Foremost W750

Operation &
Maintenance
Manual
AK Drilling Int.
Prospector
W750
Serial #122637
UNCONTROLLED COPY All information subject to change

without notice. © 2012 FOREMOST INDUSTRIES LP.
Introduction
Introduction
The Foremost machine which you have purchased is capable of providing
many hours of reliable service. This unit is the result of many years in the
all terrain vehicle industry. The vast amount of engineering knowledge
and technical skill gained from the past has been combined to build vehi-
cles that incorporate durability, simplicity, power and long life.
This operators manual is presented to furnish you with the neces-

sary information for operating and maintaining your vehicle. Its primary
purpose is to assist you, the operator, in lubricating and adjusting the
vehicles for daily and seasonal operations. You are urged to study its con-
tents thoroughly in order to derive the greatest benefit from the desirable
features built into your vehicle. Although this machine is designed with the
safety of the operator in mind, the possibility of accident cannot be com-
pletely eliminated until you understand and practice all safety precau-
tions.
For additional information consult the manufacturer, whose trained

service personnel will assist with any problems encountered.
Timely maintenance saves costly repairs and valuable time lost

because of breakdown. For these reasons, we recommend that lubrica-
tion and maintenance guides be closely followed.
Before the vehicles is driven, the operator should check the follow-
ing to become familiar with the vehicle and also possibly avoid undue
repairs and down time.
1. Check oil level in the engine crankcase, transmission, drop box, differ-
ential, and power steering reservoir.
2. Check coolant level in radiator.
3. Check electrolyte in battery.
4. In cold temperature (-30º or less) preheat differential.
FOREMOST Industries LP.

W750 Operations & Maintenance Manual
Safety Rules
General And Personal Safety
Working safely is common sense. Common rules are made to govern

the way we act in a particular environment. The following guidelines
are a mixture of rules, warnings and reminders that will help you to
work safely.
• Read the manual, and the warning and advisory stickers

on your drill.
• Be aware of maintenance and operating equipment.
• Don't make assumptions about working conditions.
• Make sure vehicles are parked in an appropriate area.

Always keep personnel working around the drill in your line
of sight.
• Don't experiment with new drilling methods. Discuss your

ideas with your supervisor and other team members.
• Always wear appropriate personal protective equipment.

Remember to wear a helmet, glasses and hearing
protection.
• Be aware of hot surfaces on your machine. These surfaces

cause burns.
• Do not allow sparks or exposed flames around batteries.

Wet cell batteries generate explosive gases.
• Do not carry loose objects in the cabin. They can act as

missiles in an accident.
• Remember a careful operator always is the best insurance

against accident.
• Never refuel vehicle when the engine is hot or running. Do

not smoke when refueling.
• Be sure all vehicles drives are in neutral before starting

engine.
• Engage the clutch gently if so equipped.
• Keep vehicle in gear when going down steep hills or

grades.
FOREMOST Industries LP
Safety Rules
• Reduce high speed before making a sharp turn.
• Drive vehicle at speeds slow enough to insure safety, especially

over rough terrain or near cliffs.
• Never dismount from vehicles while it is in motion; wait until it

stops.
• Be careful when removing cap when radiator is hot. Refill only

with engine stopped or slowly idling. Do not fill radiator when
engine is overheated.
• Keep a first aid kit and fire extinguisher in vehicle in case of an

emergency.
• Never operate the engine in a closed garage or shelter.
• Keep hands away from all moving parts.
• Be extra careful when working on steep inclines.
• Set parking brake when leaving vehicle.
Housekeeping
Many safety incidents can be prevented by good housekeeping.

Do everything you can to prevent damage to your drill.
It's Your Drill, Look After It!

Safety Rules
Fire Prevention
Fire prevention is the first step in the control of any potential fire.
Avoid fires by keeping the cab and deck clean. Clean up oil spills,
repair damaged electrical wiring and oil lines and check for adequate
lubrication. Make sure that fire extinguishers can be easily removed,
are fully charged and that the safety nozzle is secure. Also, check that
there are no obstructions in the nozzle.
Location Of Hand-held Fire Extinguishers
There is a fire extinguisher on all Exploration Series drills. The loca-

tion of the fire extinguisher for W750 is on the right side of the driver’s
seat.
Emergency Procedures
If a fire occurs, follow this procedure:
1. Park the drill.

2. Shut down the engine.
3. Remove the fire extinguisher from the mount.
4. Fight the fire by aiming the extinguisher at the base of the
fire.
Under no circumstances should you place yourself in a position where

injury could result.
Defect Reporting And Identification
Effective safety practice includes the prompt repair of machine

defects.
Notes

Operation & Maintenance Manual
This manual will help the operator with the procedures needed for the proper operation and
maintenance of Prospector W750
A thorough study of this manual is recommended before operation or maintenance of the drill
is attempted. Failure to follow the procedures outlined within may result in injury to personnel
or damage to equipment, and violates the drill warranty.
Careful attention should be given to the service and maintenance instructions for the various
components and systems of the drill. Compliance with these procedures will help to ensure
trouble free operation of the drill.
Literature Information
This manual contains information and instructions concerning drill safety, operation, lubrication and
maintenance. Read, study and keep it available for further consultations.
Some illustrations in this publication may show details or attachments that may differ from the
specific configuration of your drill. Continuing improvement and advancement of product de-
sign may have caused changes to your drill which are not in this publication.
Whenever a question arises regarding your drill, please contact Foremost’s Field Service Department:
US and Canadian customers, please call:1-800-661-9190.
International customers, please call: (403) 295-5800
If you have any questions about this publication or require further technical information, please contact
Foremost’s Technical Publications Coordinator.
US and Canadian customers, please call:1-800-661-9190.
International customers, please call: (403) 295-5800
Operation
The drill operation outlined in this publication is basic. Drill operators gain additional knowledge
of the drill through experience, this experience develops operation skills and techniques which
enhance efficient economical drill operation.
Safety
The safety chapter lists basic safety precautions. In addition, this section identifies hazardous
situations. Read and understand the basic precautions listed in the safety section before operating
or performing maintenance and/or repair on the drill.
Operation & Maintenance Manual
Maintenance
The maintenance section is a guide to drill care. The instructions are grouped by maintenance
service intervals. The actual operating environment of the drill also governs the maintenance
schedule. Under extremely severe, dusty, or frigid operating conditions, more frequent lubri-
cation and maintenance checks are necessary.
Maintenance Intervals
Use the service hourmeter to determine service intervals. Calendar intervals (daily, weekly,
monthly, etc.) can be used instead of service hourmeter intervals, if they provide more convenient
servicing schedules and approximate the indicated service hourmeter reading. Recommend-
ed service should always be performed at the interval that occurs first.
We recommend that the maintenance schedules be reproduced for ease of inspection. We

also recommend that ongoing maintenance records be kept to document drill service.
See the maintenance records section of this publication for information regarding documents
that are generally accepted as proof of maintenance or repair. The Technical Service depart-
ment of Foremost Industries LP can assist you in tailoring your maintenance schedule to meet
the needs of your operating environment.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the state of California to
cause cancer, birth defects, and other reproductive harm.
Contents Operations and Maintenance Manual
Prospector W750
Chapter Description
1 Safety First
Important Safety Notice ......................................................................2
Safety Decals & Locations..................................................................3
Safety Decals Explanations ................................................................4
2 Specifications
Suspension .........................................................................................8
Axle .....................................................................................................8
Frame .................................................................................................8
Engine ................................................................................................8
Transmission & Transfer Case ...........................................................9
Drive Shafts ........................................................................................9
Electrical .............................................................................................9
Cab ................................................................................................... 10
Hydraulic Controls............................................................................. 10
Reservoir & Air Dryer - Air System ................................................... 11
Tank .................................................................................................. 11
Tool Box............................................................................................ 11
Outrigger ........................................................................................... 11
Dozer Add-On Option ....................................................................... 11
Compressor Package........................................................................ 11
Circulation ......................................................................................... 11
Cyclone Add-On Option .................................................................... 12
Mast .................................................................................................. 12
Mast Add-On Option ......................................................................... 12
Rotary Top Drive............................................................................... 12
Driller Controls .................................................................................. 12
Pipe Handling & Storage Tub ........................................................... 12
Swivel Assembly - Drill Add-On ........................................................ 12
Casing............................................................................................... 12
Tooling .............................................................................................. 13
Paint.................................................................................................. 13
3 Principles of Drilling
Reverse Circulation Theory............................................................. 18
Pull Down/Holdback ........................................................................ 18
Rotation ........................................................................................... 18
Hydraulic System Theory ................................................................ 19
Air System Theory........................................................................... 19
Operations and Maintenance Manual Contents
Chapter Description
4 Cab Console
Cab Console .................................................................................... 22
5 Drill Console
Drill Console..................................................................................... 32
6 Drill Set-Up
Drill Set-Up.......................................................................................38
Drilling Area INspection ...................................................................38
Machine Inspection ..........................................................................38
Placement of the Drill Rig ................................................................39
7 Drill Maintenance
Fluid Specifications ..........................................................................52
Maintenance for Operators...............................................................52
Lubrication Maintenance ..................................................................52
Daily .........................................................................................54
Weekly .......................................................................................55
Every 300 Hours ........................................................................56
Every 6 months..........................................................................56
Hydraulic System Maintenance........................................................57
Daily .....................................................................................58
Weekly .....................................................................................58
Six Months....................................................................................58
General Maintenance .......................................................................59
Daily ......................................................................................59
Every 150 Hours ...........................................................................59
Every 300 Hours ...........................................................................59
Every 6 Months.............................................................................59
As Required ..................................................................................59
Preventive Maintenance...................................................................61
To Change the Rotary Swivel Packing .........................................61
To Adjust Rotary Top Drive Cable ................................................62
To Adjust Sullair Compressor Settings .........................................63
Maintenance Records ......................................................................64
Maintenance Log..............................................................................65
Índice Manual de Funcionamiento y Mantenimiento
Modulo Descripción
8 Mantenimiento preventivo
Programa de mantenimiento preventivo....................................................... 70
Programa de mantenimiento rutinario .......................................................... 74
Revisar alrededor y debajo de la unidad ...................................................... 77
Revisar el nivel de aceite del tanque hidráulico ............................................ 77
Tanque de combustible ................................................................................ 77
Revisar el nivel de refrigerante del sistema de refrigeración ........................ 78
Indicador de servicio y seguridad del sistema de aire del motor .................. 80
Nivel de aceite del motor .............................................................................. 81
Filtro primario del sistema de combustible/separador de agua ................... 81
Toma de fuerza............................................................................................. 81
Nivel de aceite de la caja de transferencia ................................................... 82
Registro horómetro del motor diesel............................................................. 82
Arrancar motor diesel ................................................................................... 82
Inspección visual y auditiva .......................................................................... 83
Purgar el depósito del tanque de aire ........................................................... 83
Hacer el servicio al motor diesel................................................................... 83
Sistema hidráulico......................................................................................... 85
Aditivo suplementarios para refrigerante del sistema de refrigeración ......... 85
Correas ......................................................................................................... 86
Muestra de refrigerante del sistema de refrigeración ................................... 86
Turbocargador .............................................................................................. 87
Revisar las transmisiones, sujeciones, juntas universales ........................... 87
Aceite del cárter del malacate Pullmaster PL2 ............................................. 87
Accionamiento de bomba Denison ............................................................... 87
Presentar análisis de muestra de aceite ....................................................... 88
Filtro de sistema hidráulico ........................................................................... 88
Muestra de refrigerante del sistema de refrigeración ................................... 88
Limpiar el sistema hidráulico......................................................................... 89
Cambiar el elemento del filtro de refrigerante............................................... 90
Baterías ........................................................................................................ 90
Muestra de aceite del motor ......................................................................... 90
Radiador ....................................................................................................... 91
Cambiar elementos del purificador de aire ................................................... 91
Refrigerante del sistema de refrigeración ..................................................... 92
Notes
Chapter
1
Safety First
Contents
Important Safety Notice......................................................................2
Safety Decals & Locations .................................................................3
Safety Decals Explanations................................................................4
1 Safety Decals
IMPORTANT SAFETY NOTICE

It is your responsibility to be completely familiar with the warnings and cautions
described in this Operation and Maintenance Manual.
These warnings and cautions advise against the use of specific operation and
maintenance methods that can result in personal injury, damage to equipment or
cause the equipment to be unsafe. It is, however, important to understand that these
warnings and cautions are not exhaustive.
Foremost Industries LP can not know, evaluate and advise the operator of all possi-
ble operation and maintenance methods or of the possible hazardous consequences
of each method. Consequently, Foremost Industries LP has not undertaken any
such broad evaluation.
Proper service and repair is important to the safe, reliable operation of the equip-
ment. The operation and maintenance described in this Operation and Mainte-
nance Manual are effective methods for operating and maintaining the
Exploration Series Drills.

2 W750 Operations & Maintenance Manual
ETIQUETAS DE SEGURIDAD
(RTO, RTLO, RTOX)
C E
B D
Q
S
P
F G H I J
E DETRAS DE LA PUERTA
S A B
F
D C
Q R
O
M
K L N R
P O K
N M L J I
FOREMOST Industries LP. PROSPECTOR W750 3

1 Safety Decals
Safety Decal A - This decal is located above the control panel in the cab or the
operator station. Ensure that the park brake is engaged prior to drill set up and the
red light is lit up to confirm.
Safety Decal B - Shift Lever Position decal is located at the overhead panel in
operators station.
Refer to OEM (original equipment manufacturer) operators manual for detailed
description, safety and maintenance of Eaton RTLOF transmission.
Safety Decal C - The vehicle must be stationary as described in drill set up proce-
dure and park brake is engaged before starting compressor.
Safety Decal D - The vehicle must be stationary as described in drill set up proce-
dure and park brake is engaged before performing these procedures.
Safety Decal E - Ensure the vent valve is shut off and the gauge must register zero
pressure during drilling operation.
Safety Decal F - Never attempt to make any inspection or adjustment to drive

shaft. Ensure that the engine is shut off and the vehicle is in park and safety brakes
are engaged before performing any service.
Safety Decal G - Never make adjustment to correct the position of the guide tube
by placing your hands under it. There is a possibility that the guide could slip out of
position and injury could occur. Loosen the tension on the winch line and slight
push on the tube to correct the center would suffice.
Safety Decal H - Before preparing to drill, perform a walk around inspection of the
drilling area. Your inspection should include a check for:
• power lines and other overhead hazards,
• ground hazards such as power cables, underground pipes or unstable ground
conditions.
Safety Decal I - Ensure that the ground wire is connected to the frame before
attempting to perform any welding. Sudden electrical surge could cause damages to
the electronic circuitry on the vehicle.
Safety Decal J - Operators must be familiar with the safety instructions as outlined,
Failure to do so could cause personal injury and jeopardizes your safety program
and damage to equipment.
Safety Decal K - This decal is attached to the battery compartment below the
driver’s seat. Keep this area clear of any tools that may come in contact with the
housing.
4 FOREMOST Industries LP.

