improperly adjusted low gauge usually reads too high.
Refrigeration:
Insufficient refrigerant in system Bubbles in sight glass; high gauge read- Test for leaks. Repair as necessary.
ings excessively low. Recharge system until bubbles
disappear and gauge readings stabilize
to specifications.
Clogged screen in expansion valve Gauge pressures may be normal or may Purge system, remove screen, clean
show slightly increased head pressure and replace.
and low suction pressure; discharge out-
put temperature higher than specified.
Expansion valve thermal bulb has lost Excessively high or low gauge readings; Purge system; replace expansion valve.
charge may cool in excess or not enough.
Clogged screen in receiver High pressure gauge usually higher than Purge system; replace receiver.
normal; receiver cold to touch and may
frost.
Excessive moisture in system Excessive high and low gauge reading. Inspect system for refrigerant
Lack of cooling. overcharge. Correct.
If gauges still read high, inspect con-
denser for oil clogging.
NOTE After completing repairs above, system MUST have dehydrator replaced purged, evacuated and charged.

Air Conditioner
Troubleshooting
II. System Will Not Produce Sufficient Cooling (cont.)

Refrigeration (cont.):
Air in system Excessive high and low gauge reading. Purge system, replace filter/drier,
Sight glass shows bubbles or is cloudy. evacuate and charge system with new
System contaminated. refrigerant.
Evaporator pressure control valve im- High air temperature off of evaporator Adjust pressure setting on valve to
properly set coil, high evaporator coil temperature. 28–30 psi. (1.9–2.1 bar).
NOTE When a unit must be removed from the system for service or replacement, the system must
have the dehydrator replaced also, and the system must be purged, evacuated and recharged
to remove excess moisture.
III. System Cools Intermittently

Electrical:
Defective fuse or circuit breaker, blower Electrical units operate intermittently. Remove defective part for service or
switch, or blower motor replacement.
Partially open, improper ground or loose Clutch disengages prematurely during Check connections or remove clutch coil
connections in compressor clutch coil operation. for service or replacement.
Mechanical:
Compressor clutch slipping Visual inspection operates until head Slippage over a prolonged period will
pressure builds up (as viewed on high require that clutch be removed for
pressure gauge) at which time clutch service; may require readjustment for
begins slipping, may or may not be proper spacing.
noisy.
Refrigeration:
Unit icing up may be caused by exces- Unit ices up intermittently. Replace expansion valve if excess
sive moisture in system, incorrect super- moisture present, adjust thermostat.
heat adjustment in expansion valve or Purge system, evacuate, recharge.
thermostat adjusted too low
Thermostat defective Low side pressure may be low or exces- Replace thermostat.
sively high; adjustments will not correct.
Stuck regulator valve Both head and suction pressures low; Purge system and evacuate and replace
moisture in system usually indicated. dehydrator to remove moisture; if still
stuck, replace regulator valve.

Air Conditioner
Troubleshooting
IV. Excessively Noisy System

Electrical:
Effective winding or improper connec- Visual inspection; clutch vibrates. Replace or repair as necessary.
tion in compressor clutch coil
Mechanical:
Loose or excessively worn drive belts Belts slip and are noisy. Tighten or replace as required.
Noisy clutch May or may not slip; noisy when en- Remove clutch for service or replace-
gaged ment as necessary.
Compressor noisy Loose mounting, worn part inside com- Check mountings and repair; remove
pressor. compressor for service or replacement.
Loose panels Excessive rattles during operations. Check and tighten all panels; hose hold
down clamps, or rubbing or vibrations of
hoses or pipes.
Compressor oil level low Compressor noisy and lower portion hot If oil level low, determine cause of loss.
to touch. If correction made, fill with specified oil.
Blower fan noisy; excessive wear in Blower motor noisy. Remove blower motor for service or
blower motor. replacement as necessary.
Refrigeration:
Excessive charge in system Rumbling noise or vibration in high pres- Discharge excess freon until high pres-
sure line; thumping noise in compressor; sure gauge drops within specifications.
excessive head pressure and suction
pressure; bubbles in sight glass.
Low charge in system Hissing in evaporator case at expansion Check system leaks, charge system.
valve; bubbles or cloudiness in sight
glass, low head pressure.
Excessive moisture in system Expansion valve noisy; suction pressure Replace dehydrator, purge system,
low. evacuate and charge system.
High pressure service valve closed Compressor has excessive knocking Open valve immediately.
noise; high pressure gauge reads above
normal.

Operator's Seat

Operator's Seat

Section 4
Operating Instructions
Operating Instructions 4-1

Notes
4-2 Operating Instructions

Pre-Start Checks
Commissioning A New Machine

The rotary blasthole drill will (in most cases) arrive on two trucks. The mast is shipped separate (in
most cases) from the drill rig itself. With the drill rig unloaded from the truck and on level and stable ground,
the mast will need to be installed. A manufacturer representative will be on hand to make adjustments and
settings on a new machine.
Load drill pipe using a crane whenever possible, this is the best and safest meth-
od. If a crane is not available when drill pipe is being loaded, follow the procedure
in this section titled "Loading Drill Pipe".
Walk Around Checks:
It is the responsibility of the operator to report any damage or service problems to the supervisor.
You may wish to develop your own checklist and standard operating procedure, such as starting point,
what to look for, etc. Generally, you should check the following areas before start-up, this applies to new
and used machines:
• Check around and under machine for leaks. Determine source of leak and have repairs made.
• Check crawler belts for broken or cracked pads, missing lock pins or bolts, loose track pins and
crawler belt tension. Check track rollers for proper lubrication and wear. Check crawler frames for
cracks or damage.
• Check dust curtains for wear and tear.
• Check for loose or missing bolts. Report any damage and have repairs made.
• Check connections to air filters, make sure they are tight. Check to see that filter elements are in
place.
• Check radiator and oil cooler hoses for cracks and loose clamps.
• Check engine vee belts for cracks or other damage.
• Check engine fuel/water separator if so equipped and drain water.
• Check all pivot points to be sure they are receiving adequate lubrication.
• Check fire suppression equipment to be sure they are adequately charged.
• Check to see that all alarm systems and EMERGENCY STOPS are functioning properly.
• Check to be sure all safety guards are in place and not damaged.
• Check engine/pump driveshaft. Check for loose or missing bolts and adequate lubrication.
• Check all cables for damage or fraying, loose or missing clamps.
• Check drill bit for wear, broken or missing carbides.
• Check that all decals and nameplates are in place and are not damaged.
• Check wiring for damage and loose connections.

Pre-Start Checks
Pre-Start Checklist
Fluid Levels:
A. Radiator Coolant
B. Batteries
C. Engine Oil
D. Fuel
E. Pump Drive Gearcase
F. Water Tank
G. Hydraulic Tank
H. Compressor Oil Separator Tank
I. Rotary Drive Gearcase (check with mast vertical)
J. Winch Gearcase
K. Track Drive Gearcases
Operator Controls:
• Safety first! Become familiar with all the controls and their functions.
• Take it slow at first, as the drilling cycle and controls become more familiar, you can gradually
increase your speed to the full operating capability of the machine.
• Accidents happen quickly, which is why you should operate the machine slowly at first, until you
are satisfied that you comfortable with all the control functions.
• Check that all system gauges are operating properly after start-up.
• Be alert for any unusual noises or smells.
• Know the location of EMERGENCY STOP devices and fire extinguishers and how they operate
(refer to machine locator drawing in introduction of manual).
Fire Extinguisher Specifications:
Fire extinguishers shall comply with EN791:1995 paragraph 5.12.2 and EN 3:1975. Each fire extin-
guisher shall have an agent with a mass of not less than 13.2 lbs. (6 kg). Fire extinguishers shall be suitable
for extinguishing both oil and electrical fires.

Fire Suppression System (optional)
Description
The drill can be equipped with an optional fire suppression system.
The system is manually activated by pushing a remote actuator.
There are two actuators, one located in the operator's cab and one outside the machine. Make yourself
familiar with the location of the actuators. Location varies on different machines.
In addition there is a battery cut-off switch, which automatically cuts the power to the machine off when
the fire suppression system is activated.
Fig. 4-0 Fire Suppression System - 30 lb. Tanks with Actuators (3) Fig. 4-0a Relief Valve
Operation
When the system is activated, the fire suppression agent in the three (3) tanks is released and dis-
charged through a series of nozzles, located in critical areas around the machine. At the same time the
pneumatic battery cutoff switch cuts off the battery voltage to the machine.
Maintenance
Make sure the system is in good operating condition. A fire suppression system does little good if it
does not work when you need it. Make it a habit of daily inspection of hoses, fittings, and discharge nozzles.
The nozzles should have plastic caps in place to keep out dirt and debris. Make sure the actuators are not
damaged and not covered up with clutter. Take care of your system, and it will take care of you.
NOTE At any time if any part of the fire suppression system is suspected of not being fully op-
erational or has suffered damage, it shall only be serviced by a professional fire protec-
tion service.

Fire Suppression System (optional)
In Case of Fire
Locate nearest remote actuator.
1. Turn ignition switch off if possible
2. Pull Ring Pin on actuator.
3. Push Red Button on actuator.
4. Get away from machine and call for help.
Fig. 4-0b Pneumatic Battery Cutoff Valve Fig. 4-0c Remote Actuator in Operator's Cab
After System Has Been Discharged

After a fire, or accidental discharge, the system must be checked and serviced by a professional fire
protection service.
• Be sure the fire is completely out and there are no "hot spots" before getting near the machine.
It's good idea to keep a portable fire extinguisher on hand ( see fire extinguisher specifications on
previous page). When approaching the machine, have a fire extinguisher with you.
• Determine the cause of the fire and make necessary repairs, before putting machine back into ser-
vice.
• After discharge, and when it is safe to return to the machine, the battery cutoff valve needs to be
reset. This is done by first pulling the ring on the pressure relief valve to relieve all pressure in the
system. When all pressure is relieved, push the reset button on the battery cutoff valve IN. You will
not be able to push the reset button in with pressure still in the system.

Normal Start-Up Procedure
Before starting the engine, warn nearby members of the work crew that you are starting
the machine.
DO NOT USE ETHER on engines equipped with an Air Inlet Heater (electrically or fuel
ignited manifold heater).
To Start Engine:
1. Be sure all controls are in the Off or Neutral position.
2. Place the compressor Start-Run valve (10) in the start position or low position on high pressure
machines.
NOTE DO NOT start the engine if there is pressure in the compressor receiver tank. If the
engine has recently been running, this may require an approximate 10 minute wait to
allow complete receiver tank bleed down. Starting the engine while there is residual
pressure in the receiver tank will result in a significantly reduced life of the diesel en-
gine starter.
3. Place throttle lever (2) at about 1/3 speed.

4. Turn the ignition switch (15) On.
NOTE The engine diagnostic lamp (8) will flash while the engine is cranking. The lamp
should turn off after proper oil pressure is reached. If lamp continues to flash after
engine is running, the ECM has detected a problem in the system. Refer to engine
manual for diagnostic codes.
5. Push the engine start button (16) until the engine starts, when engine is started, release start
button. Do not crank engine for more than 30 seconds, then allow starter to cool for two minutes
before attempting to start again.
6. If temperature is below 32o F (0o C) use the optional ether injection (17) for starting, use caution
not to use too much as engine damage can occur. Press button for 3 seconds and release, then
allow 3 seconds before starting engine.
Fig. 4-1 Instrument Panel - Right Side

15. Ignition Switch
16. Engine Start Button
18. Drill Hourmeter
19. Engine Hourmeter
20. Engine Oil Pressure

Normal Start-Up Procedure
Fig. 4-1a Control Panel - Right Side

1. Level
2. Engine Throttle Lever
8. ECM Diagnostic Lamp
10. Compressor Start-Run Valve*
(*not shown)
After Start Checks:

After start checks are carried out to ensure that the machine is in a safe working condition before the
operator commences drilling procedures.
1. Check to ensure engine oil pressure is in normal operating range (consult engine manual).
2. Check to ensure compressor air pressure is at least 100 PSI (6.9 bar) for low pressure machines
or 300 PSI (20.7 bar) for high pressure machines.
Compressor air pressure must not exceed 125 PSI (8.6 bar) for low pressure machines
or 350 PSI (24.1 bar) for high pressure machines.
3. Check entire machine for oil leaks.
Normal Shut Down:

1. Allow engine to idle for a minimum of five (5) minutes before stopping.
2. Turn the ignition key to OFF position.
3. Check machine for any unusual conditions.
4. Report any defects to your immediate supervisor.

Ground Level Engine Stop (optional)
DO NOT use the ENGINE STOP switch to stop the machine, except in an emergency.
Shutting the engine down without the proper idle down period can cause engine dam-
age.
Be sure you know where the ENGINE STOP device(s) are located. These devices are optional, there-
fore not all machines will be equipped with them.
In the event of emergency shutdown, the operator should notify the supervisor and be sure corrective
action is taken to remedy the fault that caused the emergency shutdown, before restarting the machine.
1. Take necessary corrective action to correct the fault.

2. Make a walk around inspection of the machine to be sure no additional damage has been done or
could occur. Pay particular attention to the engine and compressor systems.
3. Check circuit breakers and reset the engine stop device.
Fig. 4-2 Ground Level Engine Stop Button
P61 PLUG
E-STOP
ENGINE KILL 56 +BAT (UNSWITCHED) 32
REF SWITCH +BAT (UNSWITCHED)
55 31
CAB JUNCTION
BOX TERMINAL 101 REMOTE SHUTDOWN SW 27
BLU 16 NC BLU 16
7 +BAT (SWITCHED) 26
8 DIAGNOSTIC LAMP 24
71 THROTTLE POSITION SENSOR 10
54 +BAT (UNSWITCHED) 1
ELECTRICAL SCHEMATIC
Fig. 4-3 Electrical Circuit (ref. 426571)

Cold Weather Operation
Hydraulic System Warm-Up

BE SURE machine does not overheat. Observe hydraulic and water temperature gauges.
When pump drive gearbox is disconnected all hydraulic functions are inoperative, in-
cluding the cooler fan.
1. For cold weather start, disengage the pump drive gearbox using the lever on the gearbox (if so
equipped). Start the engine and warm up for at least five (5) minutes (refer to "Engine Start-Up
Procedure" on preceding page).
2. Stop the engine, engage the pump drive gearbox and restart the engine.
3. Level the machine.
NEVER ATTEMPT to commence drilling unless the machine has been leveled and is
located on stable ground conditions. Machine can turn over, causing serious injury or
death.
DO NOT position jacks on cribbing or timber bridging.
DO NOT position machine close to a highwall.
a. Set the throttle at approximately 1600 RPM and lower all jack pads to the ground by operating
the rear and front jack control levers to the down position.
b. Operate rear right and rear left jack controls to down position until rear of machine track is
clear of the ground and approximately level by watching level indicator (refer to "Leveling Ma-
chine").
c. Operate the front jack control to down position, until front of machine track is clear of the
ground, approximately level.
4. Raising the Mast.
a. Be sure the machine is level and solidly stabilized with the leveling jacks before attempting to
raise the mast.
b. Be absolutely sure that the mast will not come in contact with power lines, telephone lines or
any other obstructions.
LOOK UP before raising or lowering mast. Operating near, or coming in contact with
electrical power lines will result in serious personal injury or death. Machine is not
insulated.
See Section 2 for Clearances from High Voltage Lines chart.
ALWAYS level machine before raising or lowering mast and before drilling.

5. Hold Rotation Lever to one-quarter speed and operate rotation in forward position.
DO NOT engage or disengage track drive while engine is running and tracks are in con-
tact with ground. Immediate machine damage could result.
Verify right and left tracks are a minimum of 3 in. (76.2 mm) off the ground.
6. Set Drill/Propel switch to Propel position.

7. Hold Propel Levers at 1/4 position and operate tracks alternately in both directions.
8. Work all hydraulic controls to distribute warming oil and to help elevate oil temperature. Pay par-
ticular attention to winch warm-up by cycling several times without load.
9. When hydraulic oil temperature reaches 1000 F (37.80 C) the system is operational.
Compressor Warm-Up (Low Pressure)

1. Run machine with Compressor Start-Run Valve in the Start position until temperature reaches
160o F (71.1o C). After warm-up, turn selector to Run position.
2. Gradually load compressor by opening air service valve, using the Drilling Air switch until pres-
sure drops to 70 - 80 PSI (4.8 - 5.5 bar). If temperature rises above 210o F (99o C), close air ser-
vice valve and continue warm-up.
3. Partially open air service valve, using the Drilling Air switch. If compressor has stabilized at 160oF
(71.1oC) it is now operational.
4. Gradually increase engine speed to 2100 RPM. Compressor pressure should read 100 PSI (7 bar)
and temperature should be 160 - 200o F (71.1 - 93.3o C). Temperature should be monitored and
maintained by the air flow direction through the cooler.

Compressor Warm-Up (High Pressure)

1. Run machine with Compressor Start-Run Valve (10) Low until compressor temperature reaches
180oF (82.2oC). After warm-up turn selector valve to High position.
2. Gradually load compressor by opening air service valve, using the Drilling Air switch (43) until
pressure drops to 140 PSI (9.7 bar). If temperature rises above 210oF (98.9oC), close air service
valve and continue warm-up.
3. Partially open air service valve, using the Drilling Air switch (43). If compressor has stabilized at
180oF (82.2oC) it is now operational.
4. Gradually increase engine speed to 2100 RPM. Compressor pressure should read 350 PSI (24.1
bar) and temperature should be 210oF (99oC). Temperature should be monitored and maintained by
the air flow direction through the cooler.
Fig. 4-3a Operator Control Panel - left side

10. Compressor START/RUN (low pressure) or LOW/HIGH (high pressure) Valve
43. Drilling Air ON/OFF Switch

Propelling Machine
ALWAYS propel the machine in reverse (towards operator's cab) where possible to pro-
vide maximum visibility. Propel the machine slowly when working on slopes, ramps, or
rough terrain. Be extremely careful when working around trenches or banks.
DO NOT travel on steep slopes or crosswise to grades.
DO NOT propel machine with mast up other than from hole to hole as this causes ma-
chine to become unstable.
Failure to follow these recommendations could result in a machine roll over.
NOTE When propelling this machine, forward is towards the radiator end of the machine, and
reverse is towards the operator's cab.

48. Drill/Propel Switch

Propelling Machine
1. Select Propel mode with the Drill/Propel switch (48).

2. Engage right and left track propel levers (5a, 5b) together slowly in the required direction of travel.
Propel speed is varied by the degree of travel, forwards or backwards of the propel levers. To pro-
pel in a straight line, the propel levers must be operated equally from the neutral positions.
3. To turn the machine left or right, one propel lever may be engaged more than the other to make the
machine turn. For very tight turns one propel lever may be engaged to the full forward position and
the opposite lever engaged to the full reverse position.
Both tracks must be operated when propelling the machine. Never allow either track to
drag while propelling in a straight line or turning.
4. To stop propelling machine once at destination, move the propel levers back to the neutral position.
5. Select Drill mode with the Drill/Propel switch (48).
ALWAYS select Drill mode once propelling functions are finished as Drill mode engages
the brakes. Never leave the machine unattended unless Drill/Propel switch is in the Drill
mode. Failure to follow these procedures could result in personal injury or property dam-
age.
Propelling Up, Down and Across Grades:
1. The mast should always be lowered before propelling the machine up, down or across grades.
2. When propelling up or down a grade, index the pipe loader to a mid position, so drill pipes cannot
slide forward out of the carousel.
3. When propelling up or down a steep grade, the operator's cab should be facing downhill. With the
mast down, the front end of the machine is heavier than the rear (cab end). This makes the ma-
chine more stable.
4. When propelling up a steep grade, a spotter should be used to guide you, as visibility is restricted
to the operator.
5. Always be careful when propelling machine across grades, as the machine is more unstable
sideways than it is lengthways. Propel with the operator's cab facing uphill when crossing grades
whenever possible.

Propelling Machine
Propelling Over Electrical Cables:
1. Always use an approved crossing point, if one has been constructed. Always cross at right angles
and do not turn machine while crossing.
NEVER propel machine across electric cables. Severe personal injury or death could oc-
cur, as well as property damage.
2. If no approved crossing point exists, then the following procedure should be used to cross electric
cables:
a. Use a spotter to help guide you. Approach the cable at 90o and stop machine when cable is
between the jack pads and the tracks.
b. Carefully lower jacks, making sure the jack pads will not rest on the cable. Raise machine
upon the jacks until tracks are clear of the ground.
c. Move cable under tracks until it is between the opposite end of the tracks and jack pads at the
other end of machine.
d. Carefully lower machine, making sure cable is not under tracks and retract jacks fully before
continuing to propel machine.

48. Drill/Propel Switch

Leveling Machine
Leveling Machine
NEVER ATTEMPT to commence drilling unless the machine has been leveled and is
located on stable ground conditions. Machine can turn over, causing serious injury or
death.
DO NOT position jacks on cribbing or timber bridging.
DO NOT position machine close to a highwall.
If machine needs to be re-leveled after it is already on all four jacks:

FIRST level rear (cab end) of machine.
ALWAYS extend front (radiator end) jacks to equalize pressure in both front jacks after
re-leveling machine.
Raising Machine (lowering jacks)

When raising machine, level the rear (cab end) of the machine first, then level the front (radiator end).
Refer to leveling procedure on following page.
Lowering Machine (raising jacks)

When lowering machine, lower the front (radiator end) of the machine first, keeping jack pads close
to the ground. When tracks are on the ground and machine is stable, jacks may be raised fully. Refer to
leveling procedure on following page.
Fig. 4-5 Control Console - Right Side

1. Level 3c. Left Rear Jack
3a. Right Rear Jack 4. Mast Lever
3b. Front Jacks

Re-Leveling Machine
Leveling Procedure
1. Using the Rear Jack levers (3a & 3c), extend the jacks to contact the ground. Level the rear (cab
end) of the machine using the Level Indicator (1) as your guide.
NOTE Front jacks must be lowered AFTER using rear jacks to level machine. This is to en-
sure equal hydraulic pressure in both front jacks.
2. Using the Front Jack Lever (3b), lower the jacks until they contact the ground. Level the front (ra-
diator end) of the machine.
3. Level machine as near to level as possible.
ALWAYS keep the machine as low to the ground as possible when leveling the machine.
This machine has safety check valves in the leveling system to prevent the jacks from
moving in the case of a power failure. Should it be noticed that the jacks are creeping,
the machine should not be operated and repairs completed immediately. Failure to fol-
low these instructions could lead to serious personal injury or equipment damage.
4. To raise the jacks (lower machine), move Jack Lever (3b) to the raise position to lower the front
(radiator end) of the machine. Move Jack Levers (3a & 3b) to the raise position to lower the rear
(cab end) of the machine. Rear jacks may be raised individually or together.
If machine needs to be re-leveled after it is already on all four jacks:

FIRST level rear (cab end) of machine.
ALWAYS extend front (radiator end) jacks to equalize pressure in both front jacks
after re-leveling machine.
Re-Leveling Procedure
If machine has been leveled and is up on all four jacks and you need to re-level the machine, use the
following procedure (refer to fig. 4-5 for leveling jack controls):
1. Level the rear (cab end) of the machine first using levers 3a and 3c.
2. Level the front (radiator end) of the machine using lever 3b even if it appears level. This MUST be
done to equalize the hydraulic pressure to the front jacks.

Raising Mast
electrical power lines will result in serious personal injury or death. Machine is not insu-
lated.
Refer to Clearances from High Voltage Lines chart below.
BE SURE to visually check to see that mast lock pins are fully engaged in the holes in the
mast lock brackets before drilling. Also be sure pins are fully retracted before lowering mast.
Clearances from High Voltage Lines

Voltage Minimum Clearance
up to 50 kv 10 ft. (3 m)
over 50 to 75 kv 11 ft. (3.4 m)
over 75 to 125 kv 13 ft. (4 m)
over 125 to 175 kv 15 ft. (4.6 m)
over 175 to 250 kv 17 ft. (5.2 m)
over 250 to 370 kv 21 ft. (6.4 m)
over 370 to 550 kv 27 ft. (8.2 m)
over 550 to 1000 kv 42 ft. (12.8 m)
1. Level the machine.

2. Check mast for loose drilling tools or parts.
3. Be sure mast lock pins are retracted and drill bit will clear work deck area.
4. Raise mast by engaging the Mast Lever (4) to the raise position. The mast should start to lift; if
not, check the auxiliary hydraulic pressure gauge to see if any other functions are engaged.
5. As the mast approaches the vertical position, the mast raising speed will tend to increase, so it will
become necessary to slow the speed to stop the mast from hitting into the base of the machine too
hard.
6. The mast angle may be set from 70 degrees to the vertical depending on drilling applications.
7. Once the mast has been set at the desired angle, lock the mast into position by pushing the Mast
Lock/Unlock Switch to the Lock position. Always visually check to be sure the mast lock pins are
fully engaged into the mast lock brackets.