Safety Decals 1
Safety Decal L - Electronics in this vehicle are highly sensitive from by sudden
electrical surges. To avoid possible damage to electronic system, disconnect the
batteries prior to welding.
Safety Decal M - After 4 hours of driving, re-torque the wheel bolts to 370-375 ft
lbs and again after about 8 hours of operation.
Safety Decal N - As an added security feature during drilling operation in addi-

tion to park brake, ensure the lock up bar is engaged to avoid possible shift of
front articulation.
Safety Decal O - located on both left and right side outriggers. Stand clear when
engaging the outriggers. Make sure the immediate areas are clear of any
obstructions, Install a wooden pad if the ground is unstable. Always wear foot
protection
Safety Decal P - Keep hands away from any rotating components such as
winches and sheaves. Do not perform any inspection or adjustment while in
operation. Check the condition of the cable as a part of daily maintenance pro-
gram. Ensure the vehicle is stopped completely before attempting to perform any
service.
Safety Decal Q - Do not perform any service to the slewing drive while the vehi-
cle is running. Ensure the vehicle is completely stopped and inoperable before
attempting to perform any services to this component.
Safety Decal R - Ensure that this area is completely cleared of personnel while
the vehicle is being moved.
Safety Decal S - Never attempt to rotate the mast while it’s at rest. Ensure to
raise the mast before performing mast rotation.
W750 Operations & Maintenance Manual 5
DRILL CONTROLS
PIPE HANDLING
STRING DRIVE
MAST & PARTS
CAB & ACCESSORIES
HEATING & COOLING
ENGINE & PARTS FRAME

TRANSMISSION &
DRIVE BOX
DRIVE SHAFTS COMPRESSOR
SUSPENSION ATTACHMENTS
AXLE & PARTS CIRCULATION

SYSTEM
TANKS
PROSPECTOR W750
Chapter
2
Specifications
Contents
Suspension.........................................................................................8
Axle ....................................................................................................8
Frame ................................................................................................8
Engine ...............................................................................................8
Transmission & Transfer Case...........................................................9
Drive Shafts........................................................................................9
Electrical.............................................................................................9
Cab...................................................................................................10
Hydraulic Controls ............................................................................10
Reservoir & Air Dryer - Air System...................................................11
Tank .................................................................................................11
Tool Box ...........................................................................................11
Outrigger ..........................................................................................11
Dozer Add-On Option.......................................................................11
Compressor Package .......................................................................11
Circulation ........................................................................................11
Cyclone Add-On Option ...................................................................12
Mast..................................................................................................12
Mast Add-On Option.........................................................................12
Rotary Top Drive ..............................................................................12
Driller Controls..................................................................................12
Pipe Handling & Storage Tub...........................................................12
Swivel Assembly - Drill Add-On........................................................12
Casing ..............................................................................................12
Tooling..............................................................................................13
Paint .................................................................................................13
2 Specifications W750
Suspension
Tire GY sure grip 23.5 x 25 x 16pr Earth mover tire c/w rim
Suspension Suspension - axle mounting for JD 1200 series front axle with
trunion mount and Jd 1400 series rear axle bolted ridged to
frame.
Axle
Axle Assembly Axle assy JD 1200/1400 combo planetary type 20.8:1 ratio
spiral bevel crown & pinion with hydraulic operated internal oil
cooled wet disc brakes for service front axle no-spin 1200
series with trunion mount rear axle 1400 series with regular
spider.
Service Brake Service brake group-hydraulic axle assy JD 1200/
1400combo hydraulic operated brakes/service internal oil
cooled wet disc
Park Brake Park brake group w/dual calipers for rear axle pinion
mounted disc brake spring applied mounts included
Frame
Frame assy & parts w750 drill heat treated high strength alloy
steel channel rails bolted construction articulated joint with
self- aligning ball bushings. Frame used with Cummins
QSX15 engine, Eaton RTX transmission & Dana 785 transfer
case includes front bumper with swing out grille & provision
for front mounted dozer includes 2 tow hooks each front &
rear
Fender Front Fender assy - front for tractor & Terra Tires
Fender Rear Fender assy - rear for tractor & Terra Tires
Engine
Engine assy - Cummins qsx15 665hp 665 hp - @ 2100 rpm

Includes engine mounted oil filters & Jacobs brake 12v
starter & 160 amp alternator EPA certified engine Include fan
assy, Air compressor, fuel filter Includes vandal kit for oil fill &
check
Fan Fan assy - multiwing 40" used with Cummins QSX15 665hp
Air Compressor Air compressor-vehicle supplied w/ Cummins QSX15 665hp

requires air tank/dryer module to complete
Fuel Filter Fuel filter assembly used w/ Cummins QSX15 665hp

includes cooler & fleet guard water separator.
Air Cleaner Air cleaner assy- Cummins QSX15

Especificaciones W750 2
Sistema de escape Silenciador vertical Cummins QSX15 665hp con tubo de
escape a 45º a la altura del capó del motor.
Montaje Herrajes de montaje para motor y transmisión usados con

Cummins QSX15 665hp y transmisión Eaton RTXF
Batería Grupo de baterías dos baterías 8D, 2 (dos) 12 voltios montados

en serie, 1400 amperios incluye caja de baterías e interruptor
montado debajo del asiento del conductor
Sistema de refrigeración Radiador reforzado empernado al motor temp. ambiente

operativa 120°F usado con Cummins QSX15 665hp
refrigeración intermedia hasta 665 HP
Caja de transmisión y transferencia Conj. transmisión y piezas Eaton RTLOF-20913A 9 marchas

adelante, 2 marchas atrás con doble accionamiento de bomba
incluye refrigerante y engrase a presión requiere montaje
2A-0528-060
Embrague Conj. embrague y piezas Eaton 208925-25 embrague freno

127760
Caja de transferencia Dana 785 no incluye refrigerante requiere montaje módulo

grupo 2a-0682-010
Grupo de montaje Caja de transferencia para Dana 785
Sistema de refrigeración Transmisión – refrigerante de aceite para Eaton RTX use

refrigerante 382329
Kit de filtro Transmisión sistema de refrigeración
Sistema de refrigeración Aire de caja de transferencia al refrigerante de aceite para

Dana 785 use refrigerante 382329
Cambiador de transmisión Conj. cambiador de transmisión para Eaton RTLOF-20913a
Embrague Controles de embrague para Spicer 108391-74a
Controles de caja de transferencia Desconexión controles de caja de transferencia para eje y

compresor de aire de perforadora
Toma de fuerza Conj. TDF usada con transmisión Eaton RTX incluye controles
para usar con motor Cummins
Ejes de mando Ejes de mando – vehículo y perforadora Spicer con estrías con
cubierta deslizante cojinetes colgantes engrasables para
RTLOF-20913A
Electricidad Indicadores y expedidores – sistema 24v estación de operador

para unidades con motor Cummins incluye voltímetro, presión
de aceite, temperatura de agua mecánica, presión de aire
mecánica, tacómetro, horómetro.
Conector eléctrico Piezas de conector eléctrico requeridas para la cabina
Freno Freno Jacobs – Caja eléctrica

Headlight Headlight assy – prospector 24V system w/dozer
Lighting Package Highway 24V
Indicator Lights 24V system required for DDEC engines
Instrument Panel Instrument panel main with automatic reset

breakers
Circuit Breakers Master circuit breaker - 120 amp auto reset
Alarm Back Up alarm
Rear Console Electrical - rear drill console drill w/DDEC 24V
Deck Light Standard 24V system
CAB
Dome Lights 24V Optional used in cab
Electrical Cab shell
Cab Cab welded assy 1-man open w/ wide fenders
Dash Dash assembly and parts used with 1 man cab and DDEC
engines
Windshield Windshield assembly plexiglass used with 1 man open

type cab
Seat Seat – driver vinyl padded used with 1 man open type cab
Exterior Cab exterior parts W750 drill two exterior mounted mirrors
with heated heads
Engine Hood Engine hood assembly used with Cummins QSX15 665
HP charge air cooled 665HP
Horn Air horn electrically operated
Seat Belt Seat belt 2”-non-retractable lap type
Hydraulic Controls
Steering Cylinder Steering cylinder and parts 4" bore x 2" rod x 16" stroke
Hydraulic System Drill Hydraulic Schematic – W750 drill use with 22' mast (20'
pipe) hydraulic steering, brakes front dozer, drill set-up
functions & pipe tub utilizes two engine driven pumps
47,000 lbs pull-up & 16,500 lbs pulldown 10,000 lbs rotary
use new style axial piston variable flow Rexroth pumps c/
w Regen system pump driven from PTO see module 2a-
1250-001 includes hydraulic cooling package for 220°F
used with Cummins QSX15 665hp & 35 gpm water pump

Specifications W750 2
Hydraulic Pump Hydraulic pump & valve group - drill this module contains
all the hydraulic pumps and control valves that mount on
the engine, PTO and deck assy
Air Schematic W750 Drill 380677
Steering Wheel Steering wheel assembly used w/ Rexroth steering valve
Reservoir & Air Dryer - Air System Air reservoir & air dryer Includes Bendix AD9, two air
tanks, 40 oz alcohol injection.
Tanks
Fuel Tank Fuel tank assy & parts two (2) 100 us gallon steel fabri-
cated tank with glass sight gauge and access ladder one
mounted each side
Hydraulic Tank Hydraulic tank assy/parts one (1) 170 gallon fabricated
steel tank with hand transfer pump for filling
Tool Box
Tool Box Chain box RHS and tool box LHS for mounting on front
bumper
Outrigger
Outrigger Assy Outrigger assembly two (2) vertical rear mounted 36"
stroke
Dozer Add-On Option
Dozer Dozer assy and parts two (2) way control up/down 31 in.
X width of tires
Compressor Package
Compressor Compressor pkg. Sullair1150/350 sullair 1150 cfm/350

psi screw style component model with receiver tank oil
cooling pkg.foremost grille guard
Air Cleaner Air cleaner-drill compressor Two (2) donaldson

to match engine air cleaners
Air Plumbing Air plumbing arrangement used with 22' mast compres-
sor Sullair 1150/350. Includes deck air with booster
plumbing and 3" discharge hose. JIC fitting on all 2:
hoses, sock type double whip check.
Circulation
Water Pump Water pump assembly hydraulically driven 35 gpm Bean

1122B includes wash down & suction hose with foot
valve
2 Especificaciones W750
Oiler Oiler assy Graco - drill 20 Gal
Cyclone - Add-On Option
Cyclone Cyclone assembly used with vertical outrigger includes

cyclone chimney and funnel
Mast
Mast Rest Mast rest/parts - heavy-duty used with all masts 10' to 22'
Deck & Mast Slide Deck and mast slide assy for angle drilling 0-45° chain
drive mechanism for Mast rotation 180°
Mast Assembly Mast assembly - 22' HD tubular construction accepts 20'

drill pipe. Rotary travel in mast: 22' pull up 47,700 lbs pull-
down 16,500 lbs used with deck and mast slide for angle
drilling Includes 2000 lbs capacity jib winch includes front
opening gate and adjustable legs in mast base.
Mast Add-On Option
Pipe Guide Pipe guide MPD 4" CIP & 4" Matrix
Breakout Wrench Breakout wrench assembly Hydraulically operated 48"

mounted LHS of mast
Wrench Slot wrench 4" MPD pipe 4" Matrix
Rotary Top Drive
Carriage & Top Drive Carriage & Top Drive assy high torque 2 speed motors
110,000 in lbs 0-100 rpm with two cylinder hydraulic tilt
arrangement. Maximum torque on low range: 10,000 ft lbs
at 116 rpm
Top drive rotary Rated at 6 780 Nm (5,000 lbs-ft) 0 – 120 RPM
Driller Controls
Driller Console Controls drill used with Cummins QSX15 665 HP rotates
with mast, included drill controls, gauges and lights. Decal
console in Spanish.
Drillers Platform Platform - rear console drill used with 2a-2400-060
Pipe Handling & Storage Tub
Pipe Tub Pipe tub assy-drill moves with mast holds 300 ft of 4" x 10'
lengths DSI pipe
Swivel Assembly - Drill, Add-on
Air Swivel Air swivel assy& parts 4” can be used with 2a-2310-030
includes floating swivel and king swivel packing
Casing
Seal Casing seal assy-with 4" wiper

Specifications W750 2
Tooling
Tools Wheel wrench for JD axles
Tooling for 4"pipe includes saver-sub saver-sub adapter,

center tube
Paint
Drill PPG Foremost Red
Cab PPG Foremost Red
Air Compressor PPG Foremost Red
Top Drive PPG Foremost Red
Mast PPG Foremost Black
General
Rated drilling depth 1,500 ft (455m) using 3 3/4" (9.6m) RC Pipe
Chassis Mast Rotates 180° for side drilling
Ground pressure 35.5 psi (2.5 kg/sq. cm)
7.5 cm (3 in) penetration
Length 46 ft. 14.4m)
Weight 52,800 lbs (23,950 kg)
Height (Mast up) 30 ft 8 in (9.3 m)
Height (Mast down) 12 ft 1 in (3.7m)
Width 9 ft 6 in (2.9m) w/ 23.5 x 25 tires
Outrigger pad diameter 30.5 cm (12 in)
Rotary head stroke 22 ft 1 in (6.7m)
Drilling 0 - 45° angle drilling

Notes
Notes

Chapter
3
Principles of Drilling
Contents
Reverse Circulation Theory..............................................................18
Pull Down/Holdback .........................................................................18
Rotation ............................................................................................18
Hydraulic System Theory .................................................................19
Air System Theory............................................................................19
3 Principles of Drilling
Reverse Circulation (RC) Theory
Reverse circulation drilling uses a drilling fluid of compressed air within

double-walled pipe. The system forces air down the drill string, between
the inner and outer pipe, to the face of the drill bit. The circulation air and
the geological cuttings return up to the surface within the inner pipe. At the
surface, a cyclone slows the velocity of the air and cuttings so that samples can
be collected.
Reverse circulation drilling uses reverse circulation pipe. This style of

pipe is double-walled; it is constructed of an inner pipe and an outer pipe.
The outer pipe is designed to withstand the torque and shock loads
associated with rotary or percussion drilling. The inner pipe is sus-
pended inside the outer pipe and is relatively unstressed during drilling.
Pull-Down/Holdback
Pull-down is the downward force applied to the drill bit. Pull-down needs
to be applied so that the teeth of the bit are fully embedded into the rock.
Correct pull-down is important in achieving optimum penetration rate.
Too much pull-down can cause premature wear on the body of the cones
and overload the bearings unnecessarily. It is also very easy to constrict
the bit with too much pull-down. However, if not enough pull-down is
applied, smaller cuttings will be produced and the penetration rate will be
lower.
Rotation
For every revolution of the bit, a certain penetration is achieved. The depth
of this penetration depends on four factors: correct pull-down, correct air
pressure, fracture toughness of the rock and type of bit being used.
In optimum drilling conditions, the penetration per revolution can be as

high as the length of the tooth multiplied by three (because there are
three cones).