Lowering Mast
electrical power lines will result in serious personal injury or death. Machine is not insu-
lated.
Refer to Clearances from High Voltage Lines chart below.
BE SURE to visually check to see that mast lock pins are fully engaged in the holes in the
mast lock brackets before drilling. Also be sure pins are fully retracted before lowering mast.
1. Retract the drill string from the hole, ensuring that the drill bit will clear the work deck area.
2. Rotate the drill pipe loader to the stored position and swing the loader into the center of the mast.
3. Unlock the mast by pushing the Mast Lock/Unlock Switch (fig. 4-6) to the Unlock position.
4. Lower the mast by engaging the Mast Lever (4) to the Lower position, controlling the lowering
speed with the mast lever.
MAST LOCK
Fig. 4-6 Drill Function Panel - Mast Lock Switch

Fig. 4-5 Control Console - Right Side
1. Level 3c. Left Rear Jack
3a. Right Rear Jack 4. Mast Lever
3b. Front Jacks

Loading Drill Pipe
Load drill pipe using a crane whenever possible, this is the best and safest method. If
a crane is not available when drill pipe is being loaded, follow the procedure outlined
below.
Equipment Required:
1. Service truck with service winch capable of lifting male end of pipe above the drilling platform of the
machine.
2. Adequate lifting straps.
Procedure:
1. Be sure machine is on level and solid ground.

2. Check all pipe rack control functions to be sure they operate according to labels on control panel.
Switch hoses if necessary. Check fluid level in rotary gearbox.
3. Lift the male end of the pipe to approximately the height of the middle railing around the drilling plat-
form. Be sure pipe is secure and won't slip.
4. Raise mast to the same angle as pipe and back machine up to the pipe.
5. Apply grease to drill pipe threads and lower the rotary head until the top sub-adapter engages the
threads of the pipe. Thread the pipe all the way to the shoulder of the pipe and top sub-adapter.
6. Stabilize machine by lowering all four jacks to the ground. Machine does not have to be lifted off the
ground, but jack pads should be in solid contact with ground.
7. Raise the rotary head up the mast with the pipe, but do not let the pipe go above the deck bushing
in the mast base. It is also a good idea to use the pipe support if you have an angle hole machine.
8. When the lower end of the drill pipe approaches the deck bushing, stop the rotary head and raise
the mast to the vertical position. Use the pipe rack controls to rack the pipe (refer to instructions on
"Retracting Drill Pipe" in this section).
9. Repeat steps 3-8 for the remaining pipe sections.
Installing and Removing Drill Bit

Before drilling can commence, you must first install the drill bit sub and the drill bit.
1. Remove the rotary deck bushing from the work deck and insert the drill bit breakout basket into the
work deck.
2. Place the drill bit into the bit basket.
3. Place the bit sub onto the drill bit and make-up thread joint "hand" tight.
4. Engage the drill pipe to the bit sub and rotate drill pipe clockwise slowly until the thread joint be-
comes tight. Tighten thread joint to 3000 PSI (207 bar) on the rotation pressure gauge.
5. For removal of drill bit, place bit breakout basket into the work deck.
6. Lower drill bit into the breakout basket and use the breakout wrench to break the thread joint.
7. Once thread joint is loose, simultaneously rotate drill pipe counterclockwise and slowly raise drill
pipe until the drill bit is unscrewed.

Drilling Procedures
LOOK UP before raising or lowering mast. Operating near, or coming in contact with elec-
trical power lines will result in serious personal injury or death. Machine is not insulated.
Refer to Clearances from High Voltage Lines chart in Section 2.
DO NOT operate machine when wind speed is above 75 MPH (120.8 Km/h).
Fig.4-7 Drilling Controls

C. Rotary Torque Control 27. Pulldown Pressure Gauge
6. Rotation Lever 28. Hydraulic System Pressure Gauge
7. Hoist/Pulldown Lever 29. Drilling Air Pressure Gauge
9. Pulldown System Pressure Control 35. Water Injection/Dust Collector Switch
9a. Holdback System Pressure Control 43. Drilling Air Switch
14a. Water Injection Flow Control 44. Pulldown System (Auto Feed) Switch
26. Rotation/Left Track Pressure Gauge

Drilling Procedures
Drilling with Standard Bit (refer to fig. 4-7)

The machine MUST be level and up on all four jacks BEFORE the mast is raised. Once the drill pipe,
bit sub, and drill bit have been coupled up, drilling operations are ready to commence.
1. Lower the drill bit until it comes in contact with the ground.
2. Zero the drill monitor, if equipped.
3. Turn on the drilling air by switching the Drilling Air switch (43) to the ON position. Note the air
pressure on the Drilling Air Pressure Gauge (29).
4. Start rotating the drill string forward slowly (30-40 RPM) using Rotation Lever (6). Forward rota-
tion is clockwise.
5. Slowly lower the drill string using Pulldown Lever (7) until the drill bit is firmly collared in the drill
hole (about 2 - 3 ft.[0.6 - 0.9 m]). Collaring of the hole should be done slowly and carefully to en-
sure that the hole will be straight.
6. Once the hole is collared, engage the Auto Feed (44) by pushing the switch down to the engage
position, then start increasing the Pulldown Pressure (9) and rotation speed until a satisfactory
rate of penetration is achieved. Pulldown pressure and rotation speed will be dictated by the type
of ground being drilled. Refer to Section 5 - Drilling Practices for more information. Adjust Rotary
Torque Control (C) as needed.
NOTE Applying excessive weight or using too fast of rotation speed will result in damage to
the drill bit.
7. Watch the air and rotation pressure gauges while drilling. If a rise in pressure is noted, gently push
the Hoist/Pulldown Lever (7) back towards the hoist position just enough to take weight off the bit,
then move back to original position. Repeat as necessary until drill string "sounds right" for normal
drilling.
8. If dust suppression is required, either the dust collector or water injection systems may be used.
Switch Water Injection/Dust Collector Switch (35) Down for dust collector, Up for water injection.
Adjust water flow for water injection with Flow Control Valve (14a).
NOTE Do not use the dust collector if ground water is encountered. Excessive water injec-
tion will reduce drill bit service life.
9. Drill down until the desired depth of the hole is reached, then disengage the Auto Feed Switch
(44) and start raising the drill string out of the hole using the Hoist/Pulldown Lever (7). As the drill
bit approaches the top of the hole, turn off the air and stop rotating the pipe. Lift the drill bit clear of
the ground, high enough to allow good clearance when moving to the next hole.
NOTE If depths of more than one drill pipe are required, follow the operating procedures for
multiple pass drilling.

Drilling Procedures
Drilling with a Down-the-Hole Hammer (refer to fig. 4-7)

ALWAYS check bit manufacturer's literature for proper bit size, safety, operation and
maintenance information.
It is the responsibility of the operator to be sure they understand the proper operating
procedures supplied by the bit manufacturer.
The manufacturer will not be responsible for equipment damage due to improper use or
misapplication of down-the-hole hammer equipment.
The following is a general guideline for drilling with down-the-hole hammers. Always refer to manu-
facturer's specifications for correct application and specific drilling procedures.
Preparation
1. Tighten all joints to recommended torque by bit supplier.
2. Use proper size choke in the rigid valve (according to manufacturer's specifications) before tool is
operated.
3. Always use the largest diameter bit first, and if necessary, follow with the next smaller diameter bit.
Never use the bit to ream; this will damage the carbides.
4. Place driver sub over bit, followed by o ring and bit retainer ring. Screw the driver sub/bit assem-
bly into the piston case hand tight before using power make-up. Use slow rotation to tighten to the
recommended torque provided by the bit supplier.
Start Up
1. Be sure the lubricator is working properly and oil has fully coated the drill pipe inside diameter.
2. Turn on Drilling Air switch (43) and rotate slowly.
3. Lower the tool slowly into the hole until the bit contacts the bottom and the piston starts operating.
Add just enough pressure to start breaking rock.
ALWAYS apply air and start rotation before putting weight on bit to avoid damage to bit.
4. As the bit starts breaking rock, apply minimum total weight on bit (refer to manufacturer's specifica-
tions).
5. After drilling a few feet, increase weight on bit until the tool runs smoothly. The air pressure will rise
slowly and then stabilize.
NOTE Additional weight on bit will not increase penetration rate appreciably.

Drilling Procedures
Drilling with a Down-the-Hole Hammer (cont.)

Total Weight On Bit
It is important that the minimum weight on the bit be maintained throughout the hole depth. As the
hole gets deeper and pipe sections are added the holdback pressure control (9a) must be turned IN
(clockwise) to decrease pressure on the bit to compensate for the added weight of the drill pipe.
NOTE When reading the pulldown pressure gauge (27), remember this is hydraulic pressure
and not weight in actual pounds (see bit manufacturer's specifications for minimum
total weight on bit).
Fig. 4-7 Drilling Controls

C. Rotary Torque Control 27. Pulldown Pressure Gauge
6. Rotation Lever 28. Hydraulic System Pressure Gauge
7. Hoist/Pulldown Lever 29. Drilling Air Pressure Gauge
9. Pulldown System Pressure Control 35. Water Injection/Dust Collector Switch
9a. Holdback System Pressure Control 43. Drilling Air Switch
14a. Water Injection Flow Control 44. Pulldown System (Auto Feed) Switch
26. Rotation/Left Track Pressure Gauge

Drilling Procedures
Back Pressure
When a pneumatic tool is operating near the surface, it is exhausting directly to atmosphere and is
producing the maximum horsepower for a given inlet pressure. If any positive pressure above atmospheric
pressure (back pressure) is encountered at the exhaust, the tool's efficiency will be reduced.
As the hole is drilled deeper, back pressure is constantly increasing, therefore blow energy will be
reduced.
To compensate for this reduced efficiency, it is necessary to increase air pressure at the inlet. Increase
the inlet pressure until normal drilling rate is obtained.
Rotation Speed
• Proper rotation speed is important for long bit life and good penetration.
• Refer to manufacturer's bit size vs. rotation speed specifications.
• Recommended Rotation Speed Range: 5–60 RPM
• Use slower rotation for hard abrasive formations.
• Use faster rotation for softer, less abrasive formations.
• The bit should penetrate about 3/8 in. (9.7 mm) per tool revolution (except for bits 10 in. (254 mm)
diameter and larger).
For example:
If the rate of penetration is 50 ft. (15.25 m) per hour, the RPM should be about 25. RPM is about
one-half of the penetration rate in feet per hour.
• Adjust the rotation to obtain the best drilling rate and to minimize wear on the bit.
Water or Foam Injection

During drilling operations, water or foam injection can be beneficial in some applications.
• Reduces dust damage to drilling equipment on the surface.
• Reduces dust inhalation of the drilling personnel.
• Reduces temperature of the compressed air, preventing close fitting parts from seizing or galling.
• Helps clean the drilled hole when the formation is producing small amounts water.
The following are helpful hints when using water or foam injection:
1. Increase the oil injection rate when water or foam is being used.
2. Test water periodically to assure the proper pH factor. Water with a pH of less than 10 will cause
corrosion on steel parts.
3. Insure that water being used is free from solids contamination.
4. Upon completion of each hole or any time tool is not being used for three or more hours, clean the
tool and the drill pipe by blowing lubricated air through the system.
5. Water or foam injection will cause the tool to corrode if the tool is not properly maintained. Follow
bit manufacturer's maintenance procedures to assure long bit life.

Drilling Procedures
Drilling with a Down-the-Hole Hammer (cont.)

Suggested Operating Procedures
1. Maintain good pulldown pressure on the tool and insure that the hole is being cleaned.
2. Small amounts of water may form mud and partially block the hole. Inject about 1-4 GPM (3.8 - 15
l/min) of water into the air stream during drilling (see manufacturer's specifications for tool size vs.
water injection rate).
If the tool starts drilling extremely fast, the pulldown system may not be capable of
maintaining the recommended weight required on the bit. The piston will strike the bit
when it is not against the rock face, causing severe damage to the bit. Every effort must
be made to avoid this condition.
3. If there is a drop off in the size and volume of cuttings or an air pressure build-up while the tool is
operating at a normal rate, raise the tool without turning off the rotation. Work the tool up and down
to assure that the tool and pipe are free and the hole is clean before continuing to drill.
4. Cracks in the formation may cause the tool to bind in the hole. Raise the tool, clear the hole with
air and work the tool up and down to assure the tool and pipe are free, before continuing to drill.
Rotate slowly and feed the tool down the hole slowly to resume drilling.
5. If the top of the hole craters and cuttings and debris fall into the hole, install a short length of casing
into the hole. Allow the casing to extend about 6 in. (152.4 mm) above the surface and pack rags,
clay or dirt around the outside of the casing.
6. When rotation stops, the tool will continue hammering until it is raised up off the bottom. If the tool
is not raised up off the bottom, the bit carbides will become buried in the formation. Severe damage
to the bit can occur if rotation is resumed without first raising the tool up off the rock surface.
7. Very rough rotation can be caused by a dull bit or in certain rock formations.
8. If tool fails to function properly, refer to manufacturer's service and troubleshooting information.

Multiple Pass Drilling
Adding Drill Pipe (refer to fig. 4-7)

1. Drill down until the rotary head stops at the bottom of the mast.
2. Disengage the pulldown system by switching Auto Feed Switch OFF. Stop rotation with Rotation
Lever (6).
3. Lift the drill string and align the flats on the drill pipe with the deck wrench. Turn Dust Suppression
Switch OFF, engage Deck Wrench with switch onto pipe, and turn Drilling Air Switch OFF.
4. Using reverse rotation, break the thread joint and undo the threads slowly, simultaneously raising
the rotary head clear of the bottom threads.
DO NOT allow drill pipe to drop in deep holes, pipe thread damage and bit damage will
occur.
5. Apply thread grease to the drill pipe threads by pressing Drill Stem Thread Lube Switch.
6. Raise the rotary head to the top of the mast with Hoist/Pulldown Lever (7).
7. Swing the drill pipe loader into position using the Pipe Loader Swing Switch. A drill pipe should
now be located under the rotary head. If not, you will need to rotate the loader to align the next
pipe.
To Rotate Drill Pipe Loader
a. Unlock the pipe loader by switching the Drill Pipe Loader Lock Switch to UNLOCK.
b. Index the pipe loader to the next position by using the Pipe Loader Rotate Switch. Once in
position, lock the loader by switching the Drill Pipe Loader Lock Switch to LOCK.
8. Lower the rotary head slowly onto the drill pipe, once the head engages the drill pipe thread, stop
lowering the head. Slowly engage forward rotation, keep rotating until the thread joint becomes
tight, which is indicated by an increase in rotation pressure as seen on the Rotation Pressure
Gauge (26).
ALWAYS tighten the drill pipe joints in the pipe loader.
9. Lift the drill pipe clear of the holder on the pipe loader and swing the loader out to the drilling posi-
tion using the Drill Pipe Loader Swing Switch.
10. Lower the drill pipe until it engages with the pipe in the deck wrench. Slowly rotate the drill pipe in
the forward direction until the joint becomes tight, which is indicated by an increase in rotation pres-
sure as seen on the Rotation Pressure Gauge.
11. Retract the deck wrench, using the Deck Wrench switch. You are now ready to resume drilling.

Multiple Pass Drilling
Retracting Drill Pipe (refer to fig. 4-7)

1. Once the desired hole depth is reached, turn the Auto Feed switch OFF and raise the rotary head
with the Hoist/Pulldown lever (7) until the drill pipe thread joint is above the deck wrench.
2. Turn the Water Injection/Dust Collector Switch and Drilling Air switch OFF.
3. Align the flats on the lower drill pipe with the deck wrench, the flats should be approximately 2
inches above the deck wrench. Engage the deck wrench on the flats of the drill pipe using Deck
Wrench switch.
4. Slowly place the Rotation lever (6) into reverse and allow the rotation pressure to increase until
the drill pipe joint breaks loose.
If the upper thread joint becomes loose before the lower joint, retighten the upper joint
and use the breakout wrench to loosen the lower joint.
DO NOT allow the upper drill pipe joint to unscrew unless positioned in the drill pipe
loader.
5. Once the pipe joint is broken loose, continue reverse rotation and simultaneously raise the rotary
head with the Hoist/Pulldown lever (7) until the threads are disengaged. Stop rotation.
6. Raise the drill pipe until the bottom of the drill pipe will clear the drill pipe holder when the loader is
swung into the center of the mast.
7. Align the flats on the drill pipe to the same position that would be required to engage the deck
wrench.
8. Swing the pipe loader into the center of the mast with the Drill Pipe Loader Swing switch, ensur-
ing that the drill pipe goes into the pipe loader easily. Do not force the drill pipe into the pipe loader.
9. Once the loader is in position, lower the drill pipe into the holder, stop the pipe approximately 2 in.
(50.8 mm) from the bottom of the holder.
10. Slowly place the Rotation lever (6) in reverse, allowing the rotation pressure to increase until the
top joint breaks, which can be identified by a decrease in rotation pressure. Once the joint breaks,
continue reverse rotation until the drill pipe drops into the holder.
NEVER use excessive force when breaking joints. Make sure loader locking pin is locked
before attempting to break joints. Make sure drill pipe is properly secured in loader.
11. Once the rotary head is disengaged from the drill pipe, raise the rotary head at least 8 in. so it will
clear the top of the drill pipe.
12. Swing pipe loader to the drilling position. Use Drill Pipe Loader Rotate switch to rotate carousel
to the next position if required.
13. Lower rotary head to the drill pipe in the deck wrench using the Hoist/Pulldown lever (7). Use
the Fast Down switch to increase the lowering speed of the rotary head. Use forward rotation to
engage and tighten to full rotation pressure to ensure joint will remain tight.
14. Repeat items 3-13 until all pipes have been removed.

Section 5
Drilling Practices
Drilling Practices 5-1

Drilling Terminology
A.P.I. Thread
American Petroleum Industry Standard type thread. Pulldown
The amount of weight that is being applied to the
Beco Thread bit.
A heavy duty thread type used on Blast Hole drill
pipe. Stabilizers
Stabilizers are used to reduce possible hole deflec-
Bit Basket tion.
Used to hold the drill bit when adding or removing
the bit. Substitutes (Subs)
Subs or adapters are used where different thread
Blade Bit sizes or types are required to be joined together.
A drill bit with three or four fixed cutting edges.
T.C.I.
Bootleg Tungsten Carbide Inserts, used on Tri-Cone roller
The portion of the borehole remaining after the blast. bits.
Carousel Thread Grease

The carousel or drill pipe loader is used to hold Thread Grease is used to lubricate the threads on
spare drill pipe in the mast for deeper drilling the pipe.
requirements.
Tri-Cone Roller Bit
Compressed Air A drill bit with three rolling cones, inserted with
Used to blow drilled cuttings from the hole and to tungsten carbide buttons or milled teeth.
cool the bit bearings.
U.H.V.
Down-The-Hole Hammer Up Hole Velocity, is the speed at which the drill cut-
A pneumatically operated bottom-hole percussion tings are being blown out of the hole,
drill that is rotated mechanically by the drill rig. this speed is usually referred to in feet per minute.
Drill Bit Water Injection

Drill bits are used to break the rock by a chipping or Used to help with dust suppression and aid hole
cutting action cleaning.
Drill Pipe
Drill pipe is used as a modem to rotate the drill bit,
transfer force to the drill bit and to pass air or water
to the bit to aid in hole cleaning.
Dust Collector
Used to control dust exiting the drill hole.
Nozzles
Orifices in the bit used to control air flow and pres-
sure.
Penetration Rate
The speed at which the drill bit is cutting.
5-2 Drilling Practices

Bit Weight & Rotary Speeds
Many variations in formation characteristics can affect the weight on bit and rotary speed requirements.
Your own field experience is the best guideline for determining the appropriate weight on bit and rotation
speed combination for your particular drilling operation. However, bit force and rotation speeds must be
kept within the safe and economic limits of the drill rig and drill string.
When calculating the pulldown force on the drill bit, you must include the weights of the rotary head
and drill string into your calculation, because when more drill pipes are added, the weight on the bit will
increase and in some cases it may be necessary to reduce the hydraulic pulldown force being supplied to
avoid blocking or damaging the drill bit.
Drill bit manufacturers suggest that a pulldown force of 3500-7000 pounds per inch of drill bit diameter
can be exerted to the drill bit in the right drilling conditions, however this is only a guideline and ground
conditions will dictate how much weight can be applied.
PULLDOWN FORCE CALCULATION
Bit Diameter = 7- 7/8"

7.875 x 3500 = 27,562.5 Pounds Force
7.875 x 7000 = 55,125 Pounds Force
The rotary blasthole drills utilize hydraulic pressure to exert pulldown force on the drill bit; this pres-
sure is indicated on the pulldown system pressure gauge. However, the pressure readings on this gauge
indicate hydraulic pressure only and must be converted into actual Weight on Bit (pounds force) per square
inch of drill bit diameter.
Check with your bit supplier for optimum drilling efficiency operation.
Laboratory experiments have shown that uniform rock formations, when drilled with rotary drill bits
react as follows:
1. Penetration rate is at least directly proportional to the weight on bit.

2. Penetration rate is directly proportional to the rotary speed.
In principal, the faster that we could rotate and the more weight we put on the drill bit, the higher the
rate of penetration. Although in actual drilling practices it is important to note that the many variations in
formation characteristics, drill bit condition and chip removal affect the rate of penetration, therefore state-
ments 1 and 2 must only serve as a guideline.
In soft, easily drilled formations, the use of high pulldown pressures are restricted due to the drill bit's
tendency to "Ball Up" thereby reducing its efficiency. However, it is usually possible to offset the reduction
in pulldown force by increasing the rotary speed. The danger of bit damage is reduced in low strength
formations.
The extent to which you can increase the rotary speed is limited by the presence of abrasive proper-
ties and the ability to clear the cuttings immediately from the bit face, which would prematurely erode the
cutting structure or bit bearings under excessive rotary speeds.

Bit Weight & Rotary Speeds
(cont.)
In hard formations, it is necessary to use higher pulldown pressures to overcome the compressive
strength of the rock formation. The operation of tri-cone roller bits in hard rock is complicated by the sliding
and skipping of the bit cutters as the rock breaks away unevenly. Failure to get complete clearing of the
drill cuttings becomes a larger problem when high rotation speeds are used.
The use of excessive rotation speeds can cause increased abrasive wear and create shock loads too
great for the drill bit, pipe and drill rig. Therefore, there may be little advantage in increasing rotary speeds
above recommended levels. Smooth vibration free drilling produces holes most efficiently and possible
gains from high rotation speeds may need to be sacrificed to get a constant rate of penetration and eco-
nomical bit life.

Rotary Drill Bits
The two main bit types available for rotary blast hole drilling are:
1. Drag or Blade Bits

2. Tri-Cone Roller Bits
Rotary drill bits operate using a combination of two forces:
1. Thrust "Weight on Bit"

2. Torque "Rotation"
Drill bits must make chips or cuttings and combined with air pressure and volume contribute to the
clearing of the drilled cuttings.
Drag Bits
Drag bits are used in soft formations like clay, shale, and soft overburden materials. These bits make
maximum use of rotary torque for chip making.
Drag bits generally have 3 or 4 cutting wings which are tipped with tungsten carbide inserts to resist
heat during drilling.
Advantages of Drag Bits
1. Relatively low in cost compared to tri-cone roller bits.

2. High penetration rates in soft formations.
3. Good penetration of difficult formations such as clay.
Disadvantages of Drag Bits
1. Shorter service life than tri-cone bits.

2. Not good for drilling hard formations.
3. Unstabilized drag bits are prone to drill crooked holes.

Rotary Drill Bits
Tri-Cone Roller Bits

Tri-Cone roller bits are made for four general types of drilling conditions, these are soft, medium, hard
and very hard ground formations.
Roller bits consist of a bit body with three cones equipped with steel teeth or tungsten carbide buttons.
The teeth or buttons are distributed over the three roller cones in such a manner that the entire bottom of
the hole is worked when the bit is rotated.
General characteristics for soft formation bits are that the bits have larger, more widely spaced teeth
or buttons and differing cone centering geometry, while hard formation bits have smaller tungsten carbide
inserts for cutting teeth which are closely spaced to reduce torque and the size of the chips in hard material.
The cones of the drill bit are mounted on bearings which are designed to withstand the thrust and
rotation forces exerted on the bit. The gauge or size for the bit is protected by hard facing or tungsten
compacts on the outer surface of the cones and the shirt tails of the bit body.
Tri-cone bits are fitted with air tubes and nozzles which allow air to pass through the bit. The air tubes
are designed to allow air to pass through the bit. The air tubes are designed to allow air to flow through to
the bit bearings, the air then aids in cooling and cleaning the bearings.
The bit nozzles allow the main volume of air to flow through the bit for cleaning the cuttings from the hole.
These nozzles are designed so that different sized orifices can be installed for different drilling conditions.
To make sure air gets down to the bearing air tubes, ensure a certain amount of working air pressure
at the bit face. Change this pressure by changing the size of the nozzles, which might be needed if the
drilling conditions get softer. The orifice size would probably need to be increased to allow more air to pass
through the bit for better hole cleaning.
Advantages of Tungsten Carbide, Tri-Cone Roller Bits
1. Four to Ten times more footage per bit than conventional hard formation steel tooth bits.
2. The penetration rate will usually equal or exceed that of conventional hard formation bits.
3. Higher feed pressures can be used in hard formations.
4. Bits can be used in both soft and hard formations.
Disadvantages of Tungsten Carbide, Tri-Cone Roller Bits
1. More expensive than conventional bits.

2. Generally not good for drilling clay formations.

Rotary Drill Bits
Tri-Cone Roller Bits (cont.)

Tungsten carbide bits may cost more than steel tooth bits and economics must be considered when
choosing the correct bits for each application and should enter into your decision when to use them.
All tungsten carbide bit designs incorporated the use of compacts in the gauge surface or the cones,
and varying combinations of compacts and hard facing on the gauge surface of the bit leg to provide in-
creased resistance to abrasive wear.
When the formation is relatively uniform, these bits characteristically drill at a constant penetration
rate throughout their life.
Sufficient weight must be applied to the bit to produce an effective chipping-crushing action of the for-
mation. However, you should be aware that weights in excess of "sufficient" are not necessarily economical,
as they may result in breakage of the compacts as well as reducing the life of the bearings.
Normally the weights used on tri-cone roller bits range from 3,500 to 7,000 pounds per inch of bit
diameter with rotary speeds varying up to 200 revolutions per minute.

Rotary Blast Hole Drill Strings
Drill Pipe
Drill pipe is used as a modem to transfer rotation to the drill bit and to convey air to clean the cuttings
from the hole.
Blast hole drill pipe is selected to suit the diameter of the hole being drilled, the pulldown and hoisting
capacity of the machine, and up-hole velocity requirements to clean the hole.
Standard drill pipe is designed to be run in tension. Drill pipe run in tension is held relatively straight,
bending and wear are therefore kept to a minimum. However, Blast Hole rigs apply pressure to the bit
through the pull-down system on the machine.
Since blast hole pipe is run in compression it must be made from heavy wall tubing to resist forces
which not only may be high, but are also changing rapidly. The pipe must continue to do this in spite of
abrasive wear and continual bending stresses. Drilling operations often place great stresses on the drill
string, therefore the drill pipe must be manufactured to the highest degree to achieve the ultimate service life.
Periodic inspections should be made of the condition of your drill pipe and should include the follow-
ing items:
1. Outside diameter measurement of pipe.

2. Check welded joints for cracks or excess wear.
3. Check threads for excessive wear or galling.
4. Check pipe for bends or eccentric joints.
Fabricated Drill Pipe

Blast hole drill pipe design features tool joints made from steels selected specifically for the application
and heat treated to obtain optimum strength and toughness.
The tool joints are designed with long tangs that are internally tapered, which enables them to be
forced or shrink fitted to the tubing and then welded. Wrench slots or flats are milled to suit the break-out
requirements of the drill.

Pipe Threads
There are many different types of threads available for drill pipe connections most of which are not
acceptable for blast hole drilling because of their vulnerability to damage from excessive forces to the drill
string in blast hole drilling.
The two most commonly used threads are:
1. A.P.I. Regular (American Petroleum Industry Standard)

2. BECO style thread
With the increase in demand for efficient, economical blast hole drilling, it was observed that several
factors caused greater thread wear on blast hole drills.
1. The drilling of multiple pass holes demands frequent pipe changes. This increased frequency
greatly contributes to thread wear.
2. The coupling of the rotary head to a drill pipe in the pipe loader often occurs at an elevation high in
the mast, affording very poor visibility to the operator. This operation is often done by feel and cross
threading is not an uncommon result.
3. Thread loading during joint make-up should be instrument controlled. The rotary head used on
blast hole drills can generate very high torque and the skills of the operator usually determines the
actual magnitude of the axial forces used. A careless operator can destroy the threads if care is not
exercised.
4. All drill pipe that operates in compression has the tendency to bend and rub on the walls of the
hole. These bending forces also act on the threads which increases the possibility of cracks,
breaks and tool joint failures.
A.P.I. Regular Threads

Field experiences have shown that the normal A.P.I. Regular threads have displayed less than satisfac-
tory life under the above conditions. The majority of drill bits are provided with A.P.I. Regular pins, but since
bit changes are less frequent than pipe changes, thread wear is less, making the A.P.I. Regular threads
acceptable for bit connections.
BECO Threads
The primary feature of the BECO thread series is that 2 threads per inch pitch is utilized. This coarser
thread survives much better under adverse conditions. The coarse threads are stronger, less susceptible
to damage, more tolerant of wear and easier to loosen from a tight condition. Since the incorporation of
the BECO thread system in the early 1960's, the thread has become an unofficial world wide standard for
drill pipe used in rotary blast hole drilling operations.

1
2 API Box Thread
API Thread
BECO Thread
3
Sub Length Measured
Shoulder to Shoulder
4
5
1. Rotary Head
2. Spindle
3. Shock Sub
Pipe Length Measured 4. Crossover Sub
Shoulder to Shoulder 5. Top Sub
6 6. Drill Pipe (Rod)
7. Bit Sub
8. Bit Basket
9. Deck Bushing
10. Tri-Cone Drill Bit
Bit Sub Length Measured

Shoulder to Shoulder 7
8
9
10
Basic Drill–Basic Design Features and Make-up

Thread Grease
Precision machined threads and shoulders must be protected from damage. Threads are subjected
to a lot of abuse, therefore it is imperative that they are inspected and greased regularly. Prior to each use,
clean and visually inspect each pin and box for thread and shoulder damage. Check carefully for galls,
burrs, scratches and particularly for cracks. Clean or repair if necessary. Use a zinc, lead or copper based
lubricant that is recommended for rotary connections and apply thoroughly to all thread and shoulder sur-
faces. Ensure grease is clean and free of dust and debris.
Substitutes
Substitutes (subs) or adapters are used where threads of one size or type must be coupled with threads
of another size or type. They are also used at points of heat wear to provide readily replaceable threads.
Changes in drill pipe diameter must occur gradually. Subs should be gently tapered.
Drill Bit Stabilizers

Drill bit stabilizers are used to reduce possible hole deflection and to ensure that the drill bit runs con-
centrically (evenly in the center of the hole) about its axis and thereby optimizes bit life and penetration rates.
There are two main types of stabilizers available, blade and roller. Blade stabilizers have fixed wings
that have been either hard faced or mounted with tungsten carbide inserts. Roller stabilizers are mounted
with replaceable rollers which are built up with a special tungsten carbide weld and held in place by long
lasting non grease bearings.
Advantages of Blade Type Stabilizers

1. Generally cheaper.
2. May use replaceable wear bars for rapid rebuilding.
3. Can use replaceable sleeves.
Disadvantages of Blade Type Stabilizers

1. Require rebuilding for each new drill bit.
2. Have relatively high torque requirements.
3. In hard ground they may provide little stabilization after the first couple of holes.
Advantages of Roller Type Stabilizers

1. Lower torque requirements than blades.
2. Better stabilization.
3. Generally give more economical life.
4. Throw away or replaceable rollers.
Disadvantages of Roller Type Stabilizers

1. High purchase cost.
2. Expensive replacement of parts

Compressed Air
Compressed air is the most common method used with blast hole drills for clearing chips from the
hole. The advantages of drilling blast holes with compressed air are fast chip removal, and that holes are
normally left dry.
In some circumstances a controlled amount of water or foam can be injected into the air stream to aid
chip removal, enhance hole stability and control dust problems.
Chips not cleared immediately will be broken into smaller pieces. Secondary breaking wastes energy
and increases bit wear.
Air Requirements
In rotary blast hole drilling we must always be concerned with delivery of air in sufficient volume and
at the proper pressure to assure optimum bit life when drilling with recommended bit weight and RPM.
Sufficient air volume should be provided to produce an up-hole velocity of 4,000 to 6,000 feet per minute
( 1220 to 1830 meters per minute).
Up-Hole Velocity Calculations

Cubic Feet Per Minute:
Velocity = Free Air CFM x 183.4

(D - d2) .7854 in inches
2
D = Bit Diameter d = Drill Pipe Diameter

Drilling Related Problems
The majority of drilling problems originate from errors in judgement or simply from making a bad deci-
sion. Drilling problems generally offer several courses or action to overcome the drilling problem, therefore
we must make a decision to try another method of operation to rectify the problem. Drilling decisions often
avert or accelerate the complex drilling difficulties which we refer to as drilling problems.
EXAMPLE:
a. A decision may be made a long time before the problem is evident, like deciding to use inadequate
up hole air velocity. This may lead to slow, inefficient drilling or stuck drill strings.
b. Or the decision can bring immediate problems, like a decision to increase the pulldown pressure
may result in premature failure of the drill bit.
During drilling operations every action taken may have consequences. Operators must recognize that
their job involves a continuous sequence of making decisions and the quality of these decisions determines
the quality of the operator's performance.
Drilling consists of a continuing sequence of:

1. Being aware
2. Interpreting indicators or messages
3. Making decisions
4. Monitoring results
Many drilling problems are revealed to the operator by an indicator. This indicator can take almost any
form (e.g.: a reduction in the volume of drill cuttings being cleared from the hole). This may not be a problem
in itself, but it could be an indicator of a problem developing down the hole, therefore if the operator knows
the indicators, they are then made aware of the pending problem.
Human Error Problems

These problems have a direct and usually short term connection with a decision (e.g.: The operator
decides to try and drill one more hole with a badly worn bit before changing the bit).
Operational Related Problems

These problems are connected with the failure of the drilling equipment (e.g.: Engine fails while drill
string is in the hole, possibly leading to the drill string becoming stuck while engine is repaired).
Formation Related Problems

Some formations present problems that are not readily solved using the available drilling equipment
or skills (e.g.: Swelling ground formations due to high levels of ground water). These situations should be
viewed as a challenge rather than a problem.

Operating Problems and Indicators
1. Drill Bit Penetration Slows or Stops

This is a statement of an indicator rather than a problem. The solution depends on the correct diag-
nosis of the problem, which could be:
a. Formation Change
b. Drill Bit Blocked Up
c. Incorrect Bit Type
d. Dull Drill Bit
e. Incorrect Pulldown Pressure or Rotary Speed
f. Inadequate Hole Cleaning
2. High Drill String Torque

Excessive drill string torque is also an indicator of a pending problem, some of which might be:
a. Excessive Pulldown Pressure
b. Inadequate Hole Cleaning
c. Crooked Hole
d. Damaged or Badly Worn Drill Bit
3. Drill String Vibration

This itself often seems like a problem, but the true problem usually lies in the reason for the vibra-
tion, some of which are:
a. Incorrect Rotary Speed
b. Bent Drill Pipe
c. Eccentric Drill Pipe Joints
d. Incorrect Drill Pipe to Hole Size
e. Crooked Hole
f. Worn Deck Bushing or Stabilizer
4. Stuck Drill Pipe

a. Inadequate Hole Cleaning
b. Crooked Hole
c. Faulty Formations

Solving Drilling Problems
1. Recognize the problem. The operator must be aware of the small problems before they develop
into bigger ones.
2. Analyze the problem. Determine exactly what the problem is, what caused it and what is involved
to rectify the problem.
3. Compare the current problem with others previously encountered to assist in finding the most likely
solution. Decide on a solution.
Experienced operators make decisions almost automatically, they are immediately aware of the sig-
nificance of an indicator. They react spontaneously because their experience tells them the appropriate
action to take. By correctly selecting the desirable action in each situation, an operator will:
1. Maximize the quality of the products of drilling

2. Maximize drilling production

Notes

Section 6
Machine Transport
Machine Transport 6-1

Machine Specifications–Shipping
MD6290 Basic Shipping Weights and Dimensions

Quantity Description of Goods Approximate Dimensions
Truck one (1) MD6290 Rotary Blasthole drill c/w 1 each Owner/Operator manual 10.82 m (35 ft 5 in) L x
and warranty packet stowed within cab 4.06 m (13 ft 3 in) W x
3.96 m (13 ft) H
41,050 kg (90,500 lb)
Truck two (2) Mast assembly for MD6290 Rotary Blasthole drill 14.81 m (48 ft 7 in) L x
(mast for 35 ft pipe) 1.91 m (6 ft 3 in) W x
1.91 m (6 ft 3 in) H
14,514.96 kg (32,000 lb)
Truck two (1) Cab half for MD6290 Rotary Blasthole drill c/w 1 ea. Ship out filter kit, 2.286 m (7 ft 5 in) L x
2 ea. tubes superflex, 2 ea. brackets, 1 ea. bag of nuts & bolts, 2 ea. mast 0.81 m (2 ft 8 in) W x
bushings, 1 ea. horseshoe bushing, 1 ea. bit basket & 1 ea. lifting bale 2.51 m (8 ft 3 in) H
635 kg (1,400 lb)
Truck two (2) Walkway for MD6290 Rotary Blasthole drill c/w toolbox stowed within 2.74 m (9 ft) L x
0.86 m (2 ft 9 in) W x
1.30 m (4 ft 3 in) H
589.7 kg (1,300 lb)
Note: final dimensions and GVW and corresponding load-out vary based on options selected and final configuration.
MD6240 Basic Shipping Weights and Dimensions

Truck one (1) (12 m), Rotary Blasthole drill c/w Owner/Operator’s manual stowed in cab 10.82 m (35 ft 6 in) L x
4.0 m (13 ft 2 in) W x
3.9 m (12 ft 7 in) H
44,678.5 kg (98,500 lb)
Truck two (2) Mast assembly for (12 m), Rotary Blasthole drill 17.7 m (58 ft) L x
1.9 m (6 ft 4 in) W x
1.8 m (6 ft 2 in) H
16,329.3 kg (36,000 lb)
Truck three (3) Cab half assembly for (12 m), Rotary Blasthole drill c/w 1ea. #89044 filter kit, 2.29 m (7 ft 6 in) L x
2 ea. Superflex, 2 ea. brackets, 2 ea. mast bushings, 2 ea. dust chute c/w curtain, 0.81 m (32 in) W x
2 ea. clamps, 1 ea. horseshoe bushing, 1 ea. bit basket, 1 ea. lifting bale, 2 ea. portable 2.51 m (8 ft 2 in) H
fire suppression w/brackets, 3 ea. bag of nuts, bolts, 6 ea. handrails, 1 ea. table bushing 635 kg (1,400 lb)
and cab supports
Truck three (3) 2 each walkways bundled together with 2 each ladders, toolbox, c/w with accessories 5.1 m (16 ft 7 in) L x
stowed within, bit sub, dust chute hose and 2 each chutes for hose for (12 m) 0.9 m (3 ft 2 in) W x
1.5 m (5 ft) H
2,948.3 kg (6,500 lb)
Truck three (3) Mast support rack (mounted off front end) for (12 m) 2.9 m (9 ft 6 in) L x
2.2 m (7 ft 2 in) W x
0.4 m (15 in) H
548.8 kg (1,210 lb)
Truck three (3) 1 each walkway 2.87 m (9 ft 4 in) L x
0.61 m (2 ft) W x
1.20 m (4 ft 3 in) H
544.81 kg (1,200 lb)
Note: Final dimensions and GVW and corresponding load-out vary based on options selected and final configuration.
6-2 Machine Transport

Transporting Machine
Mast Removal and Installation

Generally, when transporting the machine, it will be necessary to remove the mast and ship it on a
separate truck, due to weight and height restrictions. Follow the steps outlined below for removal and in-
stallation of the mast.
BE SURE machine is on level and solid ground before performing any service proce-
dures.
BE SURE hydraulic and pneumatic systems are not pressurized before removing any fit-
tings or connections.
Mast Removal:
1. Remove drill pipe from mast (refer to "loading and unloading drill pipe" in Section 3) and swing
carousel all the way in.
2. Lower mast to horizontal position, so that mast is resting on mast support.
3. Shut down the machine and be sure pressure has been relieved before removing any connections
or fittings. Tag and remove all hydraulic, pneumatic and grease lines to the mast. Use numbered or
lettered caps and plugs to aid in reassembly. Disconnect electrical plug from mast valve bank.
NOTE If using one crane for lifting the mast, the lifting slings should be positioned at about a
45o angle from the mast.
4. Attach four steel cable lifting slings to the mast at the lifting points. Two are located at the mast
crown and two are located at the mast base. Use a crane capable of supporting the weight of the
mast and able to lift the mast high enough to clear the height of the machine (refer to machine
specifications). Attach two guide ropes to mast to control swinging of mast.
5. Remove the two capscrews that secure the mast pivot lug cap and remove cap from each side of
mast (fig. 6-1).
6. Support the mast cylinders to prevent movement after the cylinder pins are removed. Raise the
mast slightly to take weight off the mast cylinder pins and remove the cotter pins and cylinder pins
from mast.
Keep all personnel clear of mast when lifting. Do not allow anyone under mast when lift-
ing.
7. Lift mast clear of machine and tram machine out from under mast. Position trailer under mast and
lower mast onto trailer and secure for transport (refer to loading and unloading procedures).
8. Using a suitable lifting device lean the mast cylinders forward and secure to the "A" Frame if the
machine is being transported.

Fig. 6-1 Mast Assembly (lower end)

1. Pivot Lug (2)
2. Capscrew (4), Torque per Note below
Mast Installation
Keep all personnel clear of mast when lifting. Do not allow anyone under mast
when lifting.
1. Attach four steel cable lifting slings to the mast at the lifting points. Two are located at the mast
crown and two are located at the mast base . Use a crane capable of supporting the weight of the
mast and able to lift the mast high enough to clear the height of the machine (refer to machine
specifications on previous pages). Attach two guide ropes to mast to control swinging of mast.
2. Be sure area of mast installation is level and ground is solid. Apply a coat of grease to the mast
pivot bushings. Position machine under mast and carefully lower mast, aligning the mast pivot lugs
with the pivot bushings on the "A" Frame. Mast should be resting on the pivot bushings and the
mast rest at the front of the machine.
3. Position the mast lift cylinders to line up with the holes in the mast. The mast may have to be lifted
slightly to align the holes. Install pins, washers and cotter pins.
4. Install the pivot lug caps with capscrews and washers and torque per note below.
5. Connect all hoses, by matching the numbered or lettered caps and plugs. Be sure all grease lines
are installed (if used). Connect electrical connection to mast valve bank. Be sure all connections
are tight. Start machine and check for any leaks.
Mast Pivot Bolt Torque
NOTE MD6290 – Dry = 1820 Ft. Lbs. (2468 Nm)

Lube = 1360 Ft. Lbs. (1844 Nm)
MD6240 – Dry = 3160 Ft. Lbs. (4284 Nm)

Lube = 2360 Ft. Lbs. (3200 Nm)

Loading and Unloading of Machine
Fig. 6-2 Machine ready for transport

1. Tiedown points (4 per side)
Loading Machine
This machine is to be operated only by trained personnel, or a copy of the Operator
Manual must be provided to personnel involved with loading and unloading of ma-
chine. Operator must read and understand the safety, start-up, shutdown and operation
sections of the manual.
1. Raise dust curtains and secure with rope to prevent interference with trailer wheels (fig. 6-3).
2. Place any loose items into tool box, such as brass bushings from mast pivot, bit sub, etc.
3. Place mast raise cylinders against mast "A" frame and secure with rope to keep them from moving.
4. Remove walkway from cab. Support walkway with forklift or overhead lifting device and remove the
four bolts that secure walkway to frame. Load walkway onto trailer with mast. Install the four bolts
back on the frame, so they do not get lost.
5. Cross tape all windows with duct tape.
6. Be sure jacks are raised all the way up and secure jack pads with chain and nut (provided on each
pad). Tram machine onto trailer in reverse for greater visibility.
7. If lifting machine onto trailer or ship, use the lifting lugs welded to the jack housings. If unit is not
equipped with lifting lugs, contact the manufacturer for lifting information for your machine.
8. Tape exhaust(s) closed, clip all chains on handrail openings, check to see that all doors are closed
tight and ignition is turned off. If unit is equipped with a battery disconnect switch, this should be turned
off.
9. Machine should be secured to trailer at four places on each side (fig. 6-2). Secure frame to trailer at
front and rear and secure track to trailer at front and rear.

Fig. 6-3 Dust Curtain - tied up
Unloading Machine
This machine is to be operated only by trained personnel, or a copy of the Operator

Manual must be provided to personnel involved with loading and unloading of machine.
Operator must read and understand the safety, start-up, shutdown and operation sec-
tions of the manual.
1. Inspect machine for damage before unloading.

2. Remove tape from exhaust(s) and switch battery disconnect switch on (if so equipped).
3. With all tie-downs removed, propel machine off trailer and position on solid level ground.
4. Install cab walkway and mast (refer to mast installation on previous page).
5. Complete checklist on "Commissioning a New Machine" in Section 4 of this manual or complete
the "Pre-Start" checklist also in Section 4 of this manual.

Loading and Unloading of Mast
Fig. 6-4 Mast ready for transport

1. Tiedown points - mast crown lifting lug, middle and mast base lifting lug
Loading Mast
Keep all personnel clear of mast when lifting. Do not allow anyone under mast
when lifting.
1. Attach four (4) steel cable lifting slings to the mast at the lifting points. Two are located at the mast
crown and two are located at the mast base. Use a crane capable of supporting the weight of the mast
and able to lift the mast high enough to clear the height of the machine (refer to machine specifica-
tions on previous pages). Attach two guide ropes to mast to control swinging of mast.
2. Load mast on trailer with mast crown (top) at rear of trailer. Secure mast to trailer using the lifting lugs
(two at mast crown and two at mast base) as tiedown points. Secure mast to trailer at midpoint also.
Unloading Mast
1. For unloading of mast, refer to "Mast Installation" on page 4 of this section.
Fig. 6-5 Mast Tie Down Detail

Notes

Section 7
Options and Accessories
Options and Accessories 7-1

Description
For machines operating in arctic type conditions an optional cold weather package can be installed to
pre-heat fluids and lubricants. With the cold weather option, the machine can operate down to temperatures
of -40oF (-40oC).
The cold weather option includes the appropriate lubricants (listed in this section) in the compressor,
engine, hydraulic system and gearboxes.
An optional diesel fired heater/pump unit, using fuel from the machine's diesel tank, circulates a wa-
ter/anti-freeze mixture through heat exchanger tubes located in the hydraulic tank, fuel tank, water tank,
radiator and engine block ( see fig. 7-5).
The heating system can also be powered by a generator (GenSet) mounted on the machine, or an ex-
ternal power source, to provide 120 or 240 VAC to the system to thermostatically control heating elements
and silicone heating pads (see fig. 7-6). A heater/controller (fig. 7-2) supplies power to a distribution breaker
box and pumps heated water/anti-freeze through the engine block.
The heating elements for this type of system are installed in the hydraulic tank, fuel tank and engine while
the heating pads are installed in the compressor control box, receiver tank, auto lube grease container and
under the batteries in the battery tray.
Additional measures included for extreme cold protection are:
• Thermo-glass cab windows

• Additional heater in cab
• Spray-on insulating material under the cab, water and fuel tanks
• Cold weather wiring for AC/DC systems including low temperature conduit
• Ether injection for engine starting, if desired (cat engines only)
There are no additional fluid additives required for cold weather operation.
NOTE When cold weather operation is specified, the options discussed above may be used
separately or in combination to suit a specific operating environment.
Heater/Pump Unit
The heater/pump unit heats and circulates water

and anti-freeze through the engine, radiator, hydrau-
lic tank and fuel tank. Fig. 7-1 shows a typical instal-
lation. A 24VDC motor operates the water pump.
Diesel fuel is used to fuel the heating system.
Fig. 7-1 Heater/Pump Installation

1. Heater/Pump Unit
2. Manifold
7-2 Options and Accessories
Relieve pressure on hydraulic and pneumatic systems before loosening connections or

parts.
Operation
The pre-heat system is energized prior to starting the machine in temperatures less than 32oF. (0oC)
by a switch located on the front of the operator console. Warm up periods are in relation to outside tem-
peratures, but normally sufficient warm up can be accomplished in approximately one hour prior to starting
machine.
If the machine is supplied by a GenSet, the GenSet is switched on to provide power for preheating. After
the GenSet warms up to operating temperature, the heater/controller is switched on and the Operator can
then select which system is to be energized via the distribution breaker box (see fig. 7-6).
If the heater/controller is supplied power from an external source, the Operator plugs in the system and
then switches on the heater/controller.
ON/OFF Switch
Pump Heater
Fig. 7-3 Heat Exchanger

Element in Hydraulic Tank
Fig. 7-2 Heater/Controller Installation
Fig. 7-4 Heating Pad on Auto