18 MPD1500 Operations & Maintenance Manual
Principles of Drilling 3
Hydraulic System Theory
Both the pull-down and rotary systems use variable displacement

hydraulic pumps. As a result, the flow rate of oil being displaced by
the pump can be changed by the controls on the drill operator’s
console. In addition, the horsepower in a hydraulic system depends
on oil flow rate and oil pressure, therefore, if either the oil flow rate or
pressure increases then horsepower increases.
In the pull-down system, if the oil pressure increases then the pull-
down force has increased, if the oil flow rate increases, then the rate
of bit movement down-the-hole will increase. Maximum pull-down
force is available at any penetration rate.
In the rotary system, if the oil pressure increases then the torque
being applied to the drill rod has increased. If the oil flow increases,
then the rotation speed will increase. Maximum torque is available
within the full range of speeds.
Air System Theory
The air system has three important functions: to remove cuttings from
the down-the-hole bit, to power the bit, and to transport the cuttings up
and out of the hole.
MPD1500 Operations & Maintenance Manual 19
Notes

20 MPD1500 Operations & Maintenance Manual
Chapter
4
Cab Console
Contents
Cab Console.....................................................................................22
4 Cab Console
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Hobbs
QUARTZ
0000
PARKING BRAKE
31 27 26 25 24 23 22 19 18 17 16 15
30
21 20
29 28
32
34
33
35

Cab Console 4
Cab Console and Controls
01 WATER TEMPERATURE GAUGE 24 REAR BRAKE LIGHT INDICATOR
02 OIL PRESSURE GAUGE 25 FRONT BRAKE LIGHT INDICATOR
03 AIR PRESSURE GAUGE 26 STEERING LIGHT INDICATOR
04 VOLTMETER GAUGE 27 ENGINE BRAKE
05 DRIVE/DRILL TOGGLE SWITCH 28 JAKE BRAKE TOGGLE SWITCH
06 HOURMETER GAUGE 29 BLADE RAISE
07 HYDRAULIC LOW PRESSURE ALARM 30 HEADLIGHTS HI/LOW BEAM TOGGLE
08 HORN BUTTON 31 HEADLIGHT TOGGLE SWITCH
09 TACHOMETER 32 COMPRESSOR CLUTCH
10 CHECK ENGINE LIGHT INDICATOR 33 STICK SHIFT
11 PUMP DRIVE LEVER 34 SELECTOR SWITCH
12 DRILL COMPRESSOR LEVER 35 ISOLATOR BOX
13 REAR AXLE LEVER
14 FRONT AXLE LEVER
15 PARKING BRAKE KNOB
16 RESET BUTTON
17 START BUTTON
18 IGNITION SWITCH
19 COMPRESSOR START (NOT USED -

SEE DRILL CONSOLE)
20 GAS PEDAL (CAB THROTTLE)
21 BRAKE PEDAL
22 LOW AIR PRESSURE INDICATOR
23 STOP ENGINE INDICATOR
4 Cab Console
BEFORE Operating The Drill Rig, The Operator Must Be Completely Familiar
With The Location, Operation And Function Of All Its Controls And Indicators.
Front Console
Water Temperature Gauge [1]
This gauge indicates the engine coolant temperature.

The normal operating temperature range is between 85°C –
39°C (180°F – 200°F).
Oil Pressure Gauge [2]
This gauge indicates the pressure of the lubricating oil in the engine.
Normal operating pressure ranges between 25 psi and 60 psi.
Air Pressure Gauge [3]
This gauge indicates the air pressure in the vehicle's air brake sys-
tem.
Voltmeter Gauge [4]
This gauge indicates the battery's voltage output.
Drive/Drill Toggle Switch [5]
This switch allows the operator to toggle rig between driving and
drill function. Switch down is in normal driving mode, To initiate
drill mode, lift the guard switch cover and toggle switch up, the
cover will remain open while in drill mode. Close the switch to
return to drive mode.
Hour meter Gauge [6]
This gauge indicates the engine's completed operating hours.
Low Brake Pressure Indicator [7]
This light indicates that you have low brake pressure and will be
lit during drilling operations. This light will come on when the
pressure is below 1050 psi.
Horn Button [8]
This button operates the air horn.

• Push this button to sound the horn.
Tachometer [9]
This gauge indicates the engine rotation speed in revolutions

per minute (RPM).

Cab Console 4
Check Engine Indicator [10]
The flashing of this amber light indicates inactive DDEC codes. Inactive codes
indicate a noncritical engine problem that should be investigated and fixed when
convenient.
NOTE: See the DDEC section on page 85 for a complete diagnostic code
explanation.
Pump Drive Lever [11]
This lever engages the PTO which drives the pull-up/pull-down pump. The lever’s
indicator light will be lit when the lever is engaged.
• Push this lever up to turn ON the pump drive and thus direct pressure to the
drill.
• Pull this lever down to turn OFF the pump drive and thus direct pressure to
the axles.
NOTE: The clutch MUST be engaged before operating this lever and the
air pressure gauge must read 100 psi.
Drill Compressor Lever [12]
• Engine speed should be at 800 to 1000 RPM during com-

pressor start up
This lever allows power to travel from the engine to the compressor. It also
starts the air compressor fan. The lever’s indicator light will be lit when the lever
is engaged.
• Push this lever up to turn ON the drill compressor.

• Pull this lever down to turn off the drill compressor.
NOTE:
Ensure the front and rear axles have been disconnected from the engine drive
train.
Rear Axle Lever [13]
This switch connects the engine to the rear axle. The lever’s indicator light will
be lit when the lever is engaged.
• Push this lever up to engage the rear axle.

• Pull this lever down to disengage the rear axle.
Front Axle Lever [14]
This switch connects the engine to the front axle. The lever’s indicator light will
be lit when the lever is engaged.
• Push this lever up to engage the front axle.

• Pull this lever down to disengage the front axle.
4 Cab Console
Parking Brake Knob [15]
This knob operates the parking brake air valve. The indicator light to the left lights
when the parking brake is engaged.
• Push this knob in to release the parking brake.

• Pull this knob out to engage the parking brake.
Reset Button [16]
This button is the shutdown override for the automatic engine shutdown.
• Push this button in to activate the shutdown override.
NOTE: This button should only be used in emergency situations and for very short time
periods. You may cause severe engine damage if you ignore the critical engine shutdown
warning.
Start Button [17]
This button activates the engine starter motor.
• Push this button while the ignition switch [18] to run position to activate the
engine starter motor.
Ignition Switch [18]
There are three position options for the ignition key.
• accessory position - the key allows accessories, e.g., headlights, to be operated

without the engine running.
• off position - the key shuts down the engine.
• run position - the key allows the engine to run.
Not Used [19]
Gas Pedal (Cab Throttle) [20]
This pedal controls the RPM on the engine.
• Push the gas pedal down to increase the engine's RPM and the vehicle speed.
Brake Pedal [21]
This pedal activates the front and rear axle's disc brakes.
• Push the brake pedal down to engage the brake system.

Cab Console 4
Low Air Pressure Indicator [22]
This light indicates that the air pressure is below 65 psi.
Stop Engine Indicator [23]
The flashing of this red light indicates active DDEC codes. Active codes indicate
a critical engine problem that requires immediate attention to avoid potential
engine damage. The engine will be automatically shutdown if a critical fault
occurs.
NOTE: See the DDEC section on page 85 for a complete diagnostic

code explanation.
Rear Brake Light Indicator [24]
This light indicates that the hydraulic pressure on the rear brake is low.
Front Brake Light Indicator [25]
This light indicates that the hydraulic pressure on the front brake is low.
Steering Light Indicator [26]
This light indicates that the hydraulic pressure on the steering is low.
Engine Brake Toggle Switch [27]
This switch turn the engine brake On and Off
• Move the switch up to turn the system ON.

• Move the switch down to turn the system OFF.
Engine Brake Hi/Lo Toggle Switch [28]
• The right toggle adjusts the amount of compressed air allowed to escape
from the engine and out the exhaust system.
• Move the switch up to select Hi for the most amount of engine braking
pressure.
• Move the switch to the middle to select for a medium amount of engine
braking pressure.
• Move the switch down to select Lo for the least amount of engine braking
pressure.
Blade Raise [29]
This lever raises and lowers the blade in front of the cab.
• Push this lever forward to raise the blade.

• Pull this lever back to lower the blade.
4 Cab Console
Hi/Lo Headlight Toggle Switch [30]
This switch controls the headlights high beam output.
• Move the switch up to turn ON the high beam output.
Headlight Switch [31]
This switch controls the headlights of the drill rig.
• Move the switch up to turn ON the headlights.

• Move the switch down to turn OFF the headlights.
Clutch [32]
This lever engages and disengages the compressor and transmission from the
engine after a gear has been selected. When using the compressor, if the
ambient temperature is -15°C (5°F) or below, first select 5th gear and wait for a
few minutes, then select 7th gear for drill operation.
• Push the clutch pedal down to disengage the transmission.

• Release the clutch pedal to engage the transmission.
Stick Shift [33]
The stick shift allows the operator to choose one of nine (9)
forward and two (2) reverse gears.
Range Selector Switch [34]
This switch allows the operator to move between the low gears (1 to 4) and the
high gears (5 to 8).
Upshifting:
1. Start with the range selector down.
2. Shift Lo-1-2-3-4. Raise range selector.
3. Shift 5-6-7-8.
Downshifting:
1. Shift 8-7-6-5. Lower the range selector.
2. Shift 4-3-2-1-Lo.
NOTE: Put transmission in neutral before starting engine. Do not change range while
moving in reverse.
Isolator Box [35]

This box isolates the power from the vehicle's two batteries. Always turn the key
to the OFF position when leaving the vehicle unattended.
• Turn the key to the left to isolate the batteries.

Notes
Notes

Chapter
5
Drill Console
Contents
Drill Console .....................................................................................32
5 Drill Console
3 4 5 6 7 8
2
1
9
48 10
47
11
46 12
A
13
U
X
V
45 A
L
V
E
14
15 16 17 18 19 20 21 22 23 24
44 25
43
26
42
27
41 28
29
40 30
39 31
32
33
34
35
36
38 37
Drill Console 5
1 AIR PRESSURE 27 REGEN SWITCH
2 SERVICE AIR PRESSURE GAUGE 28 TORQUE CONTROL SWITCH
3 MURPHY POWER VIEW 29 BOOST ON/OFF SWITCH
4 ENGINE TACHOMETER (RPM) 30 HOLD BACK SPEED SWITCH
5 HYDRAULIC OIL TEMPERATURE GAUGE 31 HOLD BACK PRESSURE SWITCH
6 COMPRESSOR OIL TEMPERATURE GAUGE 32 HOLD BACK ROTARY DIAL
7 ENGINE OIL PRESSURE GAUGE 33 WATER PUMP SPEED
8 ENGINE COOLANT TEMPERATURE GAUGE 34 RIGHT OUTRIGGER
9 MAST LIGHTS SWITCH 35 LEFT OUTRIGGER
10 MAIN LIGHT SWITCH 36 TOP HEAD TILT
11 OILER SWITCH 37 PULL-UP/PULL-DOWN
12 TEST SWITCH 38 TOP DRIVE ROTARY TORQUE
13 EMERGENCY STOP BUTTON 39 HOIST DIRECTINAL CONTROL LEVER
14 AIR DUMP 40 TOP DRIVE ROTARY LEVER
15 SLOT WRENCH 41 TOP DRIVE SPEED
16 MAST ROTATE 42 OIL PRESSURE HOIST
17 DECK SLIDE 43 OIL PRESSURE ROTARY
18 MAST SLIDE 44 OIL PRESSURE ACCESSORIES
19 MAST RAISE 45 AIR SUPPLY
20 AUXILIARY VALVE 46 COMPRESSOR HI-LO SWITCH
21 PIPE RACK (TUB) SLIDE 47 COMPRESSOR START/RUN ELECTRICAL

TOGGLE SWITCH
22 PIPE RACK (TUB) RAISE
48 COMPRESSOR THROTTLE
23 WINCH
24 BREAKOUT WRENCH
25 CYCLONE DOOR CONTROL LEVER
26 TURNTABLE INDEX PIN LOCK/UNLOCK
5 Drill Console
BEFORE Operating The Drill, The Operator Must Be Completely

Familiar With The Location, Operation And Function Of All Controls
And Indicators Related To The Operation Of The Drill.
Drill Console, Gauges And Indicators
• Engine speed should be at 800 to 1000 RPM during compressor start

up
Air Pressure Gauge [1]
This gauge indicates the air flow down the drill pipe(s), through the bit, then up and out
of the hole.
Service Air Pressure Gauge [2]
This gauge indicates systems air pressure 0-160 psi
Murphy Power View [3]
Transmits data to other instruments and has a backlit LCD screen that displays text
descriptions of fault codes, translated engine and transmission parameters, and detailed
diagnostics.
Consult user’s guide for further details.
Engine Tachometer (RPM) [4]
This gauge indicates the engine rotation speed in revolutions per minute being transmit-
ted by the Power View.
Hydraulic Oil Temperature Gauge 100°F - 280°F [5]
This gauge indicates the temperature of the hydraulic oil being used by the drill unit.
Compressor Oil Temperature Gauge 140° - 320°F [6]
This gauge indicates the temperature of the compressor oil being used by the drill unit.
When the operating temperature reaches 240°F, it will send warning that it’s operating
near maximum range. Reset button located on the cab console would allow
approximately 2 minutes extension to complete current operation. Halt the operation until
the temperature is stabilized. If the temperature continue to rise and reached 250°F, the
system will completely shut down to avoid over heating and damage to other
components.
Engine Oil Pressure Gauge 0 - 100 psi [7]
This gauge indicates engine’s oil pressure transmitted by Power View. Normal operating
temperature range is -40°C to 85°C (-40°F — 185°F).