Lube Grease Container

Maintenance
BE SURE there are no fuel leaks near the burner unit.
DISCONNECT BATTERY or unplug cable to heater controller before doing any welding
on machine. Damage to controller unit will result.
Allow time for burner unit to cool before doing any repair work.
Heater/Pump Unit–Maintenance and Repair
Refer to the Espar repair manual for the Hydronic 30 compact heater in Section 10 of the Service Manual.
Order repair parts from Parts Manual for your specific machine.
Cooling System Freeze Protection
In the late fall, before temperatures drop below 32oF. (0oC), the complete cooling system should be
drained and flushed. The thermostat should be removed during flushing. Check for proper operation or
replace before reinstalling. When refilling, add a sufficient amount of anti-freeze for your climate. A 50/50
mixture is recommended for maximum protection
Water Injection System Freeze Protection
To blow water out of the lines and pump before shutting machine down, the following steps need to be
done with the machine in idle mode.
1. Turn the optional handle on the cab side crawler frame to open ball valve to drain water tank. After
water tank is drained, leave ball valve on bottom of water tank open until time to add water to tank,
then close valve.
2. After water tank is drained, open shut off valve on top of air receiver to release air into water
system. With the water injection switch in the cab in OFF position, this will blow water through the
pump and back to the tank. After 5 seconds, switch the water injection switch to ON. This will blow
water into the main air line.
3. Turn main air ON to blow water out of standpipe and drill pipe. Let run for about 15 seconds. At this
time all water is out of lines and pump.
4. Shut machine down. While the machine's air receiver is in blowdown mode, leave shut off valve on
top of air receiver open to blow into water injection system.
5. After air receiver has blown down, close shut off valve on top of air receiver to close line.
6. Before starting machine, prime the water pump by pouring water into the pipe nipple on suction
side of pump inlet.
Receiver Tank
Drain water from the receiver tank daily or whenever the machine is shut down for more than one
hour.
NOTE BE SURE to evacuate all the remaining water from the water injection pump to pre-
vent the pump from freezing.
ENGINE
A B
RETURN
SUPPLY

3/4" HOSE
3/4" HOSE
A B
REAR VIEW SIDE VIEW
3/4" HOSE
1" HOSE
1" HOSE
FUEL TANK
Using Diesel Fired Heater

1" HOSE SUPPLY
1" HOSE
RETURN
Fig. 7-5 Cold Weather Plumbing

1" HOSE
1" HOSE
WATER TANK 3/4" HOSE

1 1/2" HOSE
1 1/2" HOSE
1 1/2" HOSE
1 1/2" HOSE
1" HOSE
1" HOSE
1 1/2" HOSE
1" HOSE
SUPPLY
RETURN
1" HOSE
FUEL SUPPLY HOSE

(5 MM. I.D.)
1" HOSE SUPPLIED WITH HEATER
(403352)
HYD RESERVOIR
SUPPLY
RETURN
FUEL FILTER
7-5
7-6
ISOLATION SAFETY SWITCH ENGINE COOLANT FORCED CIRCULATION HEATER 9KW
ON BOARD GENERATOR SET
BUS BAR
V6
LOAD LINE 8 L3 10GA
MAIN BREAKER U U
U1
4GA NO BUS BAR
L1 10GA CONTACTOR
100 AMP V1 V5
2GA CUSTOMER SUPPLIED EXTERNAL POWER MAGNETIC
V 6 ON
V
100 AMP W6 W2 SOURCE 380V Y3ø/220V 1ø} 10GA GND OFF
4GA
100 AMP W 7
2GA
W
U6 W5
U5
4GA 380V
N N V2
W1 U2 TCR
TRANSFORMER GENERATOR HEATING
50KVA * ELEMENT
THERMISTOR 9KW
N/C
200 AMP RECEPTACLE AND 220V C1
X1
3 PLUG 380V 380V
120V H1
SECONDARY 100 AMP HI LIMIT
THERMOSTAT
H2
X2 100 AMP P
AUXILIARY POWER SUPPLY 220VAC
X3 COOLANT
H3 1ø}
120V EARTH NEUTRAL PUMP 10GPM
SECONDARY H4
6
CUSTOMER SUPPLIED
50 AMP
X4 CIRCUIT PROJECTION
12GA
GFI
FUEL TANK HEATERS 12GA
2@2KW
TEMP TEMP
25 AMP
CONTROL CONTROL
12GA HEATING
GFI HEATING
GND GND ELEMENT
ELEMENT
2KW
2KW
15 AMP BATTERY HEATERS

4@75W
12GA
GFI 12GA
TEMP
CONTROL
50 AMP
HEATER HEATER HEATER HEATER

WATER TANK HEATER
9KW 75W 75W 75W 75W
GFI
10GA GND GND GND
10GA
12GA
25 AMP
120/240 VAC System

TEMP
CONTROL
ENGINE OIL HEATER
GFI 12GA
(PAN) 500W
TEMP
HEATING CONTROL
10GA ELEMENT GND
GND 9KW
HEATER
15 AMP
12GA
12GA
THREAD AUTO LUBE GREASE
COMPRESSOR CONTROL BOX HEATER
50 AMP GREASE
SUCTION MANIFOLD OR HYD TANK COMPRESSOR RECEIVER TANK HEATERS 338W DRUM HEATER
WATER TANK HEATER 2@1.35KW DRUM 750W HYD. TANK HEATERS 2@2KW
HEATER HEATER
9KW 2KW 12GA 650W 12GA
GFI
Fig. 7-6 Heater Control Schematic Using

12GA ADJ FIXED TEMP
10GA 12GA 12GA TEMP CONTR0L 12GA
CONTROL 60F
10GA 25F-330F
12GA 12GA
15 AMP
10GA TEMP TEMP
CONTROL CONTROL
TEMP TEMP
CONTROL CONTROL 12GA 12GA
GFI 12GA 650W 750W

HEATING 12GA
GND HEATING HEATING
ELEMENT GND GND
ELEMENT ELEMENT
HEATING 12GA HEATING 12GA HEATING .338KW 2KW 2KW
GND GND HEATING GND
ELEMENT ELEMENT ELEMENT ELEMENT
15 AMP 9KW 2KW 1.35KW 1.35KW
NOTE:
HEATER NEUTRAL WIRE
NOT CONNECTED
NOTE: 120 VOLTS

APPLIED TO STANDARD
240 VOLT HEATER
DISTRIBUTION BREAKER
BOX

Kim Hotstart
CSS
Coolant Small System
Installation & Operation Manual
216211-000 rev-2

Notes

Kim Hotstart
The Kim Hotstart System
System Overview
Shown on the next page is the basic layout of the CSS Heating System. This circulating
heating system consists of a coolant heating chamber, heating element, adjustable
thermostatic control, a centrifugal pump, a control box with electro-mechanical controls
and a mounting plate.
Basic System Operation

Upon energizing the system, engine coolant which is taken from the coolant drain area in
the lower section of the engine is circulated via a centrifugal pump, pulled through the
heating chamber and back to a location on the engine furthest from the coolant suction
line. The pump stays on and continues this circulation process even when the heating
elements are off to provide an accurate, uniform heat to the engine. In the element
enclosure is a thermister. This device senses the temperature of the engine coolant and
sends a signal to a solid-state temperature controller in the control box that turns the
element on and off as needed.
The front panel on/off switch or a 24 VDC input for automatic operation can control
system operation manually.

Kim Hotstart

Kim Hotstart
Coolant return line to rear of engine.
Engine
Optional Shut-Off Valve
Optional Check Valve
Coolant
Inlet
Coolant
Outlet
CSS System
engcool.eps

Kim Hotstart
Coolant Requirements
Upon an initial coolant fill and each subsequent replacement, check the quality of the source
water. Proper coolant management procedures can eliminate engine and heating system
problems. Use these guidelines:
Basic Water Quality

Chlorides 50 PPM Max
Sulfates 50 PPM Max
Total Hardness 100 PPM Max
Total Solids 250 PPM Max
pH 7,5 to 10.5
To achieve the level of quality required, it may be necessary to use distilled water (not
deionized). Distilled water is corrosive without proper inhibitors. Kim Hotstart Manufacturing
also recommends use of a well-inhibited ethylene glycol cooling solution at 30% to 60% ratio.
Glycol based inhibitors provide superior corrosion protection, inhibition, a lower freeze point
and an increased boiling point.
For heavy duty engines, use a low silicate coolant formula inhibitor composition with a silicate
level of no more than 230 PPM. This coolant fill is supplemented with an inhibitor additive
package to provide specific inhibition for wet sleeve cylinder liners, cavitation, pitting and
erosion.
NOTE: The use of glycol still requires non-corrosive water, periodic re-
inhibition and inhibitor monitoring.
Kim Hotstart Manufacturing recommends use of "Fleetguard DCA4" (or equivalent), a high
quality inhibitor package that provides excellent steel, aluminum, copper and other cooling
system metals protection for the pre-heating system and engine. DCA4 formula consists of a
balanced combination of phosphate, molybdate and nitrite inhibitor, and is packaged in units for
easy calculation of coolant amounts.

Kim Hotstart
System Start-Up
After system installation has been completed, follow these steps for proper Coolant Heating
System start-up.
Coolant Heating System Start-Up
CAUTION: DO NOT START THE PUMP BEFORE FILLING THE SYSTEM WITH
COOLANT AND NEVER OPERATE THE PUMP DRY.
Step 1 Check and tighten all electrical and plumbing connections.
Step 2 Ensure isolation valves are open before starting system.
Step 3 Once the heating system is installed and the engine is filled, run the engine for
a short period before energizing the heater. This will purge any air from the
pump and heating tank. Loosen outlet flange at pump to bleed air.
Step 4 The thermostat is set at 65° from the factory for initial start-up. Energize the
coolant heating system by turning the coolant switch on the control box to the
ON position. After flow is verified through the tank and any trapped air is
expelled, adjust thermostat to the desired temperature.
NOTE: On initial startup, it may take several attempts to achieve proper flow.

Kim Hotstart
24 VDC Connection
A terminal block, labeled A and B , for the 24 VDC input signal is supplied inside the control
box of the Kim Hotstart heating system. The signal source for this connection is usually the fuel
pump or alternator. Once the signal is detected at the control circuit, the heating system will
automatically shut down during engine operation and re-energize upon engine shutdown.
CAUTION
THE HEATING SYSTEM MUST NOT BE OPERATED WHILE THE ENGINE IS
RUNNING. IF OPERATED, PREMATURE ELEMENT FAILURE MAY RESULT.

Kim Hotstart
System Components
This section describes the control box and heating tank components of the CSS Heating System.
Control Box
The control box used in the Kim Hotstart Heating System is shown. The control box contains the
electrical control components of the heating system. Parts in the control box may vary,
depending on the particular system configuration you purchased.

Kim Hotstart
Fuses
There are one or two different types of fuses located in the control box depending on the heating
system:
Transformer Primary Fuses

These fuses, located in the control box, protect the power transformer from overloading.
Transformer Secondary Fuse

This fuse, located in the control box, protects the control circuit components of the
control box and the pump.
Transformer
The transformer steps down the source primary voltage to 120 volts. Wiring information is listed
on the top of the transformer. This transformer is overload protected with fuses.
NOTE: When ordering replacement parts, be sure to reference your heating system's
model and serial numbers found on the identification plate.

Kim Hotstart
Coolant Heating Tank Assembly

The Kim Hotstart coolant heating tank assembly is shown below.
Following is an overview of operation and replacement instructions for the CSS heating tank
assembly and components, including the coolant heating element.

Kim Hotstart
Heating Element Replacement
The heating element heats the engine coolant. To replace the heating element, follow the steps on
the following page. Be sure to allow at least 12" of space for element removal. The wattage and
phase of the heating element are listed on the identification label found on the base of the heating
element assembly.
WARNING
DISCONNECT ALL POWER AT THE SOURCE LEADING TO THE KIM HOTSTART
HEATING SYSTEM PRIOR TO PERFORMING ANY MAINTENANCE ON THE
HEATING SYSTEM.

Kim Hotstart
Step 1 Turn the Kim Hotstart Heating

system OFF.
Cover
Step 2 Drain the fluid from the heating tank.
Step 3 Open the element enclosure and Enclosure

disconnect the following wires to the
heating element assembly:
• L1, L2, L3 (L1 & L3 on single

phase units)
Conduit
• The 2 wires from the thermister.
Thermistor
• The 2 wires from the hi-limit Probe
thermostat. Heating
Element
• The heating element ground wire.
Step 4 Remove the conduit connector and

electrical wires from the element
enclosure. V-Clamp
Step 5 Remove the heating element by O-Ring

loosening the clamp from the heating
tank as shown.
Step 6 Replace the heating element or

perform the necessary cleaning Inlet
procedure.
Tank
elemdis.eps
NOTE: Orientation of element thermister probe must be kept away from inlet opening
plumbing. It must be re-installed in the same orientation to the tank as it originally
came from the factory.
To re-assemble the heating element and tank, follow the steps listed above in reverse order.
Make sure the green ground and black power electrical wires are properly reconnected. To order
a new heating element, refer to part number on the label of the element, or the assembly drawing
included with this manual.

Kim Hotstart
High-Limit Thermostat Replacement
The High-Limit Thermostat Sensing Unit is a safety device designed to prevent over heating of
the coolant in the event that the heating system’s System Main Thermostat fails. The sensing
unit is located inside the element housing and is fixed at 140ºF (ON)/160ºF (OFF). To replace
the high-limit thermostat sensing unit, follow these steps.
WARNING
DISCONNECT ALL POWER AT THE SOURCE PRIOR TO PERFORMING ANY
MAINTENANCE TO THIS HEATING SYSTEM.
Step 1 Remove the enclosure cover Lock Ring

of the element housing.
Step 2 For 3-phase applications

only, remove the element Sensor Seat
jumper strap which crosses
over the top of the high-limit Thermostat Sensor
sensing unit (red wires).
Step 3 Using a small screw driver,

remove the toothed lock ring
that holds the high-limit
sensor and seat in place.
Step 4 Pull the sensor and seat hisenr.eps
straight out and disconnect

the sensor from its seat.
Step 5 Reconnect the new sensor.
Reassemble in reverse order.
High-Limit Sensing Unit Replacement Parts

Sensing Unit Temp. On Temp. Off Part Number
LSU 4 40ºF (5ºC) 60ºF (15ºC) HLC 4*
LSU 6 60ºF (15ºC) 80ºF (27ºC) HLC 6*
LSU 8 80ºF (27ºC) 100ºF (38ºC) HLC 8*
LSU 10 100ºF (38ºC) 120ºF (49ºC) HLC 10*
LSU 12 120ºF (49ºC) 140ºF (60ºC) HLC 12*
LSU 14 140ºF (60ºC) 160ºF (71ºC) HLC 14*
* Replacement stats will come with lock ring and sensor seat.

Kim Hotstart
Coolant System Temperature Setting Adjustments

The system temperature setting adjustment is located inside the control box. The solid-state
adjustable thermostat provides 5° incremental settings between 65° and 140°. To adjust the
heating system's temperature, follow these steps.
CAUTION
DISCONNECT ALL POWER AT THE SOURCE PRIOR TO PERFORMING ANY
MAINTENANCE TO THIS HEATING SYSTEM.
Step 1 Open the control box.
Step 2 Inside the control box, locate the thermostat control with four dip switches.
Step 3 The system's temperature setting is factory preset at 65°F for initial start-up.
After flow is achieved a setting of 100° under normal conditions is sufficient for
normal operation. If a higher or lower temperature is required, reset the dip
switches to desired temperature.
CAUTION
SEE SET-TEMPERATURE TABLE FOR ORIENTATION OF THE COMBINED
SWITCHES THAT ARE NUMBERED 1, 2, 4 AND 8 LOCATED ON TOP
OF THE SOLID-STATE CONTROL.
After the desired temperature is achieved, close the control box and re-energize the heating
system. A few seconds will pass before the thermostat control begins to energize the element.

Kim Hotstart
Set Temperature Table

Kim Hotstart
System Maintenance & Troubleshooting

This section describes maintenance procedures for the Kim Hotstart Small Capacity Heating
System and provides tips for troubleshooting.
System Maintenance
The following maintenance procedures are provided to ensure trouble-free operation of your
heating system:
• Control Box • Plumbing Connections

• Electrical Connections • Heating Tank
• System Mounting
WARNING
DISCONNECT ALL POWER PRIOR TO PERFORMING ANY SYSTEM
MAINTENANCE.
Control Box
Y Periodically check O-rings and gaskets for proper seals.
YCheck the control box for moisture (if necessary spray with moisture repellent or add
desiccant packets).
Plumbing Connections
YPeriodically check plumbing connections for leaks and, if necessary, tighten
connections. A loose connection on the suction side will cause a loss of flow.
Electrical Connections
YExcessive vibration will eventually cause terminals to loosen. Periodically tighten all
electrical connections. Ensure that all connectors to the circuit board are firmly seated.
Y At least once every six months, spray the inside of the main control box with a moisture
repellent for electrical connections.

Kim Hotstart
Heating Tank
YAt least once per year, clean the interior of the heating tank and the heating element
with a wire brush and/or damp cloth. Periodically check the element for sediment
build-up around the hairpins. Any scaling or build-up will shorten element life.
Maintenance and replacement procedures for the heating element are described in
Section 3.
System Mounting
Y Excessive vibration may cause mounting bolts to loosen. Periodically check and
tighten all mounting bolts.
Troubleshooting
Symptoms Possible Causes Solutions
Air leaks in suction lines Tighten suction line connections
No power Energize main power supply

Replace primary and/or
Blown fuses
Coolant is not heating secondary fuses
Isolation valves are closed
Open isolation valves
(user supplied)
Adjust thermostat dip switches
Thermostat is not set properly
inside control box

Kim Hotstart
Wiring Diagram

Murphy PowerView
Description
The Cummins QST30 engine operation can be monitored by the optional Murphy PowerView dis-
play, located on the engine instrument panel (fig. 7-7). The PowerView is a multifunction gauge, that
allows the operator to monitor several engine functions. It also displays fault codes, if there is an engine
malfunction. There are four touch sensitive buttons that allows the operator easy access to the displays.
Refer the following PowerView Installation and Operations Manual for complete instructions.
Fig. 7-7 Murphy PowerView Display

Murphy PowerView
PV-02124N
Revised 05/04
Section 78
00-02-0528
Installation and Operations Manual

Please read the following information before installing. A visual inspection of this product for damage during shipping is
recommended before mounting. It is your responsibility to have a qualified person install this unit.
GENERAL INFORMATION
Display Parameters
The following are some of the engine and transmission parameters displayed
WARNING
by the PowerView in English or Metric units as well as in Spanish, French,
or German (when applicable, consult engine or transmission manufacturer
for SAE J1939 supported parameters):
❖ Engine RPM
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT ❖ Engine Hours
✔ Disconnect all electrical power to the machine. ❖ Machine Hours
❖ System Voltage
✔ Make sure the machine cannot operate during installation.
❖ % Engine Load at the current RPM
✔ Follow all safety warnings of the machine manufacturer.
❖ Coolant Temperature
✔ Read and follow all installation instructions. ❖ Oil Pressure
❖ Fuel Economy
❖ Throttle Position
Description
The PowerView is a powerful new display in a line of components manufactured ❖ Engine Manifold Air Temperature
by FWMurphy as part of its J1939 MurphyLink™† Family. The J1939 ❖ Current Fuel Consumption
MurphyLink™ Family of products have been developed to meet the needs for ❖ Transmission Oil Pressure
instrumentation and control on electronically controlled engines communicating ❖ Transmission Oil Temperature
using the SAE J1939 Controller Area Network (CAN). ❖ Transmission Gear Position
The PowerView System is comprised of the PowerView and the Mlink™ ❖ Active Service Codes
PowerView Gages. The PowerView is a multifunction tool that enables equipment ❖ Stored Service Codes (when supported)
operators to view many different engine or transmission parameters and service
❖ Set Units for display (English or Metric)
codes. The system provides a window into modern electronic engines and transmis-
sions. The PowerView includes a graphical backlit LCD screen. It has excellent ❖ Engine Configuration Parameters
contrast and viewing from all angles. Back lighting can be controlled via menu or
external dimmer potentiometer. The display can show either a single parameter or a Specifications
quadrant display showing four parameters simultaneously. Diagnostic capabilities Display: 1.3 x 2.6 in. (33 x 66 mm), 64 x 128 pixels.
include fault codes with text translation for the most common fault conditions. Operating Voltage: 8 VDC minimum to 32 VDC max.
The PowerView has four buttons using self-calibrating charge transfer activation Reversed Polarity: Withstands reversed battery terminal polarity indef-
technology, which eliminates the concern for pushbutton wear and failure. In addi- initely within operating temperatures.
tion, operators can navigate the display with ease.
Operating Temperature: -40 to +85ºC (-40 to185ºF).
The enhanced alarm indication has ultra bright alarm and shutdown LEDs (amber
& red). It has a wide operating temperature range of -40 to +85º C (-40 to185º F), Display Viewing Temperature: -40 to +75ºC (-40 to 167ºF).
display viewing -40 to +75º C (-40 to 167º F), and increased environmental sealing Storage Temperature: -40 to +85ºC (-40 to185ºF).
to +/- 5 PSI (± 34kPa). It also features Deutsch DT style connectors molded into Environmental Sealing: IP68, +/- 5 PSI (+/- 34.4 kPa).
the case and fits quickly and easily into existing 2-1/16 in. (52 mm) gage opening Power Supply Operating Current: (@ 14 VDC)=
with little effort. 52 mA minimum; 268 mA maximum (LCD heater on).
Other components in the system are microprocessor-based Mlink™ CAN BUS: SAE J1939 Compliant.
PowerView Gages for displaying critical engine data broadcast by an elec- Case: Polycarbonate / Polyester.
tronic engine or transmission’s Engine Control Unit (ECU): engine RPM, oil Clamp: Polyester (PBT).
pressure, coolant temperature, system voltage, etc. and a combination audi- Connectors: 6-Pin Deutsch DTO6 Series.
ble alarm and relay unit for warning and shutdown annunciation. Up to 32
components may be linked to the PowerView using a simple daisy chain Maximum Panel Thickness: 3/8 in. (9.6 mm).
wire connection scheme using RS485. The PowerView and all connected Mounting Hole: 2.062 inch (52 mm) in diameter.
components can be powered by 12- or 24-volt systems. Auxiliary Communications: Either:
Gages: One (1) RS485 port, MODBUS RTU master.
Warranty MODBUS: One (1) RS485 port, MODBUS RTU slave, selectable
A limited warranty on materials and workmanship is given with this baud rate; 9600; 19.2K; 38.4K.
FWMurphy product. A copy of the warranty may be viewed or printed by Potentiometer (External Dimmer)Input: 1K ohm, 1/4 W
going to www.fwmurphy.com/warranty.html
Shipping Weights (all models): 1/2 lb. (225 g.)
† MurphyLinkTM is a registered trademark of FWMurphy. All other trademarks and
service marks used in this document are the property of their respective owners. Shipping Dimensions (all models): 6 x 6 x 6 in. (152 x 152 x 152 mm).
Murphy PowerView
GENERAL INFORMATION continued
Table of Contents Faceplate Features

General Information page # Amber Red Shutdown
Warning LED Derate LED
Description................................................. 1
Display Parameters.................................... 1
Specifications............................................. 1
Display
Key Pad Functions..................................... 2 Bezel
Mechanical Installation
Typical Mounting Dimensions................... 2
Typical Quick-connect Diagram................ 3 Menu Key Enter Key
Electrical Installation
PIN Connectors Nomenclature.................. 3 Left Arrow Key (Scroll Up) Right Arrow Key (Scroll Down)
Typical Wiring Diagrams........................... 4
Keypad Functions
Operations The keypad on the PowerView is a capacitive touch sensing system.
First Time Start Up................................... 5 There are no mechanical switches to wear or stick, and the technology
has been time proven in many applications. It operates in extreme tem-
Main Menu Navigation............................. 5 peratures, with gloves, through ice, snow, mud, grease, etc., and it allows
Selecting a Language................................. 5 complete sealing of the front of the PowerView. The ‘key is touched’
Stored Fault Codes.................................... 6 feedback is provided by flashing the screen. The keys on the keypad per-
form the following functions:
Engine Configuration Data....................... 6
Faults and Warnings............................... .7 – Menu Key - The Menu Key is touched to either
Active Fault Codes................................... 8 enter or exit the menu screens.
Shutdown Codes...................................... 8
Back Light Adjustment............................ 9 – Left Arrow - The Left Arrow Key is touched
to scroll through the screen either moving the para-
Contrast Adjustment.............................. 10 meter selection toward the left or upward.
Select Units............................................... 10
Setup 1-Up Display................................... 11 – Right Arrow - The Right Arrow Key is touched
Setup 4-Up Display.................................. 14 to scroll through the screen either moving the parameter
selection toward the right or downward.
Utilities.....................................................15
MODBUS Setup....................................... 15
– Enter Key - The Enter Key (also known as Enter
J1939 Parameters....................................17 Button) is touched to select the parameter that is high-
Glossary...................................................18 lighted on the screen.
Typical Mounting Dimensions

SIDE HOLE CUTOUT
3.489 in.
(89 mm) 1.972 in.
1.94 in. 2.062 in. (50 mm)
FRONT (50 mm) (52 mm)
diameter
2.070 in. .953 in.
(53 mm) (24 mm)
2.41 in. 0.125 in. R 0.063 in.

(61 mm) (3 mm) (1.6 mm)
0.78 in. (20 mm)
4.25 in. 3.18 in. (81 mm)
(108 mm)

Murphy PowerView
MECHANICAL INSTALLATION
Typical Quick-Connect Diagram
Last PVA Gage or

PVAA Audible Alarm To optional
To Engine
external device
ECU To PVAA
A B
Audible Alarm
Terminating
To Battery Resistor PVJR
Power B
Relay N.O.
POWERVIEW A
Relay N.C.
PV100 OR Ext.
PVW-CH
Sonalert
Relay Comm.
Customer provided wire Optional PVW-A wire harness

(includes terminating resistor)
harness or CAN extension B
PVW-PH
A
harnesses or power
extension harnesses.
PVA Gage Next PVA Gage
Wire harness
External Dimmer PVW-J
Wire 24 inch.
B A B
External A
Dimmer
B+
GRND
CAN–SHLD
CAN–LO
CAN–HI
Wire harness PVW-P Wire harness PVW-J Wire harness PVW-J
ELECTRICAL INSTALLATION
PowerView Unit Back View

Deutsch DT06-6S Style Connections
Plug A Plug B
PIN 3 CAN LO PIN 4 CAN SHLD PIN 3 RS485+ PIN 4 RS485 –

– –
PIN 2 CAN HI
–
PIN 5 Dimmer A B
Potentiometer
PIN 1 V+ PIN 6 GRND PIN 1 V+ PIN 6 GRND
Recommended Connectors:
Body: Deustch DT06-6S
Wedge Lock: W6S
Terminals: 0462-201-16141
Sealing Plug: 114017

Murphy PowerView
TYPICAL WIRING DIAGRAMS
IMPORTANT: To eliminate external interference: RS485(+) and RS485(-) should be twisted pair cable or twist wires together, one twist per
inch minimum. CAN–L, CAN–H and CAN Shield should be approved J1939 CAN bus cable (CAN wire for example: RADOX plug and play cable,
from Champlain cable). (RS485 wire for example: BELDEN 9841 or 3105A).
PowerView Deutsch DT06-6S Style Unit to PVA Gage

NOTE 5 RS485 (+) Data
Pin 3
Back View
NOTE 4 120 ohms
NOTE 2 RS485 (-) Data
Pin 4
Gray-CAN_SHLD Pin 4
ENGINE See
CONTROL Pin 3 NOTE 6
Green-CAN_L
MODULE 120 Ω
(SAE J1939 Yellow-CAN_H See Note Pin 2
Compliant) PVA Gage
NOTE 1
Pin 1
Pin 1 V+
Pin 6
Pin 5
Red-V+ Pin 6 GRND
Ignition Gray-Ground
Switch
Note 1: Place Resistor between Note 4: Only use 120 ohm
Blue-Back Light CAN–H and CAN–L Line near characteristic impedance cable,
NOTE 7 PowerView (included in PVW-P or ex Belden 9841.
Battery factory purchased panels).
Note 5: RS485 shield connected
Illumination Note 2: Use SAE J1939 compliant to PowerView end only.
Control*(optional) wiring or equipment.
Note 6: Place Resistor at End of
NOTE 3 Note 3: Electronic dimmer switch Line on last PVA gage. (Included
recommended with 4A, capacity for factory purchased panels.)
or heavy duty rheostat switch,
1000 ohm, 0.25 watt. Note 7: If a backlight dimmer is not
used, connect the blue backlight wire
to ground. Do not leave the blue
backlight wire unconnected.
PowerView Deutsch DT06-6S Style Unit to MODBUS Output

NOTE 5 RS485 (+) Data
Pin 3
NOTE 4 to MODBUS Output
NOTE 2 RS485 (-) Data See NOTES 6 and 8
Pin 4
Gray-CAN_SHLD Pin 4
ENGINE
CONTROL Pin 3
Green-CAN_L
MODULE 120 Ω
(SAE J1939 Yellow-CAN_H See Note Pin 2
Compliant)
NOTE 1
Note 4: Only use 120 ohm
Pin 1
characteristic impedance cable,

Pin 6
Pin 5
Red-V+ ex Belden 9841.
Ignition Note 5: RS485 shield connected

Gray-Ground
Switch Note 1: Place Resistor between to PowerView end only.
CAN–H and CAN–L Line near
Blue-Back Light PowerView (included in PVW-P Note 6: Place Resistor at End of Line.
NOTE 7 or factory purchased panels). (Included for factory purchased panels.)
Battery
Note 2: Use SAE J1939 compliant Note 7: If a backlight dimmer is not
NOTE 3 used, connect the blue backlight wire
Illumination Control*(optional) wiring or equipment.
to ground. Do not leave the blue
Note 3: Electronic dimmer switch backlight wire unconnected.
recommended with 4A, capacity
or heavy duty rheostat switch,
For a complete listing of MODBUS Registers 1000 ohm, 0.25 watt.
Note 8: PVA gages cannot be used
with the MODBUS feature.
visit our website at www.fwmurphy.com

Murphy PowerView
POWERVIEW OPERATION
PowerView Menus (First Time Start Up) 3. Touching the right arrow button will scroll down to reveal the last
1. When power is first applied to the PowerView, the "Logo" is displayed. items of “Main Menu” screen highlighting the next item down.
ADJUST BACKLIGHT
ADJUST CONTRAST
UTILITIES
2. The "Wait to Start" message will be displayed for engines with a 4. Touch the "Arrows" to scroll to the desired menu item or touch "Menu"
pre-startup sequence. Once the "Wait to Start" message is no longer dis-
to exit the Main menu and return to the engine parameter display.
played the operator may start the engine. Note: Displays only when SAE
J1939 message is supported by engine manufacturer. GO TO 1-UP DISPLAY
LANGUAGES 98% 1000 RPM
STORED CODES LOAD@RPM ENG RPM
ENGINE CONF
WAIT TO SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY 14.2 57 PSI
START SELECT UNITS BAT VOLT OIL PRES
PREHEAT
3. Once the engine has started the single engine parameter is displayed.
Selecting a Language
0 1500 3000
1. Starting at the main menu display use the "Arrows" to scroll to the
"Language" menu and once highlighted touch the "Enter" button.
1800 RPM GO TO 1-UP DISPLAY
LANGUAGES
LANGUAGES
ENG RPM COOL TEMP STORED CODES
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
Main Menu Navigation

1. Starting at the single or four engine parameter display, touch "Menu".
2. The language choices will be displayed. Use the "Arrow" buttons to
98% 1000 RPM scroll through the selections and touch "Enter" to make a selection.
0 1500 3000 LOAD@RPM ENG RPM
1800 RPM ENGLISH ❋

14.2 57 PSI ESPAÑOL
ENG RPM COOL TEMP BAT VOLT OIL PRES
FRANÇAIS
DEUTSCH
2. The first seven items of the “Main Menu” will be displayed.

Touching the "Arrow Buttons" will scroll through the menu selection.
GO TO 1-UP DISPLAY
LANGUAGES
STORED CODES
ENGINE CONF
3. Now that you have selected the language, touch the "Menu" button to
SETUP 1-UP DISPLAY return to the main menu display.
SETUP 4-UP DISPLAY
SELECT UNITS

Murphy PowerView
POWERVIEW OPERATION continued
Stored Fault Codes 5. Touch the "Menu Button" to return to the main menu.
1. Starting at the single or the four engine parameter display touch the 1 of x
"Menu button".
SPN110 FMI10
98% 1000 RPM HIGH COOLANT TEMP
1800 RPM
▼
▼
MORE HIDE
ENG RPM COOL TEMP 14.2 57 PSI

BAT VOLT OIL PRES
6. Touch the "Menu Button" to exit the Main menu and return to the
engine parameter display.
2. The main menu will pop up on the display. Use the "Arrow Buttons" to
scroll through the menu until the Stored Fault Codes is highlighted. GO TO 1-UP DISPLAY
98% 1000 RPM
STORED CODES
LOAD@RPM ENG RPM
ENGINE CONFG
GO TO 1-UP DISPLAY SETUP 1-UP DISPLAY
STORED CODES
STORED CODES SETUP 4-UP DISPLAY
SELECT UNITS 14.2 57 PSI
ENGINE CONFG ADJUST BACKLIGHT BAT VOLT OIL PRES
SETUP 1-UP DISPLAY

SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
Engine Configuration Data

1. Starting at the single or four engine parameter display touch the
"Menu Button".
3 Once the "Stored Fault Codes" menu item has been highlighted touch 98% 1000 RPM
the "Enter Button" to view the "Stored Fault Codes" (when applicable, 0 1500 3000 LOAD@RPM ENG RPM
consult engine or transmission manufacturer for SAE J1939 supported 1800 RPM
14.2 57 PSI
parameters). ENG RPM COOL TEMP BAT VOLT OIL PRES
GO TO 1-UP DISPLAY
STORED CODES
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY 2. The main menu will pop up on the display. Use the "Arrow Buttons"
SETUP 4-UP DISPLAY to scroll through the menu until the "Engine Configuration" is highlighted.
SELECT UNITS
ADJUST BACKLIGHT GO TO 1-UP DISPLAY
STORED CODES
ENGINE
ENGINE CONFG
CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
4. If the word "MORE" appears above the "Arrow Buttons" there are
more stored fault codes that may be viewed. Use the "Arrow Buttons" to
scroll to the next Stored Diagnostic Code.
3. Once the "Engine Configuration" menu item has been highlighted
1 of x touch the "Enter Button" to view the engine configuration data.
SPN110 FMI10 GO TO 1-UP DISPLAY

STORED CODES
HIGH COOLANT TEMP ENGINE
ENGINE CONFG
CONFG
SETUP 1-UP DISPLAY
▼
▼
MORE HIDE
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT

Murphy PowerView
4. Use the "Arrow Buttons" to scroll through the engine configuration data. or normal operation an auxiliary gage should fail, the single or four para-
meter screen will be replaced with the "MLink Gage Fault" message.
ENGINE SPEED PT 1
1000 RPM 1 of x
ENGINE OIL PRESSURE

GAGE NOT RESPONDING
▼
▼
MORE
HIDE
5. Touch the "Menu Button" to return to the main menu.

ENGINE SPEED PT 1 3. To acknowledge and "Hide" the fault and return to the single or
four parameter display, touch the "Enter Button".
1000 RPM 1 of x
ENGINE OIL PRESSURE

▼
▼
MORE
GAGE NOT RESPONDING
HIDE
GO TO 1-UP DISPLAY
STORED CODES 98% 1000 RPM 4. The display will return to the single or four parameter screen.
LOAD@RPM
ENGINE CONFG
CONFG ENG RPM
SETUP 1-UP DISPLAY

SETUP 4-UP DISPLAY
SELECT UNITS 14.2 57 PSI ! 98% 1000 RPM
OIL PRES
ADJUST BACKLIGHT BAT VOLT
1800 RPM !
14.2 57 PSI
ENG RPM COOL TEMP ! BAT VOLT OIL PRES !
! Indicates Auxiliary Gage Fault
.! Indicates Fault Warning

! Indicates Derate or Shutdown Condition Fault
Faults and Warnings 5. Touching the "Enter Button" will redisplay the hidden fault.
Touching the "Enter Button" once again will hide the fault and return the
Auxiliary Gage Fault screen to the single or four parameter display. NOTE: The fault can only
1. During normal operation the single or four parameter screen will be be cleared by correcting the cause of the fault condition.
displayed. 1 of x
98% 1000 RPM ENGINE OIL PRESSURE

GAGE NOT RESPONDING
1800 RPM
14.2 57 PSI HIDE
2. The PVA Series of auxiliary gages can be attached to the PowerView.

These auxiliary gages communicate with the Modbus master PowerView
via a daisy-chained RS-485 port. If at any time during system initialization

Murphy PowerView
Active Fault Codes 5. The display will return to the single or four parameter display, but the
display will contain the "Active Fault"warning icon. Touching the "Enter
1. During normal operation the single or four parameter screen will be
Button" will redisplay the hidden fault.
displayed.
! 98% 1000 RPM
98% 1000 RPM 0 1500 3000 LOAD@RPM ENG RPM
LOAD@RPM ENG RPM
0 1500 3000
1800 RPM !
1800 RPM 14.2 57 PSI ENG RPM COOL TEMP ! 14.2
BAT VOLT
57 PSI
OIL PRES !
6. Touching the "Enter Button" once again will hide the fault and
2. When the PowerView receives a fault code from an engine control
unit the single or four parameter screen will be replaced with the "Active return the screen to the single or four parameter display.
Fault Codes" message. 1 of x WARNING
1 of x WARNING
SPN110 FMI0
SPN110 FMI0
HIGH COOLANT TEMP
HIGH COOLANT TEMP MORE HIDE
▼
▼
MORE HIDE
7. The Single or Four parameter screen will display the fault icon until
the fault condition is corrected. NOTE: Ignoring active fault codes could
3. If the word "MORE" appears above the "Arrow Buttons" there are result in severe engine damage.
more active fault codes that may be viewed.
Use the "Arrow Buttons" to scroll to the next "Active Fault Code" GO TO 1-UP DISPLAY
STORED CODES 98% 1000 RPM
LOAD@RPM ENG RPM
ENGINE CONFG
SETUP 1-UP DISPLAY
1 of x
SETUP 4-UP DISPLAY
!
SPN110 FMI0 ADJUST BACKLIGHT BAT VOLT OIL PRES !
HIGH COOLANT TEMP
▼
▼
MORE HIDE
Shutdown Codes
1. During normal operation the single or four parameter screen will be displayed.
98% 1000 RPM
4. To acknowledge and "Hide" the fault and return to the single or four
parameter display touch the "Enter Button".
1800 RPM
14.2 57 PSI
1 of x
SPN110 FMI0
HIGH COOLANT TEMP 2. When the PowerView receives a severe fault code from an engine con-
trol unit the single or four parameter screen will be replaced with the
▼
MORE HIDE "Shutdown!" message.
1 of x SHUTDOWN
SPN110 FMI0
HIGH COOLANT TEMP
MORE HIDE

Murphy PowerView
3. To acknowledge and "Hide" the fault and return to the single or 2. The main menu will pop up on the display. Use the "Arrow Buttons"
four parameter display touch the "Enter Button". to scroll through the menu until the "Adjust Backlight" is highlighted.
1 of x SHUTDOWN GO TO 1-UP DISPLAY
STORED CODES
SPN110 FM10 ENGINE CONFG
HIGH COOLANT TEMP SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
MORE HIDE SELECT UNITS
ADJUST BACKLIGHT
ADJUST BACKLIGHT
4. The display will return to the single or four parameter display, but
the display will contain the "Shut Down" icon. Touching the "Enter 3. Once the "Adjust Backlight" menu item has been highlighted touch
Button" will redisplay the hidden fault. the "Enter Button" to activate the "Adjust Backlight" function.
GO TO 1-UP DISPLAY
! 98% 1000 RPM
0 1500 3000 LOAD & RPM ENG RPM
STORED CODES
ENGINE CONFG
1800 RPM ! SETUP 1-UP DISPLAY
14.2 57 PSI SETUP 4-UP DISPLAY
ENG RPM COOL TEMP! BAT VOLT OIL PRES
SELECT UNITS
ADJUST BACKLIGHT
5. Touching the "Enter Button" once again will hide the fault and return
the screen to the single or four parameter display.
1 of x SHUTDOWN 4. Use the "Arrow Buttons" to select the desired backlight intensity.
SPN110 FM10 ADJUST BACKLIGHT
HIGH COOLANT TEMP
MORE HIDE
6. The Single or Four parameter screen will display the fault icon until
the fault condition is corrected. NOTE: Ignoring active fault codes could
result in severe engine damage. 5. Touch the "Menu Button" to return to the main menu.
! 98% ADJUST BACKLIGHT

LOAD & RPM
1000 RPM
0 1500 3000 ENG RPM
1800 RPM !
14.2 57 PSI
ENG RPM COOL TEMP ! BAT VOLT OIL PRES
!
Back Light Adjustment

1. Starting at the single or four engine parameter display touch the 6. Touch the "Menu Button" to exit the Main menu and return to the
"Menu Button".
GO TO 1-UP DISPLAY
98% 1000 RPM ENGINE CONFG LOAD@RPM ENG RPM
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
1800 RPM SELECT UNITS 14.2 57 PSI
14.2 57 PSI ADJUST BACKLIGHT BAT VOLT OIL PRES

Murphy PowerView
Contrast Adjustment 6. Touch the "Menu Button" to exit the Main menu and return to the
1. Starting at the single or four engine parameter display, touch the engine parameter display.
"Menu Button". GO TO 1-UP DISPLAY
98% 1000 RPM
STORED CODES LOAD@RPM ENG RPM
ENGINE CONFG
98% 1000 RPM SETUP 1-UP DISPLAY
0 1500 3000 LOAD@RPM ENG RPM SETUP 4-UP DISPLAY
1800 RPM ADJUST BACKLIGHT
BAT VOLT OIL PRES
14.2 57 PSI
2. The main menu will pop up on the display. Use the "Arrow Buttons"
to scroll through the menu until "Adjust Contrast" is highlighted. Select Units
1. Starting at the single or four engine parameter display touch the
GO TO 1-UP DISPLAY
STORED CODES "Menu Button".
ENGINE CONFG
SETUP 1-UP DISPLAY 98% 1000 RPM
LOAD@RPM
0 1500 3000 ENG RPM
SETUP 4-UP DISPLAY
SELECT UNITS 1800 RPM
ADJUST BACKLIGHT 14.2 57 PSI
2. The main menu will pop up on the display. Use the arrow buttons to
3. Once the "Adjust Contrast" menu item has been highlighted touch scroll through the menu until the "Select Units" is highlighted.
the "Enter Button" to activate the "Adjust Contrast" function.
GO TO 1-UP DISPLAY
STORED CODES STORED CODES
ENGINE CONFG ENGINE CONFG
SETUP 1-UP DISPLAY SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY SETUP 4-UP DISPLAY
SELECT UNITS SELECT
SELECTUNITSD
UNITS
ADJUST BACKLIGHT ADJUST BACKLIGHT
ADJUST CONTRAST
3. Once the "Select Units" menu item has been highlighted touch the
"Enter Button" to access the "Select Units" function.
4. Use the "Arrow Buttons" to select the desired contrast intensity.
GO TO 1-UP DISPLAY
STORED CODES
ADJUST CONTRAST ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT
SELECTUNITSD
UNITS
ADJUST BACKLIGHT
4. Use the arrows to highlight the desired units. "English" for Imperial
5. Touch the "Menu Button" to return to the main menu. units i.e. PSI, ºF or Metric kPa, Metric Bar for IS units i.e. kPa, Bar, ºC.
ADJUST CONTRAST ENGLISH

METRIC KPA
METRIC BAR

Murphy PowerView
5. Touch the "Enter Button" to select the highlighted units. 3. Once the "Setup 1-up Display" menu item has been highlighted
touch the "Enter Button" to access the "Setup 1-up Display" function.
ENGLISH
METRIC KPA GO TO 1-UP DISPLAY
METRIC BAR STORED CODES
ENGINE CONFG
SETUP1-UP
SETUP 1-UPDISPLAY
DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITSD
ADJUST BACKLIGHT
6. Touch the "Menu Button" to return to the "Main Menu". 4. Three options are available for modification of the 1-Up display.
a). Use Defaults – This option contains a set of engine parameters:
ENGLISH ❉
METRIC KPA Engine Hours, Engine RPM, System Voltage, Battery Voltage, %
METRIC BAR Engine Load at Current RPM, Coolant Temperature, Oil Pressure.
b). Custom Setup – This option allows for the modification of what
parameter, the number of parameters, and the order in which the
parameters are being displayed.
c). Automatic Scan – Selecting the scan function will cause the
1-Up Display to scroll through the selected set of parameters
one at a time, momentarily pausing at each.
5. Use Defaults - To select "Use Defaults" use the arrow buttons to
scroll to and highlight "Use Defaults" in the menu display.
engine parameter display. USE DEFAULTS
USE DEFAULTS
GO TO 1-UP DISPLAY
CUSTOM SETUP
STORED CODES 98% 1000 RPM AUTOMATIC SCAN OFF
LOAD@RPM ENG RPM
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
BAT VOLT OIL PRES
ADJUST BACKLIGHT
6. Touch the "Enter Button" to activate the "Use Defaults" function.

USE
USEDEFAULTS
DEFAULTS
Setup 1-Up Display CUSTOM SETUP
1. Starting at the single engine parameter display, touch the "Menu AUTOMATIC SCAN OFF
Button".
98% 1000 RPM

LOAD@RPM
0 1500 3000 ENG RPM
1800 RPM 57 PSI

14.2
7. A message indicating the “Single Engine” parameter display parame-

ters are reset to the factory defaults will be displayed, then the display
2. The main menu will pop up on the display. Use the "Arrow Buttons" to will return to the “Custom Setup” menu.
scroll through the menu until the "Setup 1-up Display" is highlighted.
GO TO 1-UP DISPLAY RESTORED TO

STORED CODES DEFAULTS
ENGINE CONFG
SETUP1-UP
SETUP 1-UPDISPLAY
DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITSD
ADJUST BACKLIGHT

Murphy PowerView
8. Custom Setup - To perform a custom setup of the 1-Up Display, use 13. Touch the "Enter button" to select the highlighted parameter for inclu-
the arrow buttons to scroll to and highlight "Custom Setup" on the display. sion in the Single Engine Parameter Display.
USE DEFAULTS
ENGINE SPEED
CUSTOM
CUSTOMSETUP
SETUP
AUTOMATIC SCAN OFF PERCENT LOAD AT CURRENT RPM 2
ENGINE OIL PRESSURE 1
ENGINE COOLANT TEMP 3
9. Touching the "Enter Button" will display a list of engine parameters.

14. Continue to scroll and select additional parameters for the custom
USE DEFAULTS 1-Up Display. Touch the "Menu button" at any time to return to the
CUSTOM
CUSTOMSETUP
SETUP
AUTOMATIC SCAN OFF
"Custom Setup" menu.
15. Automatic Scan - Selecting the scan function will cause the 1-
Up Display to scroll through the selected set of parameters one at a time.
Use the "Arrow Buttons" to scroll to the "Automatic Scan" function.
USE DEFAULTS
CUSTOM SETUP
10. Use the "Arrow Buttons" to scroll to and highlight a selected para- AUTOMATIC
AUTOMATICSCAN OFF
SCAN OFF
meter (parameter with a # symbol to right of it).
USE DEFAULTS
ENGINE SPEED 1
PERCENT LOAD AT CURRENT RPM 3
ENGINE OIL PRESSURE 2 This number indicates
the order of display for
ENGINE COOLANT TEMPERATURE
the parameters and
that the parameter is
selected for display.
16. Touching the "Enter Button" toggles the "Automatic Scan" function on.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC
AUTOMATICSCAN OFF
SCAN ON
11. Touch the "Enter Button" to deselect the selected parameter remov-
ing it from the list of parameters being displayed on the 1-up display.
USE DEFAULTS
ENGINE SPEED 1
ENGINE COOLANT TEMPERATURE
17. Touching the "Enter Button" again toggles the "Automatic Scan"
function off.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC
AUTOMATICSCAN OFF
SCAN OFF
12. Use the "Arrow Buttons" to scroll and highlight the desired parameter
that has not been selected for display.
ENGINE SPEED
ENGINE OIL PRESSURE 1 Note that the numbers
now indicate the new
ENGINE COOLANT TEMP
order of display for
the parameters.