Drill Console 5
Engine Coolant Temperature Gauge 100 - 250°F [8]
This gauge indicates engine’s coolant temperature transmitted by Power View. Normal
operating temperature range is -40°C to 85°C (-40°F — 185°F).
Mast Lights Switch [9]
This switch turns the mast lights on (2 at the top, 1 in the middle and 1 at the bottom)
• Pull the switch up to turn on the lights.

• Push the switch down to turn off the lights.
Main Light Switch [10]
This switch turns the drill console light on (2 above the console and 1 on the overhead)
• Pull the switch up to turn on the light.

• Pull the switch down to turn off the light.
Oiler Toggle Switch [11]
This switch turns on the lubricator that injects oil down the drill string to lubricate the
down hole hammer.
• Toggle the switch down to turn off the oiler.

• Toggle the switch up to turn on the oiler.
Test Toggle Switch [12]
This switch allows you to check the operation of the two red indicator lights.
• Toggle switch up to activate the test.
NOTE: See the DDEC section on for a complete explanation of the

diagnostic codes.
Emergency Stop Button [13]
This button immediately shuts down the engine.
Air Dump [14]
This control releases the air pressure in the drill string.
• Push the button to close air pressure.

• Pull the button to release air pressure.
Slot Wrench Lever [15]
This wrench is used to hold the pipe string in the hole when adding or subtracting pipe;
and, for holding pipe string in position when breaking the connection with the top pipe.
• Lift this lever up to engage the wrench.

• Push the lever down to release the wrench.
5 Drill Console
Mast Rotate Lever [16]
This lever operates the turret motor that rotates the mast 90o from centre in either
direction.
• Lift the lever up to rotate the mast clockwise.

• Push the lever down to rotate the mast counter-clockwise.
NOTE: The turntable index pin [26] MUST be released BEFORE

you operate the mast rotate lever. Also, remember to re-insert the
turntable index pin after rotating the mast.
Deck Slide Lever [17]
The deck slide lever allows the deck to move toward and away from the cab. This allows
the operator to control the horizontal positioning of the mast over the hole.
• Lift the lever up to move the deck toward the cab.

• Push the lever down to move the deck away from the cab.
Mast Slide Lever [18]
This lever controls the mast up and down position of the mast over the hole.
• Lift the lever up to raise the mast.

• Push the lever down to lower the mast.
Mast Raise Control Lever [19]
This lever controls the mast raise/lower cylinders.
• Lift the lever up to raise the mast.

• Push the lever down to lower the mast.
Auxiliary Valve [20]
This flow control valve is used as an accessory valve for other hydraulic drilling
equipment compatible with the rig’s hydraulic system. The quick disconnect is located
below the compressor receiver tank. Auxiliary circuits include the slot wrench [15], left
outrigger [35], right outrigger [34], mast raise [19], mast slide [18], deck slide [17], pipe
rack raise [22], pipe rack slide [21], breakout wrench [24], and top head tilt [36]
Pipe Rack Slide Lever [21]
This lever raises and lowers the pipe rack to fit the slope of the land.
• Lift the lever up to raise the pipe rack.

• Push the lever down to lower the pipe rack

Drill Console
5
Pipe Rack Raise Lever [22]
This lever raises and lowers the pipe rack from its horizontal position on the truck bed.
• Lift the lever up to raise the pipe rack.

• Push the lever down to lower the pipe rack.
Winch Control Lever [23]
This lever controls the direction of the winch.
• Lift the lever up for the winch to hoist.

• Push the lever down for the winch to release or unspool.
Breakout Wrench Lever [24]
This lever connects the breakout wrench to the pipe string.
• Lift this lever up to connect the wrench to the pipe string.

• Push this lever down to break the connection of the wrench to the pipe string.
NOTE: The manual slot wrench can also do this.
Cyclone Lever [25]
This lever controls the opening and closing of the cyclone doors.
• Push the lever down to open the doors.

• Lift the lever to close the doors.
Turntable Index Pin [26]
This lever inserts and retracts the turntable index pin. The pin locks the mast turntable in
place once the degree of mast rotation is determined.
• Lift the lever up to insert the pin.

• Push the lever down retract the pin.
Regen Switch [27]
The regenerative valve redirects the hydraulic fluid back into the hydraulic cylinder
instead of returning the fluid to the hydraulic tank. Although the regenerative valve
decreases the time needed to trip out of a hole it also decreases the force required to
operate the bit, therefore do not use the valve while drilling.
• UP to ACTIVATE the regenerative process.

• DOWN to DEACTIVATE the regenerative process.
5 Drill Console
Top Drive - Torque Control Switch [28]
• UP to turn ON top drive torque control variable pressure.

• DOWN to turn OFF top drive torque control variable pressure.
At OFF position, top drive torque is set to maximum.
Top Drive Boost [29]
This increases oil flow to top drive and increases speed.
• UP to turn ON top drive boost.

• DOWN to turn OFF top drive boost.
Hold Back Pressure Speed Off/On Switch [30]
This controls the speed at which the upper hoist is held back.
• UP to set the upper hoist’s hold back speed to high

• DOWN to set the upper hoist’s hold back speed to low.
When set to low, the drill string is prevented from a rapid descent when the driller comes
across a soft formation in the ground.
Upper Hoist - Hold Back Speed Switch[31]
• UP to turn ON upper hoist - hold back variable pressure.

• DOWN to turn OFF upper hoist - hold back variable pressure.
At OFF position, upper hoist hold back pressure is set to maximum.
Hold Back Pressure Knob [32]
This knob is used to increase or decrease pressure required to hold back drill string.
(Holdback pressure is used when drilling with a hammer or insert bits.)
• Turn the knob to the right to increase pressure holding back drill string.
NOTE: This knob works with the Hold Back Pressure Speed Switches [31]
Water Pump Lever [33]
This lever controls the amount of water being pumped into the hole.
• Push the lever forward to increase water supply.

• push down to decrease water supply and turn the pump off.
NOTE: This lever will NOT automatically return to the neutral position.

Drill Console 5
Right Outrigger [34]
This lever controls the right outrigger.
• Push the lever forward to raise the outrigger.

• Pull the lever back to lower the outrigger.
NOTE: Check all outriggers are stable before drilling. In addition, always CHECK that ALL
outriggers are retracted before attempting to move the drill rig or lifting the deck. If the ground
is soft and unstable, place a solid wooden plank underneath before lowering the outrigger.
Left Outrigger [35]
This lever controls the left outrigger.
• Push the lever forward to raise the outrigger.

• Pull the lever back to lower the outrigger.
NOTE: Check all outriggers are stable before drilling. In addition, always CHECK that ALL
outriggers are retracted before attempting to move the drill rig or lifting the deck. If the ground
is soft and unstable, place a solid wooden plank underneath before lowering the outrigger.
Head Tilt Control Lever [36]
This valve allows for the rotary head to tilt outward allowing easier attachment of pipe to
the rotary drive.
• PUSH this lever forward to tip out the rotary head for pipe pick up (OUT).
• PULL this lever back to return the rotary head to the mast for drilling (IN).
Pull-up/Pull Down Speed Rotary Switch [37]
This switch allows you to change the speed of hoist when pulling the pipe string out of
the hole.
• Turn narrow end of the dial or counterclockwise to increase speed and decrease force.
• Turn the dial clockwise to wider end of the dial to decrease speed and increase force.
Top Drive Rotary Torque Knob [38]
This knob regulates the oil pressure in the rotation circuit.

The minimum forward rotation for the top drive rotary is 800 psi.
The maximum forward rotation for the top drive rotary is 3000 psi.
• Turn the knob clockwise to increase torque.

• Turn the knob counter-clockwise to decrease torque.
5 Drill Console
Hoist Directional Control Lever [39]
This lever controls the travel direction of the lower hoist.
• Push the lever up to move the lower hoist up.

• Pull the lever down to move the lower hoist down.
Top Drive Rotary Lever [40]
This lever controls the flow of hydraulic fluid to the rotation motors.
• Push the lever forward to drive the top drive rotary head counterclockwise (reverse).
• Pull the lever back to drive the top drive rotary head clockwise (forward).
NOTE: This lever is lockable to any desired rotation speed. In addition, rotation torque is
controlled by the rotary torque knob.
Top Drive HI/LO Selector Valve [41]
• Turn the knob up for High speed.

• Turn the knob down for Low speed.
Oil Pressure Hoist Gauge [42]
This gauge indicates top hoist’s oil pressure which indicates the amount of pressure
being applied to the hoist motors. The oil pressure to the hoist is controlled by the rotary
control knob [37].
Rotary Oil Pressure Gauge [43]
This gauge indicates top drive rotary oil pressure which indicates the amount of
pressure being applied to the top drive rotary motors. The oil pressure to the top drive
rotary is controlled by the rotary torque knob.
• The minimum top drive rotary oil pressure is 500 psi.

• The maximum top drive rotary oil pressure, while in forward rotation, is 3000 psi.
• The maximum top drive rotary oil pressure, while in reverse rotation, is 3500 psi.
Oil Pressure Accessories [44]
This gauge indicates the pressure in the hydraulic system which supplies the accessory
circuits. Accessory circuits include the head tilt [45], winch [47], service air [48], left jack
[49], right jack [50], front jacks [51], and mast raise [52].
This gauge should read a maximum of 2200 psi.

Drill Console 5
Air Supply [45]
This control supplies the air pressure in the drill string.
• Push the button to close air pressure.

• Pull the button to release air pressure.
Compressor Hi-Lo Switch [46]
This switch controls the air pressure down the pipe string.
• Turn the narrow end up for Hi pressure. (350 psi)

• Turn the narrow end down for Lo pressure. (180 psi)
Compressor Toggle Switch [47]
This switch activate compressor system.
• UP to start the compressor

• DOWN to run the compressor
Compressor Throttle Rotary Dial [48]
This dial increases the amount of air pressure in the drill string.
• Turn clockwise to increase

• Turn counterclockwise to decrease
Notes

Chapter
6
Drill Set-Up
Contents
Drill Set-Up .......................................................................................44
Drilling Area Inspection ....................................................................44
Machine Inspection ..........................................................................44
Placement of the Drill Rig.................................................................45
6 Drill Set-Up
NOTE: Allow engine to run at an idling speed of between 600-700 RPM and hydraulic
fluid to circulate until both are warmed. Engines should not be loaded if the hydraulic fluid
has not been warmed. This temperature is normally reached after the engine has idled
for 15 minutes (longer in colder climates). Do not immediately begin to operate drill at
full load in cold weather as seal damage could result.
Drilling Area Inspection
When preparing to drill, perform a walk around inspection of the drilling

area. Your inspection should include a check for:
• power lines and other overhead hazards.

• ground hazards such as power cables, underground pipes
or unstable ground conditions.
Machine Inspection
Perform a visual inspection of the drill before attempting setup. Your

inspection should include a check for:
• damage and structural cracking,

• damage to the outriggers,
• mud, rocks and debris in the tires or track pads,
• damage to the drill bit,
• water and oil leaks,
• hydraulic oil level.

Drill Set-Up 6
Placement of the Drill Rig
1. Park the drill rig on either a level surface or with the cab facing down the
slope.
2. Lower the blade to the ground.
3. Move the drill rig forward, pushing the blade into the ground.
4. Pull out the parking brake knob.
5. Push down on the clutch pedal to engage the clutch.
6. Disengage the front and rear axles by pushing the front and rear axle levers
to the OFF position.
7. Release the clutch pedal to disengage the clutch.
8. Check that all the drill console levers are in the neutral position.
AIR PRESSURE COMPR. OIL TEMP. AUX. VALVE BANK LIFT & HOLDBACK PULLDOWN ROTARY
HOLD-BACK PRESSURE DOWN PRESSURE

KEY
1 2 3 4 OILER
ON
DIAGNOSTIC MAIN MAST

TEST OILER
REQUEST LIGHTS LIGHTS
STOP ENGINE RPM

AIR SUPPLY
PULL-UP LOCK
H
NEUTRAL
I
C
O
M
AIR DUMP P
L
O
S T D M M S T T B W
L O E A A P U U R A
O P C S S A B B W E T
T K T T R I A E
H E S R N K R
W E S S R L A C O
R A L L A O I I H U P
E D I I I U D S T U
N D D S T E E M
C T E E E L W P
H I E R
L T E
T N
C
H
R
H O
I T T
A H
P R R
U Y O
L T
L T T
O L
U R E
P Q
U
L E
O
ROTARY CHARGE TURNTABLE

OPEN CYCLONE CLOSE IN INDEX PIN OUT
P
U
L
L
D
R O
O W
T N
A
R
Y P
U
L
L
L. R. M
U A
P R R S
E E T WATER PUMP SPEED
A A
R R R
O
O O T
U U A
T T T
R R E
I I
G G
G G
E E
R R
9. Push down on the clutch pedal to engage the clutch.
6 Drill Set-Up
10. Engage the pump drive by pushing the pump drive lever to the ON position.
NOTE: Engaging the pump drive lever locks the steering wheel in
place.
11. Activate the rig to drill console turning the DRILL/DRIVE selector switch on
the dash panel.
12. Go to the drill console, set the throttle and ensure the tachometer is reading
1200 RPM.
1200 RPM
13. Return to the cab and close the DRILL/DRIVE selector switch cover to
return to power to the cab. Wait for the engine to idle down. Normal warm
up time is about 15 minutes.
NOTE: The drill rig should also be allowed to cool for five minutes
when finished operation.
15.Lower the left and right outriggers.
NOTE: Before lowering the outriggers, check that the ground beneath the
outrigger pads is stable and that all people are clear of the outriggers.
Place a solid wooden plank under the outrigger if the ground is soft and
unstable.
16.Raise the pipe rack from its horizontal position on the deck.