Murphy PowerView
18. Once the "Use Defaults", "Custom Setup" and "Automatic Scan" func- 4. Touch the "Enter Button" to activate the "Use Defaults" function.
tions have been set touch the "Menu Button" to return to the main menu. This action will reset the unit to the factory default.
USE DEFAULTS USE
USE DEFAULTS
DEFAULTS
CUSTOM SETUP CUSTOM SETUP
AUTOMATIC
AUTOMATICSCAN OFF
SCAN ON
5. The "Use Defaults"screen will be displayed during the reseting peri-

19. Touch the "Menu Button" to exit the Main menu and return to the od then will automatically return to the "Setup 4-Up Display" menu.
GO TO 1-UP DISPLAY
STORED CODES RESTORED TO
ENGINE CONFG 0 1500 3000
SETUP 1-UP DISPLAY DEFAULTS
SETUP 4-UP DISPLAY
SELECT UNITS
1800 RPM
ADJUST BACKLIGHT ENG RPM COOL TEMP
6. Select the "4-Up Custom Setup" from the "4-Up Setup" menu.
Setup 4-Up Display USE DEFAULTS
1. From the single or four engine parameter display touch the "Menu Button". CUSTOM
CUSTOM SETUP
SETUP
98% 1000 RPM

LOAD@RPM
0 1500 3000 ENG RPM
1800 RPM 57 PSI

14.2
2. The main menu will pop up on the display. Use the "Arrow Buttons" to 7. The quadrent with the backlit parameter value is the current selected
scroll through the menu until the "Setup 4-Up Display" is highlighted. parameter. Use the "Arrow Buttons" to highlight the parameter value in
the quadrant you wish to place a new parameter.
GO TO 1-UP DISPLAY
STORED CODES 125°F 1000 RPM
ENGINE CONFG COOL TEMP ENG RPM
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
14.2
14.2 57 PSI
SELECT UNITS
ADJUST BACKLIGHT BAT VOLT OIL PRESP
3. Once the "Setup 4-Up Display" menu item has been highlighted
8. Touch the "Enter Button" and a list of parameters will appear.
touch the "Enter Button" to activate the "Setup 4-Up Display" menu.
GO TO 1-UP DISPLAY 125°F 1000 RPM

STORED CODES COOL TEMP ENG RPM
ENGINE CONFG
SETUP 1-UP DISPLAY 14.2
14.2 57 PSI
SETUP
SETUP 4-UP
4-UP DISPLAY
DISPLAY BAT VOLT OIL PRESP
SELECT UNITS
ADJUST BACKLIGHT

Murphy PowerView
9. The parameter that is highlighted is the selected parameter for the 15. Touch the "Menu Button" to exit the Main menu and return to the
screen. Use the "Arrow Buttons" to highlight the new parameter to be engine parameter display.
placed in the quadrent selected in the previous screen. GO TO 1-UP DISPLAY
ENGINE SPEED 3 The number to the right of the ENGINE CONFG COOL TEMP ENG RPM
ENGINE HOURS parameter indicates the quadrant SETUP 1-UP DISPLAY

in which it is displayed. SETUP 4-UP DISPLAY
DISPLAY
ENGINE COOLANT TEMPERATURE 1 SELECT UNITS 143°F 57 PSI
BATTERY POTENTIAL 1. = Upper Left Quadrent ADJUST BACKLIGHT OIL TEMP OIL PRES
ENGINE OIL TEMPERATURE

TEMPERATURE 2 2. = Lower Left Quadrent
ENGINE OIL PRESSURE 4 3. = Upper Right Quadrent
4.= Lower Right Quadrent
10. Touch the "Enter Button" to change the selected parameter in the Utilities (Information and troubleshooting)
quadrant to the new parameter. 1. Starting at the single or four engine parameter display, touch the “Menu button”.
ENGINE SPEED 3
ENGINE HOURS 125% 1000 RPM
0 1500 3000 COOL TEMP ENG RPM
ENGINE COOLANT TEMPERATURE 1
BATTERY POTENTIAL 2 1800 RPM
TEMPERATURE 143°F 57 PSI
ENG RPM COOL TEMP OIL TEMP OIL PRES
2. The main menu will be displayed. Use the “Arrow buttons” to scroll
11. Use the "Menu Button" to return to the “4-UP Custom Setup” screen. through the menu until the “Utilities” is highlighted.
ENGINE SPEED 3 STORED CODES

ENGINE HOURS ENGINE CONFG
SETUP 1-UP DISPLAY
ENGINE COOLANT TEMPERATURE 1
SETUP 4-UP DISPLAY
BATTERY POTENTIAL SELECT UNITS
TEMPERATURE 2 2 Note the number to the right of
ADJUST BACKLIGHT
ENGINE OIL PRESSURE 4 the selected parameter indicating
UTILITIES
that the parameter is now
assigned to that display location.
12. The parameter in the selected quadrent has changed to the parame- 3. Once the “Utilities” menu item has been highlighted, touch the
ter selected in the previous screen. “Enter Button” to activate the “Utilities” functions.
STORED CODES
125°F ØRPM
1000 RPM ENGINE CONFG
COOL TEMP ENG RPM SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
143°F 57 PSI ADJUST BACKLIGHT
OIL TEMP OIL PRESP UTILITIES
4. Touch "Select" to enter the “Gage Data” display. When “Gage Data” is
13. Repeat the parameter selection process until all spaces are filled. selected the PowerView will communicate with the analog gages at a fixed
14. Touch the "Menu Button" to return to the main menu. rate of 38.4 k Baud, 8 data bits, no parity check, 1 stop bits, half duplex.
125°F ØRPM GAGE DATA

1000 RPM
REMOVE ALL GAGES
COOL TEMP ENG RPM
SOFTWARE VERSION
MODBUS SETUP
143°F 57 PSI FAULT CONVERSION
OIL TEMP OIL PRESP DEMO MODE ON

Murphy PowerView
5. Use the “Arrow buttons” to scroll through the items or touch “Menu” 11. Use the “Arrows” to scroll and highlight the version then touch “Select”
to return to the “Utilities” menu. and an asterisks appears to the right of the selection.
NOTE: There are four (4) different methods for converting fault codes. The
1 of x
PowerView always looks for J1939 Version 4 and can be set to use one of the
ENGINE OIL PRESSURE 3 other J1939 versions. Most engine ECU’s use Version 4, therefore in most
ADDRESS: 20 cases adjustment of this menu option will not be required.
SOFTWARE REVISION #: Upon receiving an unrecognizable fault, change to a different J1939
ERRORS: NONE Version. If the fault SPN does not change when the version is changed, the
ECU generating the fault is using Fault Conversion method 4. If the SPN
number does change but is still unrecognizable, try changing to another
J1939 Version not yet used and continue to check the SPN number.
6. Touch “Menu Button” to return to the “Utilities” menu. J1939 VERSION
VERSION 11 *
J1939 VERSION 2
1 of x J1939 VERSION 3
J1939 VERSION 4
ENGINE OIL PRESSURE
ADDRESS: 20
SOFTWARE REVISION #:
ERRORS: NONE
12. Touch the “Menu” button to return to “Utilities” menu. Touch the
7. Use the “Arrows” to highlight “Remove All Gages”. Touch “Select” to “Menu” button again to to return to the “Main” menu.
clear gage data from memory. It takes a moment to clear all gages.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
CLEARING GAGES SELECT UNITS
PLEASE WAIT ADJUST BACKLIGHT
UTILITIES
8. When the gage data has cleared, the display automatically returns to
the “Utilities” menu. Scroll to “Software Version”. Touch “Select” to MODBUS Setup
view the software version currently in the PowerView. 1. Starting at the single or four engine parameter display, touch the “Menu
button”.
SOFTWARE 98% 1000 RPM

VERSION 0 1500 3000 LOAD@RPM ENG RPM
MURPHY: X.XX 1800 RPM

ENG RPM COOL TEMP 14.2 57 PSI
BAT VOLT OIL PRES
2. The main menu will be displayed. Use the “Arrow buttons” to scroll
9. Touch “Menu” to return to “Utilities”. Highlight “Fault Conversion”
through the menu until the “Utilities” is highlighted, then touch “Enter”.
using the “Arrows”. Touch “Select” to enter the Fault convertion menu.
STORED CODES
GAGE DATA ENGINE CONFG
REMOVE ALL GAGES SETUP 1-UP DISPLAY
SOFTWARE VERSION SETUP 4-UP DISPLAY
FAULT
FAULTCONVERSION
CONVERSION SELECT UNITS
ADJUST BACKLIGHT
UTILITIES

Murphy PowerView
3. Once in the “Utilities” menu use the “Arrows” to scroll through the menu
until the “Modbus Setup” menu is highlighted, then touch “Enter”.
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
MODBUS SETUP
MODBUS SETUP
FAULT CONVERSION
4. Use the “Arrows” to scroll down to and highlight either the “Slave
Active or Master Active” modes. Touch the “Enter” button to toggle
between master and slave.
USE FACTORY DEFAULT
SERIAL PORT SETUP
SOFTWARE VERSION
SLAVE ADDRESS SETUP
MASTER ACTIVE
MASTER ACTIVE
5. Use the “Arrows” to scroll to the “Serial Port” menu to highlight it,
then touch “Enter”.
USE FACTORY DEFAULT
SERIAL PORT SETUP
SERIAL PORT SETUP
SOFTWARE VERSION
SLAVE ADDRESS SETUP
MASTER ACTIVE
6. Use the “Arrow” button to scroll to each selection to configure the

MODBUS values for your application.
BAUD RATE
PARITY
PARITY
DATA BITS
STOP BITS
7. When finished, touch “Menu” to return to the previous screen.

Murphy PowerView
SAE J1939 MurphyLink System Implementation of J1939 Parameters

Source: SAEJ1939-71 Surface Vehicle Recommended Practice
SAE J1939 Section Description PGN Parameter Display Value
5.3.6 Elec Eng Cont #2 - EEC2 61443 Accelerator Pedal Position THROTTLE
Percent Load at Current RPM LOAD@RPM
5.3.7 Elec Eng Cont #1 - EEC1 61444 Actual engine % torque ENG TORQ
Engine Speed ENG RPM
5.3.14 Vehicle Distance 65248 Trip Distance TRIP DIST
Total Vehicle Distance VEH DIST
5.3.19 Engine hours, Revolutions 65253 Total Engine Hours ENG HRS
5.3.23 Fuel Consumption 65257 Trip Fuel TRIP FUEL
Total Fuel Used FUEL USED
5.3.28 Engine Temperature 65262 Engine Coolant Temp COOL TEMP
Fuel Temperature FUEL TEMP
Engine Oil Temperature OIL TEMP
Engine Intercooler Temperature INTC TEMP
5.3.29 Engine Fluid Level/Pressure 65263 Fuel Delivery Pressure FUEL PRES
Engine Oil Level OIL LVL
Engine Oil Pressure OIL PRES
Coolant Pressure COOL PRES
Coolant Level COOL LVL
5.3.31 Cruise Control /Vehicle Speed 65265 Wheel Based Vehicle Speed VEH SPD
5.3.32 Fuel Economy 65266 Fuel Rate FUEL RATE
Instantaneous Fuel Economy FUEL ECON
Average Fuel Economy AVG ECON
5.3.35 Ambient Conditions 65269 Barometric Pressure BARO PRES
Air Inlet Temperature AIR IN TP
5.3.36 Inlet/Exhaust Conditions 65270 Boost Pressure BST PRES
Intake Manifold Temp MANI TEMP
Air Filter Differential Pressure AIR DIF PR
Exhaust Gas Temperature EXH TEMP
Alternator Voltage ALT VOLT
5.3.37 Vehicle Electrical Power 65271 Electrical Potential (Voltage) SYS VOLT
Battery Pot. Voltage (Switched) BAT VOLT
5.3.8 Electronic Transmission Controller #2 61445 Selected Gear SLECT GEAR
61445 Current Gear CURNT GEAR
5.3.38 Transmission Fluids 65272 Transmission Oil Pressure TRAN PRES
Transmission Oil Temperature TRAN TEMP
5.3.46 Engine Fluid Level/Pressure #2 65243 Injector Metering Rail 1 Pres INJ PRES1
Injector Metering Rail 2 Pres INJ PRES2
5.3.58 Fan Drive 65213 FAN SPD
5.3.111 Auxiliary Pressures & Temperatures 65164 Auxiliary Temperature AUX TEMP
Auxiliary Pressure AUX PRES
65226 DM1 - Active Diagnostic SRVCCODE
Diagnostic Messages 65227 DM2 - Previously Act Diag Codes STORCODE
65228 DM3 - Diagnostic Clear
J1939 N/A Machine Hours (PowerView Calculated) N/A Machine Hours MACH HRS
5.3.17 Engine Conf. 65251 Engine Configuration ENG CONF
Electronic Transmission Controller #1 61442 Output Shaft Speed OUT SFT SP
5.3.5 Electronic Transmission Controller #1 61442 Input Shaft Speed IN SFT SPD
Electronic Transmission Controller #1 61442 Torque Converter Lockup Engaged TORQ LOCK

Murphy PowerView
GLOSSARY (Troubleshooting information)
CANBUS FAILURE
PowerView has not received any CAN messages for at least 30 seconds.
NO DATA
PowerView has not received the particular message being displayed for
at least 5 seconds.
NOT SUPPORTED
PowerView has received a message from the ECU stating the displayed
message is not supperted.
DATA ERROR
PowerView has received an error message from the ECU for the dis-
played message.
EMPTY
No parameter selected for this 4-UP quadrant.
WAIT TO START PREHEATING

This is a message from the engine indicating it is in a preheating cycle.
Wait until this message clears before starting the engine.
TIMEOUT ECU NOT RESPONDING

The ECU did not respond to the PowerView request.
NO GAGE DATA
The PowerView has no record of connected gages to the RS485 bus.

Foremost Shock Sub

Foremost Shock Sub

Foremost Shock Sub

Foremost Shock Sub

Foremost Shock Sub

Foremost Shock Sub

Foremost Shock Sub

Foremost Shock Sub

Section 8
Lubrication and Preventative Maintenance
NOTE This section contains recommended procedures and instructions which personnel
will need in order to properly perform necessary lubrication and preventive mainte-
nance. This information should be considered as the manufacturer's recommenda-
tions only and are based upon normal operation. For severe or unusual conditions
the recommended lubrication instructions should be varied in accordance with ex-
tended hours of operation, climate and drilling conditions.
Lubrication and Preventative Maintenance 8-1

Notes
8-2 Lubrication and Preventative Maintenance

Service Points–Mainframe
In most cases lubrication points on the drill will be connected to the auto lube system (if used), or will
be connected to lubrication lines from a remote lube bulkhead (manual lube system).
Auto Lube System

The auto lube system consists of an air powered pump assembly which is fitted to 120 lb. (54 kg.)
grease container (Fig. 8-1). The pump supplies grease under pressure (2500 PSI [172 bar]) to manifolds
containing injectors which supply grease to points required. A filter/regulator/lubricator supplies 90–100
PSI (6.2–7 bar) to the pump.
The system is controlled by a lube & sensor controller mounted in the operator's cab. The controller
controls the lubrication system and also will verify delivery of lubricant into a bearing. See Section 10 in the
Service Manual for component service information.
Auto Lube System

Description No. of Lube Points
Mast Crown Sheaves 2
Mast Lower Sheaves 2
Pipe Rack Bearing–Upper 1
Pipe Rack Bearing–Lower 1
Carousel–Upper 1
Carousel–Lower 1
Pipe Rack Roller 1
Mast Pivot Pins 2
Mast Elevating Cylinders 4
Rear Axle 2
Front Axle–Center 1
Front Axle–Ends 2
Jacks–Rear 2
Jacks–Front 2
Fig. 8-1 Auto Lube Pump and Grease
Container Regulator
Lubricator
Fig. 8-2 Auto Lube Pump Water
Controller in Cab Trap
Fig. 8-3 Auto Lube Regulation

Central Lube System
Fig. 8-4 Lube Point Locations
NOTE Lubrication points may vary by location and/or quantity based upon drill model.

Manual Lube System
Manual Lube System

R.H. Pump Drive Mount (11) Points
Jacks–Front 2
Jacks–Rear 2
Front Axle 3
Rear Axle 2
Lower Mast Raise Cylinder 2
Mast (16) Points

Upper Mast Raise Cylinder 2
Mast Pivot 2
Pulldown Sheaves 4
Pipe Rack Bearings 4
Pipe Rack Roller 1
Rotary Air Swivel 1
Mast Lock 2
PUMP DRIVE MOUNT-DUST COLLECTOR SIDE
LOWER LEFT ELEV.

LEFT REAR JACK
LEFT REAR AXLE
LOWER RIGHT ELEV.
UPPER LEFT ELEV.
RIGHT REAR JACK UPPER LEFT SHEAVE
UPPER RIGHT SHEAVE
RIGHT REAR AXLE UPPER CAROUSEL
LEFT FRONT JACK UPPER PIPE RACK
UPPER RIGHT ELEV.
LEFT FRONT AXLE RIGHT MAST PIVOT
LOWER RIGHT SHEAVE
RIGHT FRONT JACK RIGHT MAST LOCK
RIGHT FRONT AXLE CAROUSEL ROLLER
ROTARY AIR SWIVEL
FRONT AXLE CENTER CAROUSEL LOCK BOTTOM PLATE
LOWER PIPE RACK
LOWER LEFT SHEAVE
LEFT MAST LOCK
LEFT MAST PIVOT
NOTE: ROTATED 90° FOR CLARITY
Fig. 8-4a Manual Lube Bulkhead Locations

Service Points
ENGINE AIR FILTER
ENGINE COOLANT FAN DRIVE
COMPRESSOR
AIR CLEANER
COMPRESSOR
OIL FILTER
COMPRESSOR AIR/OIL
SEPARATOR TANK
DRIVE SHAFT DIESEL ENGINE

ENCLOSURE
FUEL FILL
PUMP DRIVE
CHARGE FILTER CHARGE FILTER
(LOOP FILTERS OPTIONAL) (LOOP FILTERS OPTIONAL)
DUST COLLECTOR RETURN FILTERS

FILTERS
HYDRAULIC
OIL TANK
PRESSURE/VACUUM
FILTER
PIPE
CAROUSEL WINDOW
WASHER
BOTTLE
Fig. 8-5 Service Points

Service Points
ROTARY DRIVE
BATTERY BOX
TRACK FINAL DRIVE

HYDRAULIC OIL
FILLER PUMP
A/C UNIT
Fig. 8-6 Service Points

Lubrication–General
Recommended lubrication instructions provided herein are based upon normal opera-
tion, and should be varied in accordance with other than normal operating conditions.
After lubrication and filling, remove excess spills. Always keep fittings, caps and fill
plugs clean of foreign matter.
Equipment Lubrication
Determination of when oil changes are made, filters and filter elements are to be cleaned and/or replaced,
and lubrication of equipment is required, should be based on the severity of operation.
Equipment photo's and drawings have been included to show the general location of points and equip-
ment which require scheduled and periodic lubrication. The lubrication charts list the various lube and check
points, filters and filter elements, and provides data such as quantities, types of lubricants recommended,
and the recommended frequency of lubrication.
Care of Lubrication Points

Before lubricating, or filling hydraulic fluids, the fittings, caps, and filler plugs should be thoroughly
cleaned to prevent contamination.
NOTE For additional lubrication information, refer to vendor manuals provided with the drill.

Lubrication and Maintenance Chart
C/A = Check/Add if required
Interval Service Point Service Required Lubricant Required 5 Capacity

Engine Oil C/A (Cummins QST30) 15W-40 (factory fill) 35 gal. (133 L)
C/A (Cummins QSK19) 15W-40 (factory fill) 16 gal. (60.6 L)
C/A (Cat C27) 15W-40 (factory fill) 19 gal. (72 L)
C/A (Cat C15) 15W-40 (factory fill) 10 gal. (38 L)
Fuel Tank C/A Diesel Fuel 1 varies by model
Fuel/Water Separator Drain water ––––– –––––
Engine Coolant 2 C/A (QST30 engine only) 50/50 Anti-freeze/Water 23 gal. (85 L)
C/A (QSK19 engine only) 50/50 Anti-freeze/Water 11.1 gal (42.2 L)
C/A (C27 engine only) 50/50 Anti-freeze/Water 14.5 gal (55 L)
C/A (C15 engine only) 50/50 Anti-freeze/Water 5.4 gal. (20.8 L)
Hydraulic Oil Tank C/A Chevron AW MV ISO 32 3 223.5 gal. (846 L)
Separator Tank (low press) C/A Dexron III ATF (factory fill) 58 gal. (220 L)
Separator Tank (high press) C/A Dexron III ATF (factory fill) 35 gal. (132.5 L)
Water Tank (optional) C/A Water/Anti-freeze varies by model
Pump Drive Gearcase C/A 80W-90 Gear Oil 6.75 qt. (6.4 L)
Daily Air Cleaners Check Service Indicators ––––– –––––
or Oil Filters Check Service Indicators 4 ––––– –––––
Each Radiator & Coolers Check/Clean ––––– –––––
Shift Shock Sub & Air Swivel Lubricate NLGI No. 2 Grease as required
Tracks, Rollers, Sprockets Check/Clean ––––– –––––
Track Frames, Axles, Mounts Inspect Integrity/Damage ––––– –––––
Mast & A-Frame Inspect Integrity/Damage ––––– –––––
Cab Mountings Inspect Integrity/Damage ––––– –––––
Deck & Surrounds Inspect Integrity/Damage ––––– –––––
Rotary Head & Motor(s) Check for leaks & loose bolts ––––– –––––
Pulldown/Hoist Ropes Inspect ––––– –––––
Pulldown Sheaves Check they are getting grease ––––– –––––
Grease Pump Lubricator Top Up NLGI No. 1 Grease –––––
Pipe Thread Lubricator Top Up NLGI No. 2 Grease 9 –––––
DTH Hammer Reservoir 7 Top Up Rock Drill Oil - Grade 30 15 gal. (57 L)
Fire Suppression System Charged ––––– –––––
Fire Extinguisher Charged/Secure ––––– –––––
Operating Controls Check for correct function ––––– –––––
Walk Around Inspection Check for leaks, damage, etc ––––– –––––
Cooler Fan Check/Torque mounting bolts ––––– –––––
Hydraulic Filters Initial Change, then every 500 hrs ––––– –––––
Coolant Filter (if equipped) Initial Change, then every 500 hrs ––––– –––––
Separator Tank (low press) Initial Change, then every 300 hrs Dexron III ATF 58 gal. (220 L)
Weekly Separator Tank (high press) Initial Change, then every 300 hrs Dexron III ATF 35 gal. (132.5 L)
or Compressor Oil Filter Initial Change, then every 250 hrs ––––– –––––
50 Hrs Rotary Drive Gearbox C/A 80W-90 Gear Oil 20 gal. (75.5 L)
Water Pump (vertical) Initial Change, then every 3 mnths 80W-90 Gear Oil 1 qt. (.95 L)
Water Pump (horizontal) Initial Change, then every 300 hrs ISO 68 42 oz. (1.26 L)
Track Final Drive Gearbox 6 Initial Change, then every 1000 hrs 80W-90 Gear Oil 2.1 gal. (8 L)
PLUS ALL ITEMS LISTED IN DAILY SERVICE


Winch IInitial Change at 24 hours of winch 80W-90 Gear Oil 1/2 to 2 pints
operation (.24 to .95 L)
Compressor Oil Filter Change ––––– –––––
Engine Oil & Filter Change at 250 hours 15W-40 (factory fill) see daily
Engine Fuel Filter(s) Replace ––––– –––––
Engine Air Filter (primary) Replace ––––– –––––
Engine Air Filter (safety) Check ––––– –––––
Engine Coolant Check/Refill/Test Water/Anti-Freeze 50/50 see daily
Engine Coolant Filter Replace ––––– –––––
Radiator Cap Check Condition/Test ––––– –––––
Batteries Clean/Top Up Distilled Water –––––
150 to Fuel Tank Drain Water ––––– –––––
250 Comp. Air Filter (primary) Replace ––––– –––––
Hrs Comp. Air Filter (safety) Check ––––– –––––
Comp. Receiver Tank Drain Water ––––– –––––
Receiver Tank C/A Oil Dexron III –––––
Comp. Main Oil Filter Replace ––––– –––––
Comp. Control Cyl. Orifice (HP) Clean ––––– –––––
Comp. Control Regulator (HP) Check/Adjust ––––– –––––
Press. Control Regulators (HP) Check/Adjust ––––– –––––
Pump Drive Gearbox (Cotta) C/A 80W-90 Gear Oil 6.75 qt. (6.4 L)
Rotary Drive Gearbox Drain & Replace Oil 80W-90 Gear Oil 20 gal. (75.5 L)
Rotary Drive Spindle Check Pre-Load (0.002–0.004 in.) ––––– –––––
Rotary Head Wearpads Check/Replace (shim as required) ––––– –––––
Water Pump Pressure Check, LP=150 PSI (10 bar) ––––– –––––
HP=375–400 PSI (26–28 bar)
Water Pump Oil Level C/A see 50 hrs see 50 hrs
Water Pump Strainer Clean ––––– –––––
Water Pump Coupling Check ––––– –––––
Air Conditioner Belt Check/Adjust ––––– –––––
Alternator Belt Check/Adjust ––––– –––––
10
Mast Pivot Pins/Bushings Inspect/Lube NLGI No. 2 Grease –––––
Hoist/Pulldown Ropes Check/Adjust per Service Manual ––––– –––––
Track Chains Check/Adjust per Service Manual NLGI No. 2 Grease –––––
PLUS ALL ITEMS LISTED IN DAILY & 50 HRS SERVICE
Water Pump (horizontal) Change Oil ISO 68 42 oz. (1.26 L)
300 (500 hrs if using special Cat oil)
Hrs Separator Tank8 Change Oil Dexron III ATF see daily
PLUS ALL ITEMS LISTED IN DAILY/50/150–250 HRS SERVICE


Hydraulic Fluid Initial Change, then every 1000 hrs Chevron AW MV ISO 32 3 223.5 gal. (846 L)
Hydraulic Filters Replace ––––– –––––
Engine Air Filter (safety) Replace ––––– –––––
Engine Crankcase Breather Check/Clean ––––– –––––
Comp. Control Air Filter Replace ––––– –––––
Comp. Air Filter (safety) Replace ––––– –––––
Air Filter Housings Clean ––––– –––––
500 Pump Drive Gearbox Drain/Replace Oil 80W-90 Gear Oil 6.75 gal. (6.4 L)
Hrs Water Pump (vertical) Change Oil (every 3 months) 80W-90 Gear Oil 1 qt. (.95 L)
Water Injection Pump Strainer Replace ––––– –––––
Dust Collector Check Timer Cycle ––––– –––––
(3.2 sec. between pulses)
Check air pressure ––––– –––––
(approx. 40 psi [2.8 bar])
Air Conditioner Filter Replace ––––– –––––
Winch Drain Gear Oil/Replace 80W-90 Gear Oil 4 pints (1.9 L)
Rotary Drive Spindle Check–adjust as necessary ––––– –––––
PLUS ALL ITEMS LISTED IN DAILY/150–250/300 HRS
1000 Track Final Drive Gearbox 6 Drain/Replace 80W-90 Gear Oil see daily
Hrs or Hydraulic Tank Drain, Clean, Replace Oil Chevron AW MV ISO 32 223.5 gal. (846 L)
Yearly
PLUS ALL ITEMS LISTED IN DAILY/150–250/300/500 HRS
2000 Comp. T-Tank Separator Replace ––––– –––––
Hrs Comp. Return Strainer Replace ––––– –––––
or Engine Coolant Drain/Flush/Replace Water/Anti-freeze 50/50 see daily
Two All Pump Pressure Settings Check/Adjust per Service Manual ––––– –––––
Years All Valve/Other Settings Check/Adjust per Service Manual ––––– –––––
PLUS ALL ITEMS IN DAILY/150–250/300/500/1000 HRS
NOTES:
1. No. 1-D or No. 2-D diesel fuels as listed in ASTM D975 are acceptable fuels.
2. Distilled water or deionized water is recommended for use in engine cooling systems. Do not use hard water,
softened water that has been conditioned with salt or sea water. Use a 1:1 mixture of water/glycol for opti-
mum performance.
3. Chevron AW MV ISO 32 is the standard factory fill for hydraulic fluid. Other fluids may be used if they meet
the specifications listed in this section.
4. Indicators may show change or by-pass when fluid is cold; reset and check again.
5. For severe operating conditions (extreme cold or tropical), use appropriate viscosity of lubricants or use fully
synthetic lubricants as shown on the Cold Weather Lubricants chart is this section..
6. Tropical conditions require initial change at 50 hours then every 250 hours.
7. Optional for use with down-the-hole hammer.
8. See compressor oil lubrication chart for alternate oils and change intervals.
9. Lithium Base with 3% Molydbenum Disulfide.
10. Replacement of the retaining pins is recommened whenever mast raise/lower cylinder is removed or re-
placed.

Lubricant Specifications
Hydraulic System
Selection of Hydraulic Oil
These selections assume "normal operating conditions" as expected in quarry or quarry-like opera-
tions.
Hydraulic oils meeting the following specifications will be acceptable for use in the drill. Machines are
factory filled with ISO 32 oil, unless specified otherwise when ordered. Consult manufacturer before switch-
ing to an oil of different viscosity.
CHEVRON AW MV or EQUAL
ISO Grade 15 32 46 68 100
CPS Number 232953 255678 255679 232952 232950
API Gravity 27.3 32.6 31.9 30.9 30.7
Viscosity, Kinematic
cSt at 40oC 15.8 30.4 43.7 64.6 95.0
cSt at 100oC 4.0 6.1 8.0 10.6 13.5
Viscosity, Saybolt
SUS at 100oF 85.3 155 222 329 487
SUS at 210oF 39.7 46.6 53.0 62.3 73.4
Viscosity Index 159 153 157 154 143
oC (oF)
Pour Point, -54 (-65) -48 (-54) -42 (-44) -42 (-44) -39 (-38)
oC (oF),
Flash Point, min. 150 (302) 190 (374) 186 (367) 212 (414) 232 (450)
Oxidation Life
ASTM D 943 hr.1 _ 3000+ 3000+ 3000+ 2000+
DO NOT use these products in high pressure systems in areas subject to fire hazard.
1
6000+ hours for IS0 32, 46 & 68 from the West Coast (Richmond, El Segundo and Willbridge).
NOTE Diesel fuel or kerosene used as dilutants for cold weather operation are not recom-
mended, as they are not sufficiently refined products. Do not use any fire resistant
fluids or non-petroleum oils without consulting the manufacturer.
Hydraulic Tank Capacity
Model Capacity Notes

MD6290 223.5 gal. (846 L) Fluid level should be at the half-way point on the
sight gauge on the tank, when all cylinders are
fully extended.
MD6290 178 gal. (674 L)
Fluid level should be near the top of the sight
gauge, when all cylinders are fully retracted.

Compressor Lubrication
The chart below lists manufacturer approved oils.
Ambient
Temperature Lubricant Change Interval Hours
Range oF (oC)
-20 to 120 (-29 to 49) Sullair AWF 1200
10 to 110 (-12 to 43) *D-A Torque Fluid 300
0 to 100 (-18 to 38) SAE 10W SE, SF, SG, CD 300
0 to 100 (-18 to 38) MIL-L-2104E 10W 300
* Product of D-A Lubricant® Company Inc.
Ambient Change Interval Hours

Temperature Lubricant
Range oF (oC) 250 to 300 PSIG 350 PSIG
(1724 to 2068 kPa) (2413 kPa)
-20 to 120 (-29 to 49) Sullair AWF 600 500
-20 to 100 (-29 to 38) Dexron III ATF 400 300
-20 to 100 (-29 to 38) Mobil SHC-624 1200 1000
0 to 100 (-18 to 38) Mobil SHC-626 1000 800
Compressor Lubricant Specifications

Compressor oil should conform to the following specifications:
A. Non-Detergent Turbine or Hydraulic Type Oil
Viscosity @ 100oF 160–200 SSU

o
Viscosity @ 0 F 11,000 SSU Maximum
Viscosity Index 90 Minimum
o
Pour Point F 20o Lower than minimum starting temperature
o
Flash Point F 400 Minimum
Rust Inhibitor ASTM, D665-54 No Rust after 24 hours
Oxidation Inhibitor ASTM, D949-54 Neutral No. 2.0 or less after 1000 hours
Anti-Foam Inhibitor ASTM, D892-46T, 3 cycles stability nil.
B. Automatic Transmission Fluid (ATF)
Viscosity @ 100oF 184.2 SSU

Viscosity @ 210oF 49.1 SSU
Viscosity Index 150
o
Pour Point F -40
Flash Point 390
C. Premium quality heavy-duty engine oil which meets the performance classification, letter
designation, SE or CD of SAE J183 or MIL-L-210.
Ambient Temperature Grade

o o
-10 F to 90 F SAE 10W
o
Above 90 F SAE 20W, 20

Final Drive Oil

Specifications
• Use only the lubricants listed below or oil that meets the specifications in the chart on the next
page. Unit is filled at factory with 80W-90 gear oil, unless special request is made.
• Oil must meet the specification listed on the final drive label.
o o o o
• For ambient temperatures of 50 F to 86 F (10 C to 30 C) use oil with a viscosity of
ISO-VG 150 or ISO-VG 220.
o o o o
• If ambient temperature is 14 F to 50 F (-10 C to +10 C) use an oil that is one viscosity class
lower.
o o o o
• If ambient temperature is 86 F to 122 F (30 C to +50 C) use an oil that is one viscosity class
higher.
Recommended Oils (per ISO Specifications)
ARAL Degol BG 150

Degol BG 220
AVIA Avilib RSX 150
BP Energol GR-XP 150
Energol GR-XP 220
CASTROL Alpha SP 150
Alpha SP 220
CHEVRON NL Gear Compound 150
NL Gear Compound 220
DEUTSCHE SHELL Omala EP 150
Omala EP 220
ESSO Spartan EP 150
Spartan EP 220
FINA Giran 150
Giran 220
FUCHS Renep Compound 104
GULF EP Lubricant Oil HP 150
EP Lubricant Oil HP 220
MOBIL GF 629 (Mobilgear 629)
GF 630 (Mobilgear 630)
TEXACO Meropa 150
TOTAL Carter EP 150
Carter EP 220

Final Drive Oil (cont.)
Recommended Oils (per API/MIL Specifications)
For heavy duty gearbox operation use fully synthetic oils only.

Lubricating Grease
Use SAE designation MPGM which contains 3–5% Molybdenum disulfide conforming to MIL-M-7866
and a suitable corrosion inhibitor.
From 30 to 125oF (-1 to 51.6oC) ambient use NLGI No. 2

From 10 to 100oF (-12 to 37.7oC) ambient use NLGI No. 1
From -20 to 50oF (-289 to 10oC) ambient use NLGI No. 0
From -65 to 50oF (-54 to 10oC) ambient use Mobiltemp SHC 32 synthetic
Gear Lubricant
Use any oil which meets EP gear lubricant specification MIL-L-2105C or API-GL-5 of SAE J3083C.
Lubricant Grades:
Below -10oF (-23oC) ambient use 40W
Above -10oF (-23oC) and up to 100oF (37.8oC) ambient use 80W-90 or EP90
Above 100oF (37.8oC) ambient use 85W-140
Optional: Mobil SHC 635 synthetic or equivalent (all temperature ranges)

Engine Oil (Caterpillar)

Caterpillar Diesel Engine Oil (DEO) is the preferred oil for use in Caterpillar engines. If Caterpillar DEO
multigrade is not used, use only commercial oils that meet the following classifications.
• API CH-4 multigrade oils and API CI-4 multigrade oils are acceptable if the requirements of Cat-
erpillar's ECF-1 (Engine Crankcase Fluid-1 specification) are met. API CH-4 oils and API CI-4 oils
that have not met the requirements of ECF-1 specification may cause reduced engine life.
• API CG-4 multigrade oils are acceptable for all Caterpillar diesel engines. When API CG-4 oils are
used, the oil drain interval should not exceed the standard oil drain interval for your engine.
Engine Oil Viscosities For Ambient Temperatures

o o
Viscosity Grade Min. C Max. Min. F Max.
SAE 0W-20 -40 10 -40 50
SAE 0W-30 -40 30 -40 86
SAE 0W-40 -40 40 -40 104
SAE 5W-30 -30 30 -22 86
SAE 5W-40 -30 50 -22 122
SAE 10W-30 -18 40 0 104
SAE 10W-40 -18 50 0 122
SAE 15W-40 -9.5 50 15 122
Engine Oil (Cummins)

Cummins recommends the use of oil that meets American Petroleum Institute (API) performance cat-
egories of CF-4, CG-4, CF-4/SG, or CG-4/SH.
Special break-in oils are not recommended for new or rebuilt Cummins engines. Synthetic or partially
synthetic oils can not be used during break-in period. Use standard recommended petroleum based oil for
the first drain interval. After that, synthetic oils may be used.

Extreme Weather Lubricants
The following chart lists replacement lubricants that are recommended for the temperature ranges
shown, typically in extreme cold or tropical weather operating conditions. Consult manufacturer for proper
application.
Operating Temperature
Component Description Lubricant Required Range (Ambient)
Compressor Mobil SHC 1024 Synthetic Below -20 to 100oF (-28.9 to 37.8oC)
Engine Crankcase Oil SAE 15W-40 5 to 120oF (-15 to 48.9oC)
Hydraulic Tank Mobil Synthetic ATF Below -10 to 100oF (-23 to 37.8oC)
Pump Drive Gearbox Mobil Delvac 75W-90 Synthetic -67 to 100oF (-55 to 37.8oC)
Rotary Head Mobil Delvac 75W-90 Synthetic -67 to 100oF (-55 to 37.8oC)
Undercarriage Final Drive Mobil Delvac 75W-90 Synthetic -67 to 100oF (-55 to 37.8oC)
General Grease NLGI 10 to 100oF (-12 to 37.8oC)

Lubrication Points MobilTemp SHC32 -65 to 50oF (-54 to 10oC)
Drill Rod Thread Grease Mobil CM-L NLGI 1 -30 to 350oF (-34.4 to 177oC)
Citgo Lithoplex CM1
DTH Hammer Oiler Rock Drill Oil All
Note: These recommendations are based on each systems component manufacturer's recommenda-
tions, requirements and/or manufacturer's requirements for maximum and minimum oil viscosity values
during start-up and continuous operation.

Preventative Maintenance
In order for an operator to be sure his drill is ready for operation at any time, a regular program of preven-
tive maintenance should be adopted. It is recommended that such a maintenance program be established
on the basis of the operator and/or maintenance personnel performing specific maintenance work during
various periods of equipment operations, at intervals during which the equipment will be idle, and during
extended periods of time when the equipment will be in storage.
When the drill is in continual, daily use, it is further recommended that a program of daily service re-
quirements be established with preventive maintenance being performed on a "before operation", "during
operation", and "after operation" schedule.
NOTE For additional preventive maintenance information, refer to vendor manuals provided
in the drill Service Manual.
Mast Trunnion Bolt Torque

Model Dry Torque Lube Torque
MD6290 1820 ft. lbs. (2468 Nm) 1360 ft. lbs. (1844 Nm)
1-1/4-7 UNC Gr8 (4)
MD6240 3160 ft. lbs. (4284 Nm) 2360 ft. lbs. (3200 Nm)
1-1/2-6 UNC Gr8 (4)
Fig. 8-7 Mast Trunion Assembly
Check Torque
NOTE See additional bolted joint maintenance guidelines in this section.

Preventive Maintenance
Fig. 8-8 Hydraulic Tank Oil Level and

Temperature Gauge
Charge and Loop Filters Fig. 8-9 Hydraulic Loop Filter–Two filters
The charge and loop filters have an o-ring that mounted on each side of mast "A" frame.
helps seal the filter bowl. If the bowl is leaking the
o-ring should be replaced. Do not continue to
tighten the bowl up, because this will not stop the
leak and will lead to damage of the bowl and filter
assembly. The o-ring should be changed every time
the filter is changed.
The filters have a differential indicator and a
bypass check valve to indicate when the filter is
blocking, allowing time to change the filters before
they are fully blocked.
Fig. 8-10 Hydraulic Pump Charge Filter–One filter

mounted on each side of pump drive.
1. Head Assembly
2. Bowl
3. O-Ring, Bowl
4. Filter Element
5. O-Ring, Element
6. Indicator
7. O-Ring, Indicator
8. O-Ring, Indicator
9. Bleed Plug
10. O-Ring, Bleed Plug

Hydraulic System Maintenance
The hydraulic components of the drill are built for many years of trouble-free operation. Only one pre-
ventive maintenance step is necessary to ensure the expected life of the system—CLEANLINESS.
When dirty filters are indicated, change the filter as follows:
• Clean the area around the filter covers to prevent dirt entering the filter housings.
• Pull filters from the housings. Install new filter and install the covers making sure the cover O-ring is
in place.
Sight gauges are provided on the sides of the tank for
checking oil levels.
• Oil level should be at the halfway point of the
sight gauge when all cylinders are extended.
• A temperature gauge is also provided on the
sight gauge.
CLEANLINESS cannot be overstressed:
• Use new oil only from previously unopened con-
tainers.
• Clean all tank openings.
• Fill tank through return filter.
Service Indicators
Compressor Lubrication Procedure
• Drain Receiver Condensate Fig. 8-11 Return Filters Mounted on Hydraulic Tank
In periods of cold weather and/or high humid-
ity, crack receiver drain valve prior to start-up to Tabbed Nut
remove water. Close when oil appears.
• Check Oil Level
The oil level is checked at the sight glass with
machine level at each shift. The machine must be
shut down long enough to permit oil foam to settle
or check before start-up at the beginning of the
shift. Oil level should be at the center of the sight
glass.
• Change Oil
Every 300 hours or as specified in compressor
lubrication chart. Use Dexron III ATF or consult
factory for specific recommendations if extremely
severe duty is encountered. Change oil filter ele-
ment.
• Lubricate control and linkage. Clean oil return line
strainer.
Compressor Oil Filter
• Blocked filter indicator will pop up red if the ele-
ment needs changing.
• If the filter bowl is leaking, the O-ring needs to be Fig. 8-12 Compressor Oil Filter
changed. Flogging up the tabbed locking nut will
not stop the leak.
Preventative Maintenance
Winch Lubrication
• Check oil level every 3 months or 500 operating hours whichever occurs first. Remove the large
plug located in the center of the drum support. Oil level should be at the bottom of this opening.
• Gear housing should be drained and filled with new oil after the first 100 hours of operation. Then
oil should be changed every 1000 hours of winch operating time or every six (6) months, whichever
occurs first.
• Remove and clean vent plug in solvent every time oil is changed. Vent plug must be kept clean and
free from obstructions.
• The standard factory fill from Braden for the BG8 winch is Texaco Meropa150. Other oils may be
used if they meet the following specifications: Do not mix different kinds of oil.
AGMA 4EP or API GL-2 with ISO viscosity grade 150.
The following are recommended oils:
Texaco Exxon Mobil Shell Chevron
Meropa 150 Spartan EP 150 Mobilgear 629 Omala 150 American Industrial Oils 150
Meropa 220 Spartan EP 220 Mobilgear 630 Omala 220 American Industrial Oils 220
NOTE: All gearcases are factory filled with Mobillube SCH 75W-90 Synthetic gear lube for cold weather operation.
Water Pump (Cat Pump)

The Cat Pump, Model 1050 is factory filled with Mobil SHC 626. This is suitable for temperatures below
0oF (-17.8oC). Special oil is available from Cat Pump dealers. If another type oil is used, be sure it meets
the specifications for Cat Pumps.
• Fill with oil to red dot in sight window on back of pump (Fig. 8-13).
• Lubricate the wicks monthly with 2-3 drops of oil in each hole on top of the crankcase (Fig. 8-14).
DO NOT lubricate the wicks at initial start-up. Operate pump for 10–15 minutes, then lubricate the
wicks. Use crankcase oil as lubricant.
Fig. 8-13 Cat Pump Oil Level Sight Window Fig. 8-14 Cat Pump Oil Filler Cap
(back of pump) and Wick Lubrication Points

Remove the radiator pressure cap slowly and only when the engine is cool or serious
burns could result.
Cooling System–Cummins
The engine's cooling system is designed to provide adequate cooling during all normal operating con-
ditions. Engine overheating can become the primary cause for extensive repair work, lost operating time,
and possibly result in eventual complete engine failure. Cooling system maintenance should, therefore,
hold an important place in the drill maintenance program.
The engine cooling system is filled with a 50/50 mix of anti-freeze and water. Refer to engine operating
manuals for complete cooling system specifications and maintenance. The Cummins QST30 is equipped
with two coolant filters (Fig. 8-15). These are to be changed every 250 hours of operation. Cooling system
is to be drained, flushed, and refilled every 2 years, or 6000 hours of operation, whichever occurs first. Cum-
mins recommends filling system with Fleetguard® Compleat, a fully formulated anti-freeze which contains
supplemental coolant additive
Every 250 Hours: Change Coolant Filters
1. Turn valve to OFF position, and remove filters.

2. Clean mounting base and be sure old gasket is not stuck to it.
3. Apply a thin film of oil to the gasket and install new filters. Screw filter on until gasket contacts
base, then tighten 1/2 to 3/4 turn by hand. Turn valve to ON position.
Fig. 8-15 Cummins QST30 Engine–right side Fig. 8-16 Engine Radiator
1. On/Off Valve
2. Coolant Filters
Cooling System–Caterpillar
Caterpillar recommends the following coolant types:
• Preferred–Caterpillar Extended Life Coolant (ELC) or a commercial extended life coolant that
meets the Caterpillar EC-1 specification.
• Acceptable–Caterpillar Diesel Engine Antifreeze/Coolant (DEAC) or a commercial heavy-duty
coolant/antifreeze that meets ASTM D4985 or ASTM D5345 specifications.

Supplemental Coolant Additive (SCA)
Cummins recommends DCA4 as the supplemental coolant additive. DCA4 is compatible with all type
of coolant except Methoxy Propanol. Supplemental coolant additive prevents the buildup of corrosion and
scale deposits in the cooling system. The correct concentration is 1.5 units for each gallon (3.8 L) of cool-
ant. Concentration must never drop below 1.2 units, nor exceed 3 units per gallon (3.8 L).
If coolant is added between drain intervals, the SCA concentration must be checked, and added, if
required. A coolant test kit no. CC2626 is available from Cummins dealers.
When the system is initially filled, the correct amount of liquid SCA is added to make 1.5 units of SCA
per gallon (3.8 L) of coolant. In this case, total system capacity is 71 gallons (269 L), so 47.3 SCA units are
required. When changing coolant filters at 250 hours, normally 4 SCA units will bring the system up to the
required amount. Filters contain SCA in crystal form that dissolves in the system. Filters come in 2, 4, 6,
8, 12, 15, and 23 SCA units. A filter is also available with no SCA units.
At each filter change, check the system with a Cummins coolant test kit. This kit contains strips, to dip
in the coolant that will determine the SCA level. If additional SCA is required, add liquid SCA to bring up to
correct concentration.
Air Cleaners
The air cleaner should be inspected periodically
to maintain engine and compressor protection and
maximum service life. These inspections should
include the following points:
1. Inspect the air transfer duct between the air
cleaner and the engine to be sure all clamps
are tight, all flange joints are tight, and there
are no cracks in the ducting.
2. Air cleaner mounting bolts and clamps must
be tight to hold the air cleaner securely.
3. Check the dust cup to make sure it is seal-
ing 360o around the air cleaner body.
4. Vacuator valve must be in place, not invert-
ed, and free from obstruction.
5. Check for dents and damage to the air Fig. 8-17 Air Cleaner Assembly
cleaner which could mean a leak.
Air Filter Elements

Replace air filter elements as required per maintenance schedule, or when indicated by pressure dif-
ferential indicator on filter.
DO NOT clean filter element with high pressure air (30 PSI maximum). Advise replace-
ment of filter element.
DO NOT start engine when the filter element(s) is removed from the air cleaner
NEVER attempt to clean the element by rapping it. Rapping the element will dent the
metal covering. The inner paper element will in turn rub this dent, causing the element to
puncture.

Track Final Drive Gearbox

Recommended Service for F130 Gearbox
Oil Change
1. See Lubrication and Maintenance Chart in this section.
Oil Analysis
1. Oil analysis should be performed on a regular basis (example: quarterly).
2. Particle ppm levels should be compared to Warning Level Guidelines below and necessary actions
should be taken.
3. Upon high Fe-Cr contamination levels, the sun gear/input shaft should be inspected for wear and
replaced as necessary. If the sun gear is ok, further internal gearbox inspection should be per-
formed.
Sun Gear
1. The sun gear/input shaft should be changed out upon initial wear indication.
2. The sun gear/input shaft generally has the highest wear rate and needs to be replaced periodically
to prevent other gearbox component failures. It is suggested that a maintenance program should
consider replacing the sun gear at 6,000–8,000 machine hours.
Warning Level Guidelines for Contamination and Wear Metals
Normal Caution Serious
Si (Silicon) 200 ppm >400 ppm >600 ppm
Fe (Iron) 500 ppm >1500 ppm >3000 ppm
Cu (Copper) 80 ppm >160 ppm >240 ppm
Cr (Chromium) 10 ppm >15 ppm >25 ppm
Al (Aluminum) 50 ppm >100 ppm >150 ppm
Caution: In this case the gearbox must be kept under control.

Serious: In this case the gearbox manufacturer suggests changing the oil and repeating the tests after
a short period of work. If the values are still serious, the manufacturer suggests rebuilding or
replacing the gearbox.
These values are only guidelines and can be modified due to specific applications.
Notes:
Si-Al Contamination also from external sources
Fe-Cr Wear metals by gears and bearings
''Cu Wear metal be brake discs

Preventative Maintenance–Mast Pivot
Mast Pivot Shaft Inspection and Repair Procedure
A visual inspection should be performed with the SHAFT DETAIL
mast in the horizontal position by removing the trunnion
cap and bushing. Clean the shaft and shoulder radius
free of lubricant and inspect visually for any indication
of cracking in the radius. Perform visual inspection at
the mid point of non-destructive test (NDT) interval #1
and #2.
Intervals for magnetic particle inspection will be in
accordance with AS1171 or a dye penetrant test, post
repair. Same inspection intervals apply to new machines
or replaced shafts. Intervals are operating hours on
shaft.
MD6240
Interval #1
<15,000 Hours
Inspect every 3000 Hours
Interval #2
>15,000 Hours but <25,000 Hours MD6290/MD6420
Interval #1
Interval #3
<15,000 Hours
>25,000 Hours
Interval #2
SHAFT DETAIL RO.25 ORIGINAL RADIUS >15,000 Hours but <30,000 Hours
Interval #3
RO.38 MAXIMUM RADIUS >30,000 Hours
30˚ MAX ANGLE
Approved Pivot Shaft Repair Procedure

Fatigue cracking in the A-Frame pivot shaft radius of rotary blashole drills may be repaired by completely
grinding out cracks up to a maximum depth of 0.12 in. or 3mm. This approved repair method is intended
only to extend the service life of a shaft that is in the first stages of fatigue where the cracking is not exten-
sive and is just becoming visible. Shafts with more extensive cracking, i.e. crack depths exceeding 0.12 in.
(3mm) should be replaced by removing the shaft from the A-Frame structure and rewelding a new shaft in
place in accordance with the factory repair procedure.
Unapproved Repair
No grinding that undercuts the diameter of the bearing
surface is allowed. Cracking outside of the hatched area
is not repairable by grinding and requires replacement of
the shaft. All known fatigue cracking has occured in the
hatched area. NON-REPAIRABLE
FATIGUE CRACK
Preventive Maintenance–Weld Inspection
Rev A

Preventative Maintenance–Bolted Joints
Bolted Joint Maintenance for Rotary Drills
Introduction
To properly maintain bolted joints, some technical understanding of threaded fasteners will be helpful.
Threaded fasteners are often taken for granted and are seldom viewed as the highly engineered
items that they are. Their proper selection and proper joint design are critical to ensure structures and
machine elements perform as intended. This is a detailed subject and what is intended here, is to
present a few highlights to assist with good maintenance practices for rotary drills. This guide is not
all inclusive.
Proper Bolt Tension
Proper “Preload” or residual tension in a tightened bolt means more to assembly strength than
actual bolt strength. In a bolted joint, a bolt torqued to its proper load level can resist a maximum
amount of external load without loosening. Ensuring that the intended preload is achieved and
maintained is the objective of this guide.
These rotary drills typically use SAE guidelines which are commonly recognized throughout most
industries, for non-permanent connections. All bolted joints in the drills are non-permanent joints
(bolted joints of a bridge or building structure would be considered permanent joints.) Standard SAE
torque specifications for bolt tensioning recommends that bolts be pre-tensioned to 75% of yield
strength or “Proof Load.” Bolts torqued to this level are re-useable if in good condition otherwise.
There are a couple of exceptions in these drills where bolts are tightened beyond this value, and
these will be identified. See the following chart for recommended torque values for different bolt sizes.
Reasons Properly Tensioned Bolts Loose their Preload and Require Maintenance
x Surface Degradation
Surfaces under bolt heads can degrade due to creep failure, embedment, high bearing stress,
corrosion or a combination of these. These rotary drills use hardened washers in many situations to
help prevent surfaces from degrading. Critical joints may use “Nordlock” washers which are a
hardened, zinc coated, two-piece serrated washer incorporating inclined planes at the mating
boundary of the two pieces. To loosen a bolt using this locking device, the bolt must be significantly
stretched. Critical bolted joints are identified in the “Critical Fastener ID & Inspection Schedule”
drawing in this manual. Joints that are assembled with Nordlock washers and hardened washers are
less likely to experience surface degradation, as the hardness of the washer is close to the hardness
of the fastener and is harder than the surface of most nuts used in these drill assemblies.
x Corrosion
Most critical bolted joints on these rotary drills contain components that are made from steel. Most
bolts used are also steel, and therefore susceptible to rusting. Water is a small molecule and can find
its way into the smallest spaces to attack the surfaces of a bolted joint and the bolt head, body and
threads. We recommend that all critical fasteners be lubricated using a lubricant that contains
Molybdenum Disulfide (NLGI 2 Molycoat or Never-Seize are readily available Worldwide. Good
quality NLGI 2 grease can be substituted if a Moly product is not available at the time of service.)