Drill Set-Up 6
17. Raise the mast from its horizontal position on the deck.
NOTE: Before raising the mast, ensure the winch line is slack. To
determine the angle of the mast place either a hand level or an
angle finder on the side of the mast. A system of counterbalances
lock the mast in place when either the mast raise lever or mast
slide lever are returned to the neutral position.
18. Slide the mast into position. Pulling back on the deck slide lever moves the
U
X
V
A
L
V
E
deck away from the cab. Pushing forward on the deck slide lever moves
the deck toward the cab.
19. Unlock the mast turntable the turntable index pin.
20. Rotate mast turntable to the desired position.
Range during NOTE: Ensure the mast is angled, as shown, to pass behind the
mast rotation. rear of the drill frame.
21. Reset the turntable index pin.
22. Make the final mast angle adjustment.
23. Lower the mast to the ground by pushing forward on the mast slide lever so
the feet on the bottom of the mast are on the ground.
6 Drill Set-Up
Hobbs
QUARTZ
0000
24. Push down on the clutch pedal and push up the drill compressor
lever to ON.
PARKING BRAKE

Notes
Notes

Chapter
7
Drill Maintenance
Contents
Fluid Specifications ..........................................................................52
Maintenance for Operators...............................................................52
Lubrication Maintenance ..................................................................52
Daily ...........................................................................................54
Weekly .......................................................................................55
Every 300 Hours ........................................................................56
Every 6 months ..........................................................................56
Hydraulic System Maintenance........................................................57
Daily ..........................................................................................58
Weekly.......................................................................................58
Six Months.................................................................................58
General Maintenance .......................................................................59
Daily...........................................................................................59
Every 150 Hours ........................................................................59
Every 300 Hours ........................................................................59
Every 6 Months ..........................................................................59
As Required ...............................................................................59
Preventive Maintenance...................................................................61
To Change the Rotary Swivel Packing ......................................61
To Adjust Rotary Top Drive Cable .............................................62
To Adjust Sullair Compressor Settings ......................................63
Maintenance Records ......................................................................64
Maintenance Log..............................................................................65
7 Drill Maintenance
Fluid Specifications
Engine CUMMINS QSX-15 665HP: MOBIL DELVAC 1300 15W-10ESSO XD3 15W-40
(API rating: CI-4)
Transmission EATON RTLOF: ESSOLUBE HD 50 (API rating: CH-4, CF-2)
Transfer Case DANA785: ESSOLUBE HD 50 (API rating: CH-4, CF-2)
Axles JONH DEERE 1200/1400 COMBO: HYDRAUL 56
Hydraulics ESSO HYDRAUL 56 or JOHN DEERE HY-GARD #J 20 D
Radiator ESSO HD antifreeze -45°C (-50° F)

Refer to the OEM for additive information.
Water Pump (Bean) ESSOLUBE HD 30 (API rating: CF-2)
Rotary Top Drive ESSO GEAR OIL, GX EXTRA 75W90 (API rating: GL-5)
Sullair Compressor MOBIL RARUS SCH 1026 (DIN 51506 VDL 68)
Sandline Winch ESSO GEAR OIL, GX EXTRA 75W90 (API rating: GL-5)
Drive Shafts ESSO UNIREX EP2
Articulation ESSO UNIREX EP2
Steering Cylinders ESSO UNIREX EP2

Drill Maintenance 7
Maintenance For Operators
A good maintenance program is the key to long and trouble-free drill life. The following schedule explains the main-
tenance requirements for average operating conditions. The intervals should be shortened when operating in elevated
temperatures or severe dust conditions. Detailed instructions for specific components are given in the OEM man-
uals.
Lubrication Maintenance
It is essential that lubrication be done regularly. Failure to lubricate can result in irreversible damage.
The main drill components that need lubrication are:
• transfer case
• transmission
• rotary top drive
• compressor
• axles
• grease bulkheads
• fill points
• drain points
• gear box
7 Drill Maintenance
Daily
Check
• gear oil is in the top drive rotary lubricating pump for proper lubrication of
bearings.
• leaks and tighten or repair any, if found.
• pump drive oil level.
• engine oil level.
• compressor oil level.
Grease
• travel sheaves in mast - sheaves should also be checked for wear and bush-
ings replaced if they are not running smoothly.
• swivel packing - check packing if leaking. (refer to preventive maintenance)
• hinge pins in the articulation joints.
• hydraulic fan hub on the coolers.

Drill Maintenance 7
Weekly
Check
• oil in top drive rotary, transfer case, water pump, and transmission.
• oil level in axles (do not overfill):
• parking brake adjustment
• front and rear transmission oil levels.
• check mounting bolts for hanger bearings.
• inspect U-joints.
Grease
• mast rotation bearing

• u-joints in all shafts.
• hanger bearings.
• outrigger pins.
• steering pins under the steering cylinder.
• blade.
• standard blade - angle joints.
• 6-way blade - all socket joints.
• compressor drive shaft. (Ensure the flange bolts are tight.)
• mast raise cylinder pins.
• outer axle bearings. These bearings are located behind the front and rear
tires.
7 Drill Maintenance
300 Hours
• change oil in top drive rotary, transfer case, and transmission.

• grease the mast winch.
Six Months
• change oil in winches, water pump, and axles

• change oil in final drives

Drill Maintenance 7
Hydraulic System Maintenance
It is important that you have a basic understanding of the drill’s hydraulic circuits, operation, and function. If you
require additional technical information, consult the OEM manuals or the Foremost Parts Book. (The Foremost
Parts Book contains the hydraulic schematics.)
The main hydraulic circuits are:
• drill set-up functions

• pipe rack slide
• pipe rack raise
• winch
• breakout wrench
• water pump
• brakes: Explorer
• dozer
• steering
• compressor fan
• pull-up/pull-down
• rotary
7 Drill Maintenance
Daily
Check
• hydraulic oil level.

• engine oil level and coolant levels.
• cooler fins are free of obstructions.
• mast hoses for wear.
• hose leaks.
• air filter restrictors on both the engine and drill compressors. The indicators
should be green while the drill is under working load.
• all needles on return gauges remain green while operating.
• all needles on suction filter gauges remain green while operating.
Weekly
Check
• drill rig hoses for wear.

• articulation hoses for wear.
• cylinder glands for leaks.
Six Months
Clean
• clean and flush hydraulic oil tank, change filter and refill with oil.

Drill Maintenance
7
General Maintenance
Daily
Drain
• water from filter/dryer on compressor central supply line.

• (See Sullair OEM manual.)
• air tanks.
Check
• engine and compressor oil levels.

• cooler screens for debris.
• engine coolant level.
• pull-up/pull-down cables for frays. Cables should be kept tight at all times.
Tighten the cables until they move approximately 3.8 cm/3 m (1.5 in./10 ft.).
• the pull-up cables are tightened by turning the turnbuckle at the bottom
of the mast.
• the pull-down cables are tightened by turning the threaded bolt at the
top of the mast.
•
NOTE: All cables should be tightened equally.
150 Hours
Check
• water levels in batteries

• check and adjust top drive spindle end play if needed. (.001 -.003 thousand
preload.) See top drive rotary section of the Foremost Parts Book.
• check and adjust the Sullair compressor settings.
Change
• engine oil, oil filter and top drive oil

• fuel filters
7 Drill Maintenance
300 Hours
Change
• hydraulic oil filters. (Sooner if the indicator shows restriction.)

• compressor oil filter.
• compressor oil automatic transmission fluid.
(900 hours for synthetic oil.)
• transfer case and transmission oil
• filter on compressor control line dryer.
• top drive rotary bearings.
Six Months
Set
• valves and injectors on engine. (1000 hours.)
• NOTE: OEM manual recommends a certified mechanic make

these adjustments.
As Required
• replace engine and compressor air filters when indicators show red.
• inspect and tighten all air cleaner and induction system connections.

Drill Maintenance 7
Preventive Maintenance
• the discharge hose should be rotated a 1/4 turn after every 1 219 m (4,000 ft.) of
drilling.
• NOTE: Turn more frequently when rock is abrasive, e.g., Quartz and
Limestone.
• clean the outside of the valve banks. If dust and dirt are allowed to collect,
they may interfere with the functioning of the levers.
• check all hydraulic leaks and tighten or replace loose or damaged hoses.
• check all oils are of the right viscosity for the varying seasons, temperatures
and conditions.
• change the rotary swivel packing at the first sign of leakage.
•
• NOTE: If the packing is left unattended, water and cuttings may
enter the gear box.
• check the rotary top drive cables.
To Change Rotary Swivel Packing
1. Remove the packing top plate, and replace the two rubber seals and steel
spacer ring.
2. Re-install the top plate and test by increasing the system’s air pressure.
3. If the packing leaks, loosen the lock nut.
4. Back off the top nipple until it is no longer touching the packing.
5. Insert a 1/16 feeler gauge or a thin piece of wire the thickness of a feeler
gauge under the plate.
6. Tighten the top nipple until you feel a little resistance.
7. Tighten the lock nut.
8. Re-test the swivel by increasing system’s air pressure.
9. If the packing leaks, give the nipple one full turn and retest. Do this until it
stops leaking.
10.
NOTE: The life of the packing is dramatically shortened if it is too tight.
In addition, do not replace the grease nipples without grinding off the
top and removing the spring and ball. The nipples should not act as
check valves.
7 Drill Maintenance
To Adjust Rotary Top Drive Cable
1. Lower the top drive rotary to the bottom of the mast.

2. Leave the drill running.
3. Adjust pull-down pressure to 1000 psi.
4. Check to make sure the cylinders are completely collapsed.
5. Ensure the cylinders are collapsed and the top drive rotary side plates are
against the bottom of the mast.
6. Adjust the tension on the pull-up cables.
7. Adjust the tension of the pull-down cables.
• The pull-up cables are tightened by turning the turnbuckle at the bottom
of the mast.
• The pull-down cables are tightened by turning the threaded bolt at the
top of the mast.
NOTE: All cables should be tightened equally and until they move
approximately 3.8 cm/3 m (1.5 in./10 ft.).

Drill Maintenance 7
To Adjust Sullair Compressor Settings
Low Pressure Setting Adjustment (180 – 200 psi)
When the drill rig is running but not using any air, i.e., the air service valve is closed; a) the running blow down
valve on the top of the receiver tank should be open and blowing off air through the muffler.
b) the compressor should not be cycling (cutting in and out). If the compressor does cycle, open the inlet butterfly
stop above the butterfly valve until the compressor does not cycle for 30 seconds. (When the inlet butterfly stop is
opened too much, the compressor will slowly build air. When the inlet butterfly stop is not opened enough, the com-
pressor will cycle.)
When the air service line is opened; a) the air pressure will drop below the low pressure regulator setting; b) the
running blow down valve on the top of the receiver tank will close; c) the inlet butterfly cylinder will open; and d) the
compressor will try to maintain the low pressure regulator setting.
High Pressure Setting Adjustment (350 psi)
When the drill rig is running but not using any air, i.e., the air service valve is closed; a) the running blow down
valve on the top of the receiver tank will open, blowing off air through the muffler, and then close, and b) the com-
pressor will be cycle (cut in and out).
When the air service line is opened; a) the running blow down valve on the top of the receiver tank will close, and
b) the compressor will try to maintain the high pressure regulator setting.
NOTE: The running blow down valve must let air out when the service line is closed, i.e, when adding
pipe or tripping out of the hole. This allows the oil to circulate in the compressor and keep it cool and
fresh for lubrication. Also, these adjustments should be done with the engine running at 2100 RPM.
7 Drill Maintenance
Maintenance Records
Foremost recommends that accurate maintenance records be kept. Accurate maintenance records can be used
for determining operating costs, establishing maintenance schedules for your other Foremost drills being operated
in the same environment and for a variety of other related business decisions.
Accurate maintenance records can also be used to show compliance with the required maintenance practices and inter-
vals. Maintenance records are a key element of a well-managed maintenance program. With accurate maintenance
records Foremost Industries can help you fine tune the recommended maintenance intervals to meet your specific
operating situation. This should result in a lower drill operating cost.
The following types of documents should be kept as proof of maintenance or repair for warranty and kept in your
drill history file. All documents should show date, service hours and drill serial number.
The following types of documents should be kept as proof of maintenance or repair for warranty and kept in your
drill history file:
• Work orders and itemized bills,

• Owner’s repair orders,
• Owner’s receipts,
• Maintenance Log

Drill Maintenance
7
Maintenance Log
Service
Item Serviced Date Initials
Hours
7 Drill Maintenance
Maintenance Log
Service
Hours

Drill Maintenance 7
Maintenance Log
Service
Hours
Notes

Capítulo
Mantenimiento preventivo
8
Contenidos
Programa de mantenimiento preventivo........................................................ 70
Programa de mantenimiento rutinario ........................................................... 74
Revisar alrededor y debajo de la unidad ....................................................... 77
Revisar el nivel de aceite del tanque hidráulico............................................. 77
Tanque de combustible ................................................................................. 77
Revisar el nivel de refrigerante del sistema de refrigeración ......................... 78
Indicador de servicio y seguridad del sistema de aire del motor ................... 80
Nivel de aceite del motor ............................................................................... 81
Filtro primario del sistema de combustible/separador de agua .................... 81
Toma de fuerza ............................................................................................. 81
Nivel de aceite de la caja de transferencia.................................................... 82
Registro horómetro del motor diesel.............................................................. 82
Arrancar motor diesel .................................................................................... 82
Inspección visual y auditiva ........................................................................... 83
Purgar el depósito del tanque de aire............................................................ 83
Hacer el servicio al motor diesel.................................................................... 83
Sistema hidráulico.......................................................................................... 85
Aditivo suplementarios para refrigerante del sistema de refrigeración .......... 85
Correas.......................................................................................................... 86
Muestra de refrigerante del sistema de refrigeración .................................... 86
Turbocargador ............................................................................................... 87
Revisar las transmisiones, sujeciones, juntas universales ............................ 87
Aceite del cárter del malacate Pullmaster PL2 .............................................. 87
Accionamiento de bomba Denison ................................................................ 87
Presentar análisis de muestra de aceite........................................................ 88
Filtro de sistema hidráulico ............................................................................ 88
Muestra de refrigerante del sistema de refrigeración .................................... 88
Limpiar el sistema hidráulico.......................................................................... 89
Cambiar el elemento del filtro de refrigerante ............................................... 90
Baterías ......................................................................................................... 90
Muestra de aceite del motor .......................................................................... 90
Radiador ........................................................................................................ 91
Cambiar elementos del purificador de aire.................................................... 91
Refrigerante del sistema de refrigeración ...................................................... 92
8 PREVENTIVE MAINTENANCE PROGRAM
It is with great pride Foremost Industries have taken in designing and building this vehicle with
intention to serve its purpose for many years of uninterrupted service. Just like any equipment, it
requires maintenance and service of all major components. This preventive maintenance (PM)
program will give you the basic knowledge in maintaining your vehicle to keep it at its peak
operating condition to avoid extended downtime.
The personnel are encouraged to study and become familiar to obtain the full benefit of your
Prospector W750.
• The W750 has been thoughtfully engineered and fabricated to perform at an incredible level of
reliability. It is our wish to never compromise these intended objectives.
• (OEM) Original Equipment Manufacturers warranties are never to be

compromised.
• The “Routine Maintenance Schedule” drives the whole preventive maintenance program. It
must be understood that a failure to perform procedures in one area or for a period of time can
affect the total anticipated success of the program and equipment life.
The PM program and its success rest on several key facts:
• Consumable such as oil, fuel filters and air cleaner elements are OEM supplied. Aftermarket
selections may not produce the same results. Please adhere to these recommendations.
• Oil analysis must be a part of the total program. Preventive Maintenance will succeed best when
component health is monitored.
• Operating and ambient conditions may vary, so our procedures must accommodate those facts.
• All maintenance activities should be recorded for future reference. You may need to verify your
compliance in the future.
This program deliberately covers the “Foremost Industries” installed components. Components
added to the originally delivered vehicle are not covered in this maintenance program.
70 Last Updated: 4Jun12 W750 Operations & Maintenance Manual
PREVENTIVE MAINTENANCE PROGRAM
8
SPECIAL NOTES:
1. Warm up before start up:

This machine will operate and serve you very well if all of the component systems are maintained at or
near normal operating temperatures.
Note: do not adjust the engine speed control during start up.
• Disengage any driven equipment
• Turn the key switch to RUN position and leave it for about 20 seconds.
• Turn the key switch to START position to crank the engine.
• Allow the engine to idle for approximately 10 minutes until the water temperature begins to rise. The
engine should run at low idle smoothly then gradually increases to high idle. Allow the smoke to disperse
before proceeding with normal operation.
• Operate the engine at low load until all systems reach operating temperatures. Check all the gauges dur-
ing warm up period and ensure that there are no sign of abnormalities.
2. Warm Up Time:
Two major considerations need to be kept in mind during warm up time. The first involves the engine and its asso-
ciated components. The second includes the drive train components.
The engine power unit is mechanically connected to the PTO and hydraulic pump drives. When the engine
first starts up, temperature is developed in the engine block via the cooling and lubrication circuits. As this
temperature rises, so does the flow of coolant throughout the engine, causing a cleaner and more complete
burn on all of its cylinders.
As the transmission is circulating (in neutral and at engine idle speed) the attached hydraulic pump drives are
also rotating. As they do so, the hydraulic system oil warms up and becomes more fluid also.
Safe temperature build up is essential and desirable. It will take a minimum of 20 minutes of engine low speed
idle time to develop a minimum amount of temperature throughout these attached components. In very cold
temperatures, this idle time should be increased to 30-45 minutes. You need to see substantial
temperatures showing on the engine coolant, and hydraulic system gauges before ever increasing
the engine RPM or moving the vehicle.
 The drive train components will not be engaged until the vehicle is set in motion. They have typically been
exposed to the elements and especially ambient temperatures and the lubricants found in their housings are
significantly cooled down.
We have chosen lubricants for these applications that have a great track record in extreme temperatures and
under considerable loads, but, observe this with caution. When first beginning to drive this vehicle after a num-
ber of hours of shut down, begin the drive very cautiously.
Ease into the load, and choose a low transmission gear and a slow road speed. Remember, there is no heaters
in U-joints and drivelines. You may be able to hear the sounds of these drive components on a cold, quiet start
up. There is considerable groaning, squeaking, and grinding going on. Drive at this low and cautious road speed
for 15-20 minutes before engaging in normal road speed.
8
3. Cool Down before Shut-down:
At the end of a full day (shift) and before you quickly shut the engine down, allow it to idle for 10 minutes.
Never shut an engine down abruptly after it has been doing heavy, consistent work.
The short period of idle time will allow the temperatures throughout the engine (especially the turbo charger and
upper cylinder liner regions), pump drive and hydraulic drives to stabilize and flush out. Localized high heat areas
will stabilize before the flow of coolants and lubricating oils is stopped. Small amounts of aerated fuel in the engine
cylinder heads will flush out, guaranteeing a better start the next time. In short, the entire system will be very grate-
ful if you give all of the systems an opportunity to cool down naturally before circulation is stopped.
Again, always allow at least 10 minutes of engine low speed, hydraulic system inactive,….idle time,
before shut down.
CAUTION
ROUTINE MAINTENANCE SCHEDULE
Item EVERY DAY: …Pre-Job Inspection & Service Descriptions

Prior to Start-up
1 CHECK AROUND AND UNDER THE UNIT Check for leaks – any abnormal conditions
2 CHECK HYDRAULIC TANK OIL LEVEL Check sight glass – add oil if needed
3 FUEL TANKS Ensure ample fuel volume for the day

4 COOLING SYSTEM COOLANT LEVEL Check the coolant level when the engine is stopped
and cool
5 ENGINE AIR SYSTEM SECURITY & SERVICE Inspect
INDICATOR
6 ENGINE OIL LEVEL Check dipstick before engine start up
7 FUEL SYSTEM PRIMARY FILTER/WATER Drain
SEPARATOR
8 POWER TAKE-OFF Check/adjust/lubricate/adjust
9 TRANSFER CASE OIL LEVEL Validate oil level
10 RECORD DIESEL ENGINE HOURMETER Enter and fill “Daily Maintenance Record"
START UP & WARM UP / COOL DOWN BEFORE SHUT DOWN: Allow idling time
AT AMBIENT TEMPERATURES AT / BELOW 10°C / 50°F
COLD START UP: MUST DEVELOP RECORDABLE HEAT ON PANEL GAUGES
COOL DOWN BEFORE SHUT DOWN:… AT THE END OF EVERY JOB / DAY
11 START UP DIESEL ENGINE Warm up engine, transmission and circulate
hydraulics at “low idle” speed
12 VISUAL & AUDIO INSPECTION Check all hydraulic hoses, fittings, connections,
hydraulic filter monitors, listen for unusual noises.
DURING NORMAL DAILY FIELD OPERATION
13 BLEED OFF THE AIR TANK RESERVOIR Manually discharge lower reservoir air valve
EVERY 250 SERVICE HOURS
14 ENGINE OIL AND FILTER Change/Obtain sample
15 HYDRAULIC SYSTEM Test/Obtain oil sample
16 COOLING SYSTEM SUPPLEMENTAL Test/Add
COOLANT ADDITIVES (SCA)
EVERY 500 SERVICE HOURS
17 BELTS Inspection/Replace
18 COOLING SYSTEM COOLANT SAMPLE Obtain Level 1
19 TURBOCHARGER Inspect
20 CHECK DRIVELINES, HANGERS, U-JOINT Ensure integrity of all components
21 PULLMASTER PL2 WINCH Drain and refill with specified oil
8
EVERY 6 MONTHS
22 DENISON PUMP DRIVE Drain & refill with specified oil
23 SUBMIT OIL SAMPLE ANALYSIS Hydraulic system
24 HYDRAULIC SYSTEMS FILTERS Change elements and ensure monitor indicators

are operational
EVERY YEAR
26 CLEAN HYDRAULIC SYSTEM Use stand alone hydraulic cleaning system, sample
to ensure cleanliness.
27 REPLACE COOLANT FILTER ELEMENT Ensure it is matched to the coolant requirements
28 BATTERIES Inspect
29 ENGINE OIL SAMPLE Obtain
30 RADIATOR Clean
31 REPLACE AIR CLEANER ELEMENTS Regardless of appearance
EVERY 3,000 SERVICE HOURS OR 3 YEARS Whichever occurs first
32 COOLANT SYSTEM COOLANT (DEAC) Change
THESE ARE ONLY MINIMUM REQUIREMENTS, REFER TO INDIVIDUAL COMPONENT’S

SERVICE MANUAL FOR DETAILED MAINTENANCE SCHEDULE.
Notes
8
1 CHECK AROUND AND UNDER THE UNIT Check for leaks – any abnormal conditions
Every day and before every job or move, make a full inspection around the complete unit. Check for:
 Loose or broken bolts on the chassis and undercarriage
 Visually inspect the drive line and support
 Loose or leaking hoses from either the engine cooling system, hydraulic systems, engine lubrication and pump
drive system.
Any fluids found on the ground indicate a problem and a repair to be made as soon as possible. If these conditions
are left un-repaired, a bigger condition will develop that will lead to larger repairs and a greater amount of down-
time.
2 CHECK HYDRAULIC TANK OIL LEVEL Check sight glass – add oil if needed
The hydraulic tank sight glasses are strategically placed to ensure that the operator can clearly see the existing
hydraulic tank reservoir oil level. When the tank is low on fluid, stop the engine and refill to proper level.
 Filling to the top sight glass could result in spillage from the filler as hydraulic circuits are activated.
 Filling to the center sight glass is the preferred and engineered best running level.
 Filling and maintaining the oil level to the lower sight glass could cause oil starvation for the pump especially
when the vehicle is working at steep angles.
Keeping the hydraulic tank clean,….absolutely clean, at all times and in all circumstances. There are many oppor-
tunities to get dirt and water contaminants into the system, and once they are allowed in, it is very difficult to
remove completely, even with the best filter elements in place. One of the prime entry areas happens during the
normal additions or filling process.
The hydraulic tank is vented and this vent cap must always be kept absolutely clean. Remove it from time to time
to wash out the screen mesh compacted in the cap. Always make sure that the area around this vent is clean and
dry. Also avoid directing any water or steam toward this area, any water or contamination that gets by the vent
drops into the hydraulic oil.
3 FUEL TANKS Ensure ample fuel volume for the day
Consider a fuel level indicator reading of ¼ tank as very low. Fill as soon as possible.
Contamination of fuel by water and dirt entering the fuel as a result of careless fuel handling may cause poor diesel
engine performance. Keep a very close watch of the Fleetguard FS1041 fuel filter water separator and drain off the
bottom as often as necessary.
Extreme care must be exercised. Fuel-tank caps, dispensing nozzles and hoses should be kept clean to
CAUTION eliminate potential sources of contamination.
Regularly removing water from storage tanks, vehicle fuel tanks, and filter bowls is important. Dry storage systems
will reduce fuel emulsion problems, injection system corrosion and microbial growth. Water gets into diesel fuel
storage and vehicle tanks in several ways – by condensation of humid air, during transportation from refineries to
service stations, by leakage through faulty fill pipes or vents and by careless handling.
Water can cause injector nozzle and pump corrosion, microorganism growth and fuel filter plugging with materials
resulting from the corrosion or microbial growth. Both vehicle and storage tanks should be checked frequently for
water and drained or pumped out as necessary.
4 CHECK COOLING SYSTEM COOLANT LEVEL Check the coolant level when the engine is
stopped and cool
The cooling system consists of many components that each plays a great part in the total service life of an engine.
In the daily maintenance of this system, three major factors must always be considered.
A.Cooling system level.
B.Cooling system pressure.
C.Coolant quality.
A. The Cooling System Level should always be checked before starting the unit and ensure the coolant
should be at the normal level and allow for fluid expansion when the unit warms up. If the fluid is low, it will send
and orange flashing signal on the Murphy View display at the drill console. Refill to to normal level before
continuing with operation.
Overfilling the system will mean that coolant will discharge from the overflow tube as soon as the available air
space is lost. Under filling a system will drastically reduce the cooling efficiency of the radiator and other system
components. Also, be aware of the fact that the cooling system fluid is not used up during normal operation. This
means, that adding fluids is an indication of leakage in some area. Leakage undetected and not repaired, will
immediately jeopardise the entire system.
Never add coolant or antifreeze to an overheated engine, it could cause engine problems or damage. Allow
enough time to cool the engine before opening the radiator cap. If the vehicle is to be stored, or shipped
to an area below freezing coolant. temperatures, ensure it has an adequate coolant/antifreeze to an
expected ambient temperature or drain completely to prevent damage cause by freezing
CAUTION
B. The Cooling System Pressure most certainly must be

maintained for efficient cooling. Most often, this system pressure is lost in
the areas of external leaks and/or and improperly sealed radiator cap. It
only takes a couple of seconds to ensure that the cap and seating areas
are clean, unmarked and in order. Any cracks in the filler neck must be
repaired immediately. The radiator cap should be replaced when required
or sealing ability is lost. Use an OEM recommended 10 psi. pressure cap
whenever replacing a unit. Caps can be checked with a tester and
measured for their ability to hold pressure as well as allowing air entry in,
during cool down.
8
The radiator filler neck must be clean, especially on the flange-sealing surface. As well, the twist hold down ramp
must be properly installed to ensure a tight seal from the flange to the radiator cap. The radiator cap is the means
by which cooling system pressure is developed and maintained. The expanding coolant volume against the seal of
the cap establishes the pressure and the weight of the spring limits it. Make certain that the rubber seal is always
in perfect condition.
• Ensure that the rubber seals are clean, soft and smooth rubber. The rubber tends to buckle after years of ser-
vice.
• Ensure that there is an air space above the level of the coolant in the radiator. Never fill the radiator completely
to the top. This air space should be about 1/3 of the total top surge tank depth. Cold coolant will expand when
it is heated and build the needed pressure against the tension of the radiator cap.
• If a radiator cap is removed on an operating engine, the pressure is lost until that engine is again completely
cooled down and restarted.
INSTALL A NEW RADIATOR CAP AT LEAST ONCE EVERY 3 YEARS
• Ensure that radiator cap meets all of the current pressure requirements.
• Ensure that the filler neck “screw down” ramp is healthy.
• Ensure that the rubber gasket makes a full seal against an absolutely clean filler neck lip.
C. COOLANT QUALITY and stability is very important to the long term life of an engine. If coolant additions
are necessary, it is important that the quality is maintained, so ensure that it is adequately mixed, to meet
the minimum requirements.
a. Always maintain a 50:50 mixture of water and ELC (Extended Life Coolant). This applies
regardless of cold or hot ambient conditions.
b. Always ensure that the level of coolant inhibitor is maintained in the system.
Do not mix coolant formulations. For best results, stay pure in the chosen formulation.
The coolant used in diesel engines must meet the following basic requirements:
• Coolant used must meet OEM recommendations
• Provide an adequate heat transfer medium
• Protect against cavitations damage to both cylinder liners and water pumps
• Provide a corrosion/erosion resistant environment
• Prevent formation of scale or sludge deposits
• Be compatible with cooling system hose and seal materials
• Provide adequate freeze protection.
5 ENGINE AIR SYSTEM SECURITY & SERVICE Inspect