Preventive Maintenance–Bolted Joints
x Vibratory Overload
Abusive, unusual or unforeseen loads can cause bolted joint separation. This can result in the
loosening of bolts, which in turn can cause bolt fatigue failure. Bolt fatigue will generally result in a
fracture surface and ultimately failure at the first engaged thread of the bolt or sometimes in the fillet
under the bolt head. Loose bolts can also fail quickly in fatigue. As an example, tests conducted by a
bolt manufacturer indicated that a bolt tightened to 1420 lb tension and stressed cyclically to 9215 lb
failed after 5960 load cycles. Identical bolts tightened to 8420 lb and stressed to the same 9215 lb
survived 4.65 million cycles before failure. If the bolts had been tightened beyond 9215 lb, it would
have been impractical to cycle them to failure.
x Thermal Relaxation
Bolted joints exposed to high temperatures or thermal cycling have a tendency relax or lose bolt
tension over time, due to stress creep. Since pre-loading stretches bolts, and only stretches them a
few thousandths of an inch. It is easy to imagine that a bolt heated to the operating temperature limits
of an air compressor could increase the plasticity of the bolt material, allowing it to lose some of its
initial loading. Bolted joints of a new machine that are subjected to high heat should be checked and
re-torqued to specification after the first 500 hours of operation.
Critical Bolted Joint Maintenance
Critical bolted joints are those joints which hold major structures together or hold overhead loads.
Failure of these joints could endanger personnel or seriously damage equipment. As stated earlier,
these are identified in the drawing “Critical Fastener ID & Inspection Schedule. We recommend that
critical bolted joints of drills should be checked for proper torque every 120 days or 2000
operating hours for machines that have less than 10,000 operating hours, and every 90 days or
1500 operating hours for machines that have greater than 10,000 operating hours.
If a bolt is found to be loose (less than 90% of specified torque value), it should be removed and
replaced. If the joint contains more than one bolt, all bolts in the joint should be replaced. The joint
mating surfaces and bolts should be inspected for signs of corrosion, surface degradation, and the
presence of hardened washers or Nordlock washers. Joints with Nordlock washers require the
replacement of the washers as well. Hardened washers can generally be reused as long as the
washer is undamaged. The new bolts should be lubricated with NLGI2 molycoat grease and torqued
to the proper specification. Bolts should be replaced with the same grade bolt that was originally in
the assembly. These drills primarily use SAE Grade 5 and Grade 8 bolts. These are identified by the
markings on the head of the bolt. Chart #1 of the drawing for each machine titled “Critical Fastener
Torque Values” graphically depicts the standard indentifying bolt markings.
Bolts in critical joints should also be removed and visually inspected for corrosion and re-
lubricate every 2.5 years or 15,000 hours of operation. If bolts are not damaged, they maybe re-
installed and returned to service. Any damaged or corroded bolts should be discarded and replaced.
In addition, bolts in critical joint should be replaced every 5 years or 30,000 hours of operation,
regardless of apparent condition.
Other Bolt Maintenance
All bolts contained in these drills are subject to the same topics described above, but generally do not
have the same degree of risk involved should a bolt failure occur. Every machine should have a
“walk-around” inspection performed at the beginning of each operating shift, which includes looking
for loose hardware. Other significant bolted joints include all pressurized fittings, flange connections
and all bolted pin retainer/keeper plate bolts. All machine bolts should be inspected for proper torque
specification annually at a minimum.

8-30
CRITICAL FASTENER ID & INSPECTION SCHEDULE
MAST RAISE/LOWER HYDRAULIC CYLINDER

PIN RETAINER FASTENERS
AFRAME PIVOT CAP FASTENERS REPLACEMENT OF THE RETAINING PINS IS
MAST PIVOT CAP FASTENERS RECOMMENED WHENEVER MAST RAISE/LOWER
CYLINDER IS REMOVED OR REPLACED. ROTARY HEAD MOUNTING FASTENERS
ROTARY HEAD WEAR PAD MOUNTING FASTENERS
LEVELING JACK CAP FASTENERS
WINCH MOUNTING FASTENERS
SEE BOLTED JOINT MAINTENANCE IN THIS MANUAL FOR ADDITIONAL

UNDERCARRIAGE MAIN AXLE FASTENERS INFORMATION CONCERNING BOTH GENERAL AND CRITICAL FASTENERS.
A CURSORY VISUAL INSPECTION SHOULD BE PERFORMED BY THE OPERATOR AT THE

START OF EACH SHIFT.
SEE MACHINE PARTS BOOK FOR PART NUMBERS
RECOMMENDED INTERVALS FOR PRE-LOAD VALIDATION BY VERIFYING FASTENER TORQUE OF SPECIFIC FASTNERS, WASHERS AND NUTS.
RECOMMENDED INTERVALS FOR VISUAL INSPECTION AND RE-LUBRICATION
RECOMMENDED INTERVALS FOR REPLACEMENT
MACHINE SERVICE HOURS:
LESS THAN 10,000 HOURS GREATER THAN 10,000 HOURS
VERIFY EVERY 120 DAYS OR 2000 HRS VERIFY EVERY 90 DAYS OR 1500 HRS
INSPECT AND RE-LUBRICATE OR REPLACE

IF DAMAGED EVERY 2.5 YEARS OR 15000 HRS

REPLACE EVERY 5 YEARS OR 30000 HRS

Standard Torque Values
SAE Recommended Torque Values
SAE Grade 5 SAE Grade 8

Tightening Torque Tightening Torque
Size Dry K=.2 Lub K=.15 Dry K=.2 Lub K=.15
(Ft lb) (Ft lb) (Ft lb) (Ft lb)
3/8-16 UNC 30 23 45 35
3/8-24 UNF 35 25 50 35
7/16-14 UNC 50 35 70 55
7/16-20 UNF 55 40 80 60
1/2-13 UNC 75 55 110 80

1/2-20 UNF 90 65 120 90
5/8-11 UNC 150 110 220 170

5/8-18 UNF 170 130 240 180
3/4-10 UNC 260 200 380 280

3/4-16 UNC 300 220 420 320
7/8-9 UNC 430 320 600 460

7/8-14 UNF 470 350 660 550
1-8 UNC 640 480 900 680

1-12 UNF 700 530 1000 740
1-1/8-7 UNC 800 600 1280 960

1-1/812 UNF 880 660 1440 1080
1-1/4-7 UNC 1120 840 1820 1360

1-1/4-12 UNF 1240 920 2000 1500
1-1/2-6 UNC 1940 1460 3160 2360

1-1/2-12 UNF 2200 1640 3560 2660

8-32
MAST RAISE/LOWER HYDRAULIC CYLINDER 3/4 - 10UNC GRD8
MAST PIVOT CAP FASTENERS 280 FT LBS LUBRICATED
PIN RETAINER FASTENERS
NOTE "NORDLOCK" WASHERS
REPLACEMENT OF THE RETAINING PINS IS
RECOMMENED WHENEVER MAST RAISE/LOWER
CYLINDER IS REMOVED OR REPLACED.
NOTE "NORDLOCK" 1/2 -13UNC GRD5

WASHERS 55 FT LBS LUBRICATED 1/2 - 13UNC BRASS
1-1/2 - 6UNC GRADE8
NOTE "NORDLOCK" 2360 FT LBS LUBRICATED 55 FT LBS (DO NOT LUBRICATE)
WASHERS NOTE "NORDLOCK" 1/2 -13UNC GRD5 USE LOCTITE
WASHERS 55 FT LBS LUBRICATED NOTE "NORDLOCK" WASHERS
1 - 8UNC GRD8 ROTARY HEAD MOUNTING FASTENERS

NOTE "NORDLOCK" 680 FT LBS LUBRICATED ROTARY HEAD WEAR PAD MOUNTING FASTENERS
WASHERS
UNDERCARRIAGE MAIN AXLE FASTENERS NOTE HARDENED 3/4 - 10UNC GRD5

WASHERS 200 FT LBS LUBRICATED
(.85 PROOF LOAD)
Critical Fastener Torque Values–MD6240
5/8-11UNC GRD5
110 FT LBS LUBRICATED
NOTES
LUBRICATE BOLTS WITH 3% MOLY NLGI2
EXTREME PRESSURE GREASE, P/N 966825
OR EQUIVALENT.
SEE MACHINE PARTS BOOK FOR PART

NUMBERS OF SPECIFIC FASTENERS,
WASHERS AND NUTS.

3/4 - 10UNC GRD8
MAST RAISE/LOWER HYDRAULIC CYLINDER 280 FT LBS LUBRICATED
MAST PIVOT CAP FASTENERS PIN RETAINER FASTENERS
NOTE "NORDLOCK" WASHERS
REPLACEMENT OF THE RETAINING PINS IS
RECOMMENED WHENEVER MAST RAISE/LOWER
CYLINDER IS REMOVED OR REPLACED.
1-1/4 - 7UNC GRADE8

NOTE "NORDLOCK" 1360 FT LBS LUBRICATED 1/2 -13UNC GRD5
3/8 -16UNC GRD5 1/2 - 13UNC BRASS

23 FT LBS LUBRICATED 55 FT LBS (DO NOT LUBRICATE)
1 - 8UNC GRD8 USE LOCTITE
NOTE "NORDLOCK" 680 FT LBS LUBRICATED NOTE "NORDLOCK" WASHERS
WASHERS
ROTARY HEAD MOUNTING FASTENERS
ROTARY HEAD WEAR PAD MOUNTING FASTENERS

UNDERCARRIAGE MAIN AXLE FASTENERS
NOTE HARDENED 3/4 - 10UNC GRD5

(.85 PROOF LOAD)
Critical Fastener Torque Values–MD6290
5/8-11UNC GRD5
110 FT LBS LUBRICATED
NOTES
LUBRICATE BOLTS WITH 3% MOLY NLGI2
EXTREME PRESSURE GREASE, P/N 966825
OR EQUIVALENT.
SEE MACHINE PARTS BOOK FOR PART

NUMBERS OF SPECIFIC FASTENERS,
WASHERS AND NUTS.
8-33
Electrical System
Be sure battery is filled and kept charged. A discharged battery will freeze at much higher temperatures
than a fully-charged battery.
Battery terminals should be kept clean and tight for dependable operation.
See engine manual for engine electronics and diagnostic codes for electronic engines.
Extended Machine Shutdown

If machine is to be shut down for a long period of time (more than 30 days), there are certain precau-
tions that should be followed to minimize the possibility of damage to the machine.
1. Position the machine in a safe place on level and solid ground. Do not park close to a high wall where
the machine would be in danger of rock fall or slides. Do not park in an area prone to flooding. Extend
the jacks to contact the ground, but the tracks should also be in contact with ground.
2. If freezing temperatures are expected, be sure cooling system has adequate anti-freeze to protect
system from freezing temperatures.
3. Check all fluid levels, keep fuel tank full to avoid condensation.
4. Follow pre-start checks in Section 4 before starting machine. Make walk around inspection of ma-
chine.
5. Start the machine at least once per month. Allow system to warm up and cycle all hydraulic cylin-
ders to their full stroke and back. Follow proper shutdown procedures, allowing engine to idle for at
least five minutes before shutdown.
Scheduled Oil Sampling Analysis

The manufacturer recommends that scheduled oil sampling be taken at regular intervals. This will
maintain all warranty requirements and monitor condition of component wear in the system.
Oil sampling must be carried out at regular intervals to serve as an effective indicator for component
wear. Intermittent oil sampling does not allow a wear pattern to be established. Samples should be taken
from the following components.
• Hydraulic Oil
• Compressor Oil
• Engine Oil
• Rotary Gearbox and Pump Drive Gearbox Oil
Sampling Criteria
• Recommended interval for oil samples is every 200 hours.

• Take samples when oil is warm and well mixed to assure an accurate reading.
• A proper oil analysis should include the following three elements:
1. Wear Analysis
2. Chemical and Physical Tests
3. Oil Condition Analysis

Drill Stem Thread Lubricator
Description and Adjustments

The drill can be equipped with an optional automatic drill string thread greasing system. The system
uses an air powered grease pump attached to a 35 lb. (15.9 kg.) grease container. The system is activated
by a switch on the drill control console, and the pump delivers grease to the nozzle mounted adjacent to
the drill stem.
Air supply is filtered, lubricated and regulated by the filter/regulator/lubricator mounted on the left rear
jack housing. Normal pressure setting is 80 PSI (5.5 bar). See Section 10 of the Service Manual for com-
ponent servcie information.
Thread Lube Pump Thread Lube Pump Regulation
Fig. 8-18 Drill Stem thread Lubricator System
Lubricator Water Trap

Metric Conversions
METRIC CONVERSION TABLE
English to Metric Metric to English
LINEAR
inches (in.) X 25.4 = millimeters (mm) millimeters (mm) X 0.3937 = inches (in.)
feet (ft.) X 0.3048 = meters (m) meters (m) X 3.281 = feet (ft.)
miles (mi.) X 1.6093 = kilometers (km) kilometers (km) X 0.6214 = miles (mi.)
AREA
inches2 (sq.in.) X 645.15 = millimeters 2 (mm 2) millimeters 2 (mm 2) X 0.000155 = inches2 (sq.in.)
feet2 (sq.ft.) X 0.0929 = meters2 (m 2) meters2 (m 2) X 10.764 = feet 2 (sq.ft.)
VOLUME
inches3 (cu.in.) X 0.01639 = liters (l) liters (l) X 61.024 = inches3 (cu.in.)
quarts (qts.) X 0.94635 = liters (l) liters (l) X 1.0567 = quarts (qts.)
gallons (gal.) X 3.7854 = liters (l) liters (l) X 0.2642 = gallon (gal.)
inches3 (cu.in.) X 16.39 = centimeters3 (cc) centimeters3 (cc) X 0.06102 = inches3 (cu.in.)
feet3 (cu.ft.) X 28.317 = liters (l) liters (l) X 0.03531 = feet 3 (cu.ft.)
feet3 (cu.ft.) X 0.02832 = meters3 (m 3) meters3 (m3) X 35.315 = feet 3 (cu.ft.)
fluid ounce (fl.oz.) X 29.57 = millileters (ml) milliliters (ml) X 0.03381 = fluid ounce (fl.oz.)
MASS
ounces (oz.) X 28.35 = grams (g) grams (g) X 0.03527 = ounces (oz.)
pounds (lbs.) X 0.4536 = kilograms (kg) kilograms (kg) X 2.2046 = pounds (lbs.)
tons (2000 lbs.) X 907.18 = kilograms (kg) kilograms (kg) X 0.001102 = tons (2000 lbs.)
tons (2000 lbs.) X 0.90718 = metric tons (t) metric tons (t) X 1.1023 = tons (2000 lbs.)
tons (long) (2240 lbs.) X 1013.05 = kilograms (kg) kilograms (kg) X 0.000984 = tons (long) (2240 lbs.)
PRESSURE
inches Hg (60 F)
o
X 3600 = kilopascals (kPa) kilopascals (kPa) X 0.2961 = inches Hg (60oF)
pounds/sq.in. (PSI) X 6.895 = kilopascals (kPa) kilopascals (kPa) X 0.145 = pounds/sq.in. (PSI)
pounds/sq.in. (PSI) X 0.0703 = kilograms/sq.cm. (kg/cm 2) kilograms/sq.cm. (kg/cm2) X 14.22 = pounds/sq.in. (PSI)
pounds/sq.in. (PSI) X 0.069 = bars bars X 14.5 = pounds/sq.in. (PSI)
o o
inches H2O (60 F) X 0.2488 = kilopascals (kPa) kilopascals (kPa) X 4.0193 = inches H2O (60 F)
bars X 100 = kilopascals (kPa) kilopascals (kPa) X 0.01 = bars
POWER
horsepower (hp) X 0.746 = kilowatts (kW) kilowatts (kW) X 1.34 = horsepower (hp)
ft.-lbs./min. X 0.0226 = watts (W) watts (W) X 44.25 = ft.-lbs./min.
TORQUE
pound-inches (in.-lbs.) X 0.11298 = newton-meters (N-m) newton-meters (N-m) X 8.851 = pound-inches (in.lbs.)
pound-feet (ft.-lbs.) X 1.3558 = newton-meters (N-m) newton-meters (N-m) X 0.7376 = pound-feet (ft.-lbs.)
pound-feet (ft.-lbs.) X .1383 = kilograms/meter (kg-m) kilogram/meter (kg-m) X 7.233 = pound-feet (ft.-lbs.)
VELOCITY
miles/hour (m/h) X 0.11298 = kilometers/hour (km/hr) kilometers/hour (km/hr) X 0.6214 = miles/hour (m/h)
feet/second (ft./sec.) X 0.3048 = meter/second (m/s) meters/second (m/s) X 3.281 = feet/second (ft./sec.)
feet/minute (ft./min.) X 0.3048 = meter/minute (m/min) meters/minute (m/min) X 3.281 = feet/minute (ft./min.)
TEMPERATURE
o
Celsius = 0.556 ( F - 32)
o o
Fahrenheit = (1.8oC) + 32
COMMON METRIC PREFIXES

mega (M) = 1,000,000 or 106 deci (d) = 0.1 or 10-1
kilo (k) = 1,000 or 103 centi (c) = 0.01 or 10-2
hecto (h) = 100 or 102 milli (m) = 0.001 or 10-3
deka (da) = 10 or 101 micro (m) = 0.000.001 or 10-6

Torque Values for Split Flange Connections
The following chart provides the tightening torques for split flange connections used in hydraulic systems.
Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then torque evenly.
NOTE Over-torquing bolts will damage the flanges and/or bolts, which may cause leakage.
Bolt Torque
Flange Size Bolt Size Newton Meter Pound-Force/Foot
in Inches (*) in Inches (Nm) (ft. lb.)
1/2 5/16 20–24 15–18
3/4 3/8 30–37 22–27
1 3/8 37–47 27–35
1-1/4 7/16 47–61 35–45
1-1/2 1/2 62–79 46–58
2 1/2 75–88 55–65
2-1/2 1/2 107–123 79–91
3 5/8 187–203 138–150
3-1/2 5/8 159–180 117–133
(*) Inside diameter of hydraulic tube or hose fitting.

Torque Values for Hydraulic Tubes & Fittings
O-Rings Boss Plugs

Tube Nuts and Swivel Nuts
for 37o Flared Fittings JIC 37o Seat
Torque Torque
Pound-
Tubing Thread Newton Newton Pound-
Force/
O.D. Size Meter Meter Force/Foot
Foot
Size in Inches in Inches (Nm) (Nm) (ft. lb.)
(ft. lb.)
4 1/4 7/16-20 14–27 10–20 8–14 6–10
5 5/16 1/2-20 20–34 15–25 14–20 10–15
6 3/8 9/16-18 34–47 25–35 20–27 15–20
8 1/2 3/4-16 54–75 40–55 34–41 25–30
10 5/8 7/8-14 75–102 55–75 47–54 35–40
12 3/4 1-1/16-12 102–129 75–95 81–95 60–70
14 7/8 1-3/16-12 129–156 95–115 95–108 70–80
16 1 1-5/16-12 156–197 115–145 108–122 80–90
20 1-1/4 1-5/8-12 203–244 150–180 129–156 95–115
24 1-1/2 1-7/8-12 271–339 200–250 163–190 120–140
32 2 2-1/2-12 407–475 300–350 339–407 250–300
NOTES:
1. Above Torque figures are recommended for plain, cadmium or zinc plated fittings, dry or wet installations.
2. Swivel nuts either swaged or braxed.
3. These torques are not recommended for tubes with wall thickness of 0.89 mm (0.035 in.) or less.

Maintenance Record
WORK WORK
DATE HOUR METER MAINTENANCE PERFORMED PERFORMED AUTHORIZED
BY BY

Maintenance Record
WORK WORK
BY BY

Maintenance Record
WORK WORK
BY BY

Maintenance Record
WORK WORK
BY BY

© 2012 Caterpillar All Rights Reserved. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,”
the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of
Caterpillar and may not be used without permission.
Printed in U.S.A.

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February 2012

IDENTIFICATION OF THE MACHINE

PART NUMBER AND DESCRIPTION

PRODUCT SERVICE AND WARRANTY

Caterpillar Global Mining LLC

Before Starting Engine, Study Operator’s Manual

California Proposition 65 Warnings

Drill Model : ___________________________________

Drill Serial No. : ________________________________

Date Delivered : ________________________________

1. Rotary Drill Assembly

MACHINE SPECIFICATIONS .............................................................SECTION 1

OPERATOR CONTROLS ...................................................................SECTION 3

OPERATING INSTRUCTIONS ...........................................................SECTION 4

DRILLING PRACTICES ......................................................................SECTION 5

MACHINE TRANSPORT ..................................................................SECTION 6

OPTIONS AND ACCESSORIES.........................................................SECTION 7

LUBRICATION AND PREVENTATIVE MAINTENANCE ....................SECTION 8

\Machine Specifications 1-1

Pull-down/Hoisting Capacity Cooler Assembly

Head travel (11 m config) 1,249.68 cm (492 in) Engine radiator

Cable type 1 in DYFORM 8 Hydraulic oil cooler

Performance ratings are based on 100% efficiency and on engineering

1-2 Machine Specifications

Cooler Assembly Compressor

Fan speed 1,525 rpm Compressor (Optional)

\Machine Specifications 1-3

Engine Engine (cont.)

1-4 Machine Specifications

Engine (cont.) Operator’s Cab

\Machine Specifications 1-5

Operator’s Controls (cont.) Mainframe

Drill Table & Work Deck

1-6 Machine Specifications

Hydraulic System (cont.) Accessories, Tools & Handling

Single fan: 1 Dual fan: 2 Length 71.12 cm (28 in)

Type Piston Top thread 13.97 cm (5.5 in) API Reg.

Pump Drive Gearbox Bit Sub

\Machine Specifications 1-7

Accessories, Tools and Handling

Winch–Mounted on the mast

Cable size 12.7 mm (0.5 in)

1-8 Machine Specifications

Pull-Down/Hoisting Capacity Cooler Assembly

Cable type 1 in DYFORM 8 Compressor

Rotation speed 0-220 rpm Oil filtration 12 micron replaceable element

Main thrust bearing Taper roller Compressor (Optional)

Ratio 16:04 to 1 38.2 m 3/min (1,350 cfm);

Drive motor See Hydraulic 42.5 m 3/min (1,500 cfm)

\Machine Specifications 1-9

Engine Engine (cont.)

1-10 Machine Specifications

Undercarriage Operator’s Controls

Pad width 750 mm (29.5 in) Standard Engine Controls

\Machine Specifications 1-11

Mainframe Hydraulic System

Construction Electric welded Pressure rating 413.7 bar (6,000 psi)

1-12 Machine Specifications

Lubrication Accessories, Tools & Handling

Drill Pipe (Optional, Price-Adder) Top thread Depends on pipe diameter

Pipe rack swing Hydraulic cylinders (2 )

Pipe rack index Hydraulic motor through chain drive

Location Outside mast