INDICATOR
Visual check of clamps/piping…No major
maintenance requirements are expected on a daily COMPRESSOR
basis, but it is imperative to note that the service AIR CLEANER
requirements of any air cleaner are largely dependent INDICATOR
on the present working conditions.
Clamps and hoses should be noted, to ensure that joints

have not separated or any clamps broken since the
previous shift. Give a push on any piping to ensure that
it does not separate under manual force.
Note and repair any areas that appear questionable.

Always be conscious of present dust conditions relative
to the number of hours of engine operation.
ENGINE
If the air cleaner becomes plugged, it has the potential
AIR CLEANER
to break down the filter elements thus encourage drastic INDICATOR
engine wear.
The engine is equipped with air cleaner indicator; it dis-

plays the pressure difference that is measured before
and after air cleaner element. As the air cleaner gets
dirty, the pressure differential rises.
The air cleaner should be replaced when the indicator

shows yellow diaphragm enters the red zone and the
red piston locks in the visible position.
It should be inspected and cleaned up to six times in a year and replace once a year regardless of the number of
cleaning. Before installing the new filter, it should be thoroughly checked for any tear in the element. Inspect the
gasket or seal of the air cleaner for any damage.
8
6 ENGINE OIL LEVEL Check dipstick before engine start up

Maintain oil level between “ADD” and “Full” mark. Do not overfill –
several important factors can affect when overfilling crankcase – it will
degrade the power being produced, and will force bubbles into the oil
that could reduce the oil ability to lubricate and oil pressure, it will ENGINE OIL DIPSTICK
encourage excessive oil consumption, degrade cooling of the piston
and oil blowing out of the crankcase breathers.
Excessive oil consumption will allow deposits to form on the pistons

and in the combustion chambers. Deposits could lead to packing of
carbon under piston rings, and most importantly - wear of cylinder liner.
If oil level is above full mark, drain some of the oil right away until it’s at recommended level.
Do not mix different grade when adding oil in the crankcase. Record the amount of oil that is added for next oil
sample and analysis.
7 FUEL SYSTEM PRIMARY FILTER/WATER Drain

SEPARATOR
• Check the fuel filter for signs of leakage around the perimeter mounting gasket.
• Check the lower bowl for signs of water.
• Drain off any water while the engine is shut down.
The operational reliability of this engine very much depends on the cleanliness of the diesel fuel.
It is very important that the filters are well maintained at all times and should be replaced more
CAUTION often than specified in this maintenance program if the lower bowl shows signs of water collec-
tion. Also,…find the source of the contamination.
8 POWER TAKE-OFF Check/lubricate/adjust
Due to normal and sometime at severe torsional vibrations that power take offs (PTO) are subjected to – It is
crucial to have the unit inspected before operating the vehicle. Make clutch adjustment after wear in period. Refer
to OEM service manual.
The PTO is located on the left bottom side of the transmission. The drive gear is engine driven and provides direct
engine power.
Lubricate drive shaft from PTO to hydraulic pump with Unirex EP2 grease.
• Check hoses for any leaks, clean and tighten if any loose bolts are found.
9 TRANSFER CASE OIL LEVEL Validate oil level

Check the Dana 785 Transfer case oil level while the unit is shut down or before start up.Fill and maintain the
proper oil level with the specified oil. Run the gearbox for about 5 minutes to make sure all the hoses and manifold
are full. Check again and ensure proper level. Do not overfill or under fill. In either case, failures can result if oil
level is not maintained within the specified limits.
Avoid any contamination of the oil when filling gearbox.

CAUTION
10 RECORD DIESEL ENGINE HOURMETER Enter and fill Daily Maintenance Record in
this book
Many of the major maintenance checks are determined by the
amount of hours that this machine accumulates.
The Tachometer/Hourmeter is mounted at the cab console instru- TACH/HOURMETER

ment panel.
Use this hourmeter as the entry for the daily maintenance record.
Ensure that this number is recorded on a daily basis.
It will be used for:

• determining key maintenance points.
• Determining major warranty check points.
• Trouble shooting of all unit circuits, engine, electrical, hydraulic.
11 START UP DIESEL ENGINE Warm up engine, pump drive and circulate hydraulics at low idle
speed
Start the engine and allow it to run at low idle speed for a minimum of 10 minutes during warm ambient conditions
and a minimum of 20 minutes during cold ambient conditions.
Do not increase engine throttle speed during this warm up time, but rather listen for any unusual noises.The engine
may not run smoothly at this time; and that is quite normal. As the compression pressures of all cylinders begin to
rise and stabilize, the engine will become quieter and smoother.Any white/grey or blue smoke patterns from the
exhaust will fade away to a clean smokeless exhaust.
DURING WARM UP TIME:
• Review the contents of the PM program and ensure that all items from last shift have been signed off.
Any items that require attention must be evaluated and a specific time determined for the repair.
• Watch the panel gauges and determine that all warm up pressures and temperatures are normal
• Walk around the unit and check for any leakages that may just be showing now.
• During this warm up time, the pump drive is also engaged and engaging the hydraulic pumps. It is important
to watch and listen for any abnormal conditions.
8
DURING COOL DOWN TIME:
• Watch the panel gauges and determine that all pressures and temperatures are normal
• Walk around the unit and check for any leakages that may just be showing now
• Review the contents of the PM program and ensure that all items from this shift have been done.
• Start the engine and allow it to run at low idle speed for a minimum of 10 minutes during warm ambient
conditions and a minimum of 20 minutes during cold ambient conditions.
12 VISUAL & AUDIO INSPECTION Check all hydraulic hoses, fittings, connections,
hydraulic filter monitors, listen for unusual noises.
You have just started the engine and you have noted all of the gauge readings to ensure they are at normall
specifications. Walk around the unit while it is running and note the sights and sounds associated with the start.
Check all of the hoses and fittings. Check the hydraulic filter monitors and listen for any unusual noises.
• It is not unusual to see a higher than normal restrictions while the unit is warming up to normal operating tem
perature. Do not over react to this situation until the system hydraulics is fully at operating temperature.
• Look up to the air cleaner, muffler and cab mounted air conditioning unit. Note the position of the air restriction
monitor.
Check the hydraulic tank, sight glasses and fuel tanks, and covers
13 BLEED OFF THE AIR TANK RESERVOIR Manually discharge lower reservoir air valve
The air tank has a drain valve located on the bottom.This should be drained several
times a day to ensure that water build up is discharged before it can be transferred
into any air functioning components.
Bleed off small amounts of air at this discharge locations.
1005
14 SERVICE DIESEL ENGINE Change oil/filter, oil sample for analysis
• Drain the engine crankcase oil into a container. Allow at least 20-30 minutes of drain time. Always drain
the oil just after the machine has been active;…the oil should be hot at the time of the drain.
• Change the engine crankcase oil and “spin on” oil filter
• Take an oil sample for analysis
Oil Sampling
Method 1: Suction Gun:
A. The engine must be warm or have been running immediately before the sample is taken.
B. Install a new sampling bottle on the suction gun and insert the tygon tubing into the crankcase dipstick
tube. Draw enough oil to fill the bottle.
C. Cap the bottle and submit it along with the required documentation.
Method 2: Crankcase Drain Method

A. Engine must be warm or have been running immediately before the sample is taken.
B. In order to get a representative sample, remove the drain plug and allow the oil to run for several seconds
before collecting sample.
C. Slip the sample bottle into the oil stream and fill near to the top. Tighten cap securely.
Following full commissioning of this unit, the first 4 oil changes should be made at 150-200 hours of
operation. This should take us through the “wear-in” period of time and will ensure that the power unit is
functioning properly. Following the completion of this time “wear in”, and if there has been no concern to
date, you may proceed to the next step:
• If you are currently not on a routine oil sampling program, change the crankcase oil and filter at this time. If oil
analysis is not being used, oil must be changed. Extended oil change intervals can only be attained with con-
clusive data to support it.
• OEM supplied “spin on” oil filters must be used at all times. This maintenance program is compiled
around the premise that “after market” filters will not be used at any time.
• Excellent oil filtration can only be accomplished using good filtration products. The engine manufacturer
has deliberately specified filtration products that are matched to the performance and reliability standards
expected over the long term.
• Lubricating oils specified for these engines have demonstrated excellent total life. Typically engine oils will
exceed normal oil change intervals if they are kept clean. We have chosen to mount
quality “spin on” oil filter elements.
• “Spin On” elements are full flow filters; at operating temperature all of the oil pumped
by the pump must travel through the paper medium. Contaminants are removed from
the flowing oil based on their size. Enhanced filtration will automatically reduce the
contaminant load on the oil. Hence, the oil chemistry is not challenged to the same
level as oils that are not filtered to this same extent. Oil sample analysis will give us a way of ‘measuring’
the amount of useful life left in the existing volume.
• drain the engine crankcase oil immediately after the engine shut down. Allow at least 20-30 minutes of
drain time on the hot oil to ensure that it is fully drained.
• if you are gathering an oil sample (Method 2 above) during the drain time, allow several seconds of drain-
ing before inserting the sampling bottle. This will ensure that any external dirt around the drain plug has
been washed away prior to the gathering of the sample.
• close the drain valve completely and ensure that it does not leak.
• reinstall new oil in the proper quantity and cleanly through the filler spout. Make certain to properly tighten
the filler spout plug.
15 HYDRAULIC SYSTEM Test/ Obtain Sample

An oil sample must be submitted for analysis. It is important that the sample is submitted immediately after it is
taken, or many of the benefits of the program are lost.
The hydraulic system must be warm or have been running immediately before the sample is taken.
OEM Fluid Sampling and Test Procedure:

The objective of the OEM’s contamination control program is to ensure that the hydraulic fluid is cleaned
to the point where contamination plays no role in any component or system malfunction. Since 80% of all
CAUTION hydraulic system failures are caused as a direct result of contamination, to achieve this goal will signifi-
cantly reduce downtime and increase performance of your vehicle.
8
Target Cleanliness Levels
Based on the use of High Pressure Piston Equipment, Proportional valving, frequent machine start-ups at or below
–18° C, and the critical production nature of the hydraulic system components, a target cleanliness level for the
hydraulic fluid within the Coiled Tubing Rigs is set at ISO 4406 17/14.
Fluid Sampling Frequency

To ensure the continued protection of the hydraulic system, maintenance procedures and fluid cleanliness circuit
designs are to be monitored by way of sampling the hydraulic fluid at specified time intervals.
Documenting of this information can serve to provide feedback to manufacturer in its efforts to achieve contamina-
tion reduction goals, and recommend changes to maintenance intervals for the machine.
Given normal operating conditions, extracting samples from the hydraulic system and forwarding them to a labora-
tory for particle count and viscosity analysis is recommended to occur every 250 hours of service or 3 months
whichever come first. During abnormal operating conditions, replacement of major components, or a major system
overhaul, more frequent oil sampling may be required and the service department of the manufacturer should be
consulted.
Follow-up Actions
Results of fluid analysis will continually be monitored and recorded and will help determine the effectiveness of the
field filter replacement program, the filter circuit design, filter element efficiencies, and potentially provide informa-
tion regarding other machine operations.
16 COOLING SYSTEM SUPPLEMENTAL Test/Add

COOLANT ADDITIVE (SCA)
These criteria must always be met:
1. Coolant must be at specified levels. This includes an air space at the top of the radiator on units with
a surge tank. Where no surge tank is used , there must be an air space. You must become familiar
with the system on your unit.
2. 50/50 ratio of ethylene glycol anti freeze/ to water concentration.
3. The cooling system pressure must be maintained as specified for each engine.
The coolant provides a medium for heat transfer and controls the internal temperature of the engine during opera-
tion. In an engine having proper coolant flow, the heat of combustion is conveyed through the cylinder walls and
the cylinder head into the coolant. Without adequate coolant, normal heat transfer cannot take place within the
engine, and engine temperature rapidly rises. In general, water containing various materials in solution is used for
this purpose.
Coolant solutions used in diesel engines must meet the following requirements:
1. Provide for adequate heat transfer.
2. Provide a corrosion-resistant environment within the cooling system.
3. Prevent formation of scale or sludge deposits in the cooling system.
4. Be compatible with cooling system hose and seal materials.
5. Provide adequate freeze protection during cold weather operation and boil over protection in hot
weather.
The first four requirements are satisfied by combining suitable water with reliable inhibitors. When freeze protection
is required, a solution of suitable water and antifreeze containing adequate inhibitors will provide a satisfactory
coolant. Ethylene glycol based antifreeze solutions are recommended for year round use in diesel engines.
SCA Test Procedures:

Nitrite concentration is an indication of the overall coolant inhibitor concentration. Coolant must be tested for nitrite
concentration at regular intervals. Power Trac 3-Way Test strips (or equivalent) are recommended. Nitrite levels
must be within the ranges on the color chart.
For best results make the tests while the coolant is between 50-140F (10-60C). Wait at least 60, but not
longer than 75 seconds before reading the nitrite level. Promptly replace and tighten container cap after
each use. Discard unused strips if they have turned light pink or tan.
17 BELTS Inspection/Replace
Check tension at every oil change, observe the belt for cracks and fraying. Replace the belt if these are visible. This
is done simply by loosening the tensioner and pulling the belt out.
Refer to your service manual for proper installation of the new belt.

Coolant Analysis …. Collect a sample of coolant from the radiator and fill the sample bottle.
The best approach to rig service is to prevent maintenance problems before they occur. With coolant
analysis you can stay advised of your engine system's filtration efficiency and cleanliness. This helps you
catch potential trouble spots and fix them early.
Our broad testing program provides expert laboratory analysis of your diesel engine oil, hydraulic, fuel,
transmission and coolant fluids. Results are reported quickly and accurately.
Coolant analysis keeps your rig running smoothly so you can avoid costly downtime due to maintenance delays
19 TURBOCHARGER Inspect
Periodic inspection is highly recommended for the turbocharger compressor. Overtime, fumes from the crankcase
can filter through the air inlet. Oil by products will eventually accumulate in the turbocharger housing contributing to
the engine loss of power and efficiency.
If the turbocharger fails during engine operation, damage to the turbocharger compressor wheel and possible
engine problems could occur. These damages could further result to piston, valves and cylinder head problems.
86 Last Updated: W750 Operations & Maintenance Manual
8
20 CHECK DRIVELINES, HANGERS, U-JOINT Ensure integrity of all components
DRIVELINES
Grease all of the u-joint grease fittings at this time. Be careful not to pump great amounts of grease into the
fittings,...to the point where the seals are blown and exposed. If this is done on a consistent basis, only two shots of
grease should be required at each service.
21 PULLMASTER PL2 WINCH CRANKCASE OIL Drain and refill with specified oil
After several months of operation, it is now time to change the oil in the Pullmaster PL2 winch assembly.Do this
shortly after operating the winch, at least enough to make the oil warm and fluid in the crankcase.
Note: If the winch is used in excess of 40 hours per week, the gear oil should be changed every 6 months.
• Place the vehicle on level ground. Drain the oil into a suitable container and dispose of the waste oil in an envi-
ronmentally responsible manner.
• Check the drain plug magnetic centre core to see if there are any signs of major internal metal failure. Respond
as necessary.
• Allow at least 2minutes drain time. Then install the drain plug and fill the winch with hydraulic oil and run it for 5
minutes with no load to dislodge any accumulated contaminants. Drain the hydraulic oil into a container and rein-
stall the drain plug.
• Refill the winch with the specified gear oil. See Viscosity Spec in parts manual.
22 DENISON PUMP DRIVE Drain & refill with specified oil

After initial oil change for the first 100 hours or 3 months whichever occurs first, if 6 months or 2500 hours had
elapsed, it is now time to drain and change oil in the pump drive.
23 SUBMIT OIL SAMPLE ANALYSIS Hydraulic system

How can hydraulic system life be maximized?
What does clean hydraulic fluid look like?
Looking at and smelling hydraulic fluid is the simplest and most

effective way to determine the fluid’s condition. Clean fluid is
amber in color. A milky, dark, or otherwise abnormal color may
indicate the presence of one or more contaminants.
A milky appearance implies contamination by water. If the fluid

looks milky, take immediate action to avoid severe damage to your hydraulic system. Stop the influx of water and
remove the water from the system immediately. Water can be removed by passing the fluid through water-absorb-
ing filters, or by flushing or draining the entire hydraulic system.
A distinct in the smell of the hydraulic fluid can indicate a chemical breakdown. This type of breakdown is generally
due to air that has become entrained in the fluid, which creates varnish-like nitrogen-oil compounds that contami-
nate the fluid. If a distinct change in the smell of hydraulic fluid is detected, have it chemically analyzed.
8
24 HYDRAULIC SYSTEMS FILTER Change elements and ensure monitor indicators

are operational
The hydraulic filters have been carefully specified for the demands of
this unit. The replacement elements recommended at this service
interval must be used.
Do not use aftermarket elements at any time. Replace the element

and upper gasket (seal) each time. The necessary identification of the
assembly as well as the replacement element is found in this photo.
HYDRAULIC
FILTER

Ensure that the engine is shut off.
 Before removing the existing filter element make certain that you have a replacement element on hand bearing
the same part number.
 Allow the engine adequate cool down time.
26 CLEAN HYDRAULIC SYSTEM Use stand alone hydraulic cleaning system, sample
to ensure cleanliness.
After the hydraulic system has served your needs for one year, it is time to not
only clean the oil but also the tanks that contain it. This can be done with a
“stand alone” hydraulic filter cleaning cart.
The picture to the right is an example of a very typical system. Hydraulic oil can
usually be reused, over and over again, provided it is clean to very specific
cleanliness levels.
The laboratory that has been providing oil sample results can also test your
hydraulic oil before and after such a cleaning. Be prepared to run the filter cart
for at least 8-10 hours of continual cleaning. The oil in the tanks needs to be
stirred up to move any settled contaminants away from the bottom of the tank
with the eventual purpose of drawing it through the elements of the filter cart. At
the conclusion of this process, change the in-line hydraulic filters as well as
cleaning the:
8
• Hydraulic tank filler pump stand. The stand pipe needs thorough
cleaning.
• Hydraulic tank vent. Remove and replace or thoroughly clean it.
If you find that the hydraulic tank is very severely contaminated, Foremost
has designed an access into the tank for major cleaning.
1. Change the hydraulic system filters regardless of the indicator readings.
2. Hydraulic tank clean out. Simply remove the center bolt and the housing
will fall back, away from the seal around the main tank opening. You may
need a new seal to reinstall the access cover.
3. Submit an oil sample for analysis. Samples should be taken before and
after the full service. Respond to the results in a appropriate manner.
27 REPLACE COOLANT FILTER ELEMENT Ensure it is matched to the coolant requirements

• Make certain that the coolant quality is maintained to the highest standards.
• Make certain that coolant SCA levels are tested on a regular basis
After restarting the engine ensure that the filter gets hot indicating circulation.
28 BATTERIES Inspect
The condition of the batteries that power this system are of paramount
importance. Even though this engine is powered by diesel fuel, the ability for
the fuel to be used is determined by electronic controls. These electronic
controls are very sensitive to power changes and must be treated with the
greatest respect.
1. Ensure that the battery power source is stable. A battery that has no
capacity will cause numerous problems.
2. Ensure that the electrolyte level of the battery is maintained to the proper
level.
3. Ensure that a source of charge is always being applied to hold the avail-  Ensure that the battery posts
able voltage requirements. and connections are always in
4. A 12 Volt source of power is the only power that must be applied. An excellent condition. Remember
additional boost of power may harm the ECM (Electronic Control Mod- that the engine's computer
system will not function if the
ule). A fuse circuit, housed in the control panel is there to protect the battery supply voltage drops.
system from sudden power surges, but it remains important that it not be
 Long periods of cranking and a
tested by mistake. constant heavy draw on the
5. Ensure that the battery terminals, connections and other splices in the system will cause the batteries
wires have no voltage drop due to poor connections. to run hotter and cell fluid levels
Rig is delivered from Foremost Industries with ‘Maintenance Free’ batteries. It should not be necessary to
refill the batteries with water. In the event however, that replacement maintenance required batteries are
installed, be sure to fill with distilled, deionised or demineralised water only.
29 ENGINE OIL SAMPLE Obtain

Obtain sample during oil change and filter change for analysis.
Refer to item 15 of this preventive maintenance for procedures.
30 RADIATOR Clean
Wash clean both sides, check leaks...As important as keeping the coolant system level and pressure stable, is
the fact that the radiator assembly must be kept clean outside and inside at all times. It is not enough to observe
the core from the fan side thinking that all is well. Proper checks are made in the following way:
1. Check for signs of coolant seepage or leakage over the entire radiator assembly. If coolant is being added
over a period of time, chances are that leakages are occurring right at the radiator. Check the upper and
lower radiator tanks, bolting seams and gaskets.
2. Observe the fan side of the radiator core for cleanliness and signs of antifreeze lying at the base of the core
inside the shroud area.
3. Check the extreme upper and lower sections as well as the corners. Flush the core and keep it clean at all
times. If debris is left in place for a long time it becomes more difficult to remove, as well, it causes a rotting
action of the core. Once the process has begun, the core becomes impossible to seal to hold volume and
pressure. Since most of your current equipment is equipped with suction type fans the greatest accumula-
tions of debris would be on the forward side of the radiator
4. Check the security of the radiator cap to ensure a good and positive seal and the maintenance of system
pressure.
5. Check the radiator mounting brackets to ensure their security.
31 REPLACE AIR CLEANER ELEMENTS Regardless of appearance

At this time it is important to replace both the primary and secondary air cleaner
elements if they have not been replaced for other reasons over this past year.
They have both filtered a great volume of air; wet and dry, hot and cold, INDICATOR
contaminated with fuel and oil fumes along with various amounts of airborne
dust and dirt.
AIR CLEANER
The primary (outside) element may have already been replaced over this past ASSY
year, but it is not unusual to have the backup or secondary element remain in
1009
place for an entire year. Replace both at this time and while you are doing this,
examine the inside of the canister to make certain that it is in perfect condition.
Remember that these are very specific filter elements that must not be substituted for any other element.
“Donaldson” supplies these primary air filter elements. The part number of the element is stamped into the end of
the element. Always use this part number in making the replacement.
Always check the inside of the air cleaner canister. Make certain there are no dents or fractures in the metal
backing or the cylinder shaped flanges that actually hold the elements in place.
8
32 COOLING SYSTEM COOLANT Change

Do not open the radiator cap when it’s under pressure. Stop the engine and wait until it’s cold to the touch. Loosen
the cap slowly to relieve the pressure.
DRAIN COOLANT
• Open the drain valve if equipped and drain the coolant.
• Flush the cooling system with clean water in order to clean any debris.
• Clean the drain plugs.
• Fill the cooling system with clean water and cooling system cleaner.
• Start the engine and run the engine at low idle for about 30 minutes.
• Stop the engine and allow the engine to cool.
• Remove cap slowly to relieve pressure.
• Open the drain valve and allow water to drain.
• Flush the cooling system with clean water.
• Clean the drain plugs and replace
FILL COOLING SYSTEM
• Fill the cooling system with 50/50 mix of coolant/antifreeze.
• Start the engine and run at low idle and slowly increasing the rpm to get rid of air from the cavities.
• Stop the engine
• Add coolant until full.
• Clean the filler cap and inspect the gasket, if damage, install a new one.
• Perform pressure test according to the pressure stamped on the filler cap.
• Pour coolant in the recovery tank to COLD FULL, clean the cap and re-install.
• Start the engine and inspect for leaks and proper operating temperature.
Notes

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Operation &

UNCONTROLLED COPY All information subject to change

This operators manual is presented to furnish you with the neces-

For additional information consult the manufacturer, whose trained

Timely maintenance saves costly repairs and valuable time lost

FOREMOST Industries LP.

General And Personal Safety

Working safely is common sense. Common rules are made to govern

• Read the manual, and the warning and advisory stickers

• Be aware of maintenance and operating equipment.

• Don't make assumptions about working conditions.

• Make sure vehicles are parked in an appropriate area.

• Don't experiment with new drilling methods. Discuss your

• Always wear appropriate personal protective equipment.

• Be aware of hot surfaces on your machine. These surfaces

• Do not allow sparks or exposed flames around batteries.

• Do not carry loose objects in the cabin. They can act as

• Remember a careful operator always is the best insurance

• Never refuel vehicle when the engine is hot or running. Do

• Be sure all vehicles drives are in neutral before starting

• Engage the clutch gently if so equipped.

• Keep vehicle in gear when going down steep hills or

• Reduce high speed before making a sharp turn.

• Drive vehicle at speeds slow enough to insure safety, especially

• Never dismount from vehicles while it is in motion; wait until it

• Be careful when removing cap when radiator is hot. Refill only

• Keep a first aid kit and fire extinguisher in vehicle in case of an

• Never operate the engine in a closed garage or shelter.

• Keep hands away from all moving parts.

• Be extra careful when working on steep inclines.

• Set parking brake when leaving vehicle.

Many safety incidents can be prevented by good housekeeping.

It's Your Drill, Look After It!

FOREMOST Industries LP.

Location Of Hand-held Fire Extinguishers

There is a fire extinguisher on all Exploration Series drills. The loca-

If a fire occurs, follow this procedure:

1. Park the drill.

Under no circumstances should you place yourself in a position where

Defect Reporting And Identification

Effective safety practice includes the prompt repair of machine

FOREMOST Industries LP.

We recommend that the maintenance schedules be reproduced for ease of inspection. We

California Proposition 65 Warning

IMPORTANT SAFETY NOTICE

FOREMOST Industries LP.

(RTO, RTLO, RTOX)

FOREMOST Industries LP. PROSPECTOR W750 3

Safety Decal F - Never attempt to make any inspection or adjustment to drive

4 FOREMOST Industries LP.

Safety Decal N - As an added security feature during drilling operation in addi-

MAST & PARTS

CAB & ACCESSORIES

HEATING & COOLING

ENGINE & PARTS FRAME

AXLE & PARTS CIRCULATION

Engine assy - Cummins qsx15 665hp 665 hp - @ 2100 rpm

Air Compressor Air compressor-vehicle supplied w/ Cummins QSX15 665hp

Fuel Filter Fuel filter assembly used w/ Cummins QSX15 665hp

Air Cleaner Air cleaner assy- Cummins QSX15

FOREMOST Industries LP.

Montaje Herrajes de montaje para motor y transmisión usados con

Batería Grupo de baterías dos baterías 8D, 2 (dos) 12 voltios montados

Sistema de refrigeración Radiador reforzado empernado al motor temp. ambiente