Model SKF

Rotary Blasthole Drill

Service Manual
P/N 417199
Rev. 05

59.5844

19.4852

9.2949

19.2949

158°

2.2500

Bucyrus Mining Equipment, Inc.

3501 S. FM Hwy 1417 Denison, Texas 75020 USA
PARTS ORDERING AND PRODUCT SUPPORT
Use only genuine Bucyrus parts in the maintenance, rebuild or repair of these machines. The manufacturer shall have
no liability as to any unauthorized modification of machines or parts. The manufacturer is also not obligated or liable for
machines or parts that have been improperly handled; that have not been operated, maintained or repaired according
to furnished manuals or other written instructions, and that have been operated with other than genuine Bucyrus parts
or authorized OEM components.

IDENTIFICATION OF THE MACHINE

Always furnish the Model Number and Serial Number when ordering parts. This informa-
tion is found on the machine nameplate.

PART NUMBER AND DESCRIPTION

In addition to the Model and Serial Number, always give the part number and description
of each part ordered. If there is any doubt as to the correct part number and description,
furnish a dimensioned sketch or return the part to be replaced, transportation charges
prepaid. Your cooperation in furnishing as much information as possible will assist us in
filling your orders correctly and in the shortest possible time.

SHIPMENT
Unless otherwise instructed, all shipments will be made via motor freight collect, freight
forwarder or UPS prepaid and charged on our invoice. Shipments cannot be made on
open account until your credit has been approved by our accounting department.

PARTS ORDERING
In North America Telephone 1-800-854-9030
or Telefax 1-800-582-6570
Telephone (903) 786-2981
Telefax (903) 786-6407

PRODUCT SERVICE AND WARRANTY

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

Bucyrus Mining Equipment, Inc.

3501 S. FM Hwy 1417, Denison, TX 75020
www.bucyrus.com

© 2011 Bucyrus International, Inc.

All Rights Reserved
 Safety Information

This safety alert symbol indicates important safety mes-

sages in this manual. When you see this symbol, care-
fully read the message that follows and be alert to the
possibility of personal injury or property damage.

WARNING:
BEFORE STARTING ENGINE:

* Study Operator and Service Manuals

* Study Engine Operator and Maintenance Manual
* Practice All Safety Precautions
* Make Pre-Operation Check
* Learn Controls Before Operating

It is YOUR responsibility to understand and follow manufacturer's

instructions on machine operation and service, and to observe
pertinent safety precautions, laws and regulations.
Failure to read and understand this manual and all safety, capac-
ity and instruction placards on the machine before operating the
unit, constitutes a misuse of the machine. It is your responsibility
to know the manufacturer's specific requirements, government
regulations, required precautions and any work hazards which
may exist. You must make these known to all personnel working
with the equipment or in the area, so that all may take the neces-
sary and required safety precautions. Keep all children, visitors,
and untrained personnel away from the equipment. It is also your
responsibility to operate your equipment with skill, good judg-
ment, and caution. Following recognized safety procedures will
help avoid accidents. Failure to heed these instructions can result
in property damage, serious injury or death.

Drill Model : ___________________________________

Drill Serial No. : ________________________________

Date Delivered : ________________________________

Dealer : _______________________________________

Customer : ____________________________________

The descriptions and specifications contained in this manual were in effect at the time of printing. The right is
reserved to make changes at any time without notice and without obligation. 02/14/2011
Introduction i
Safety Support Placement

Support (Jack Stand) Guidelines for Rotary Drills

SKSW AND SKSS

IF DURING MAINTENANCE MACHINE

REQUIRES ADDITIONAL SAFETY SUPPORTS,
PLACE SUPPORTS (JACK STANDS) AS CLOSE TO
LEVELING JACKS AS POSSIBLE. THESE AREAS
SUPPORT THE MACHINE DURING DRILLING OPERATIONS.

SKF AND SKFX

NEVER SUPPORT THE MACHINE BY PLACING

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

ii Introduction
 Product Description

WARNING:
DO NOT use this machine for any other purpose than
blasthole drilling.
The SKF rotary blasthole drill is designed for blasthole
drilling purposes only.
Any other use could result in personal injury and/or
property damage and will void the warranty.

The SKF is specifically designed for blast hole drilling operations.

The SKF is a crawler mounted drill rig, which consist of two (2) major assemblies:

1. Rotary Drill Assembly

2. Excavator Type Undercarriage (Crawler)

The Rotary Drill Assembly is made up of the Engine Package, Compressor Package, Hydraulic
System, Rotary Drive, Pull-Down and Hoisting System and Drill Pipe Handling mechanism.

The Crawlers are powered by two (2) hydrostatic motors. Each Crawler has its own indepen-
dent, variable and reversible speed control, and is equipped with triple cleated grousers.

Manual Contents
This manual is furnished with the SKF rotary blasthole drill to in performing the necessary ser-
vice work to maintain the drill in good operating condition.

CAUTION:
Each person performing service work must be satisfied
that they have adequate knowledge and training to
perform the required tasks. A thorough understanding of
hydraulic and pneumatic systems as well as electrical
and mechanical knowledge and experience is required.

This manual contains repair and adjustment information for all major operating systems on the
machine. In some cases such as hydraulic pumps and motors it is better to replace the unit with a
new or rebuilt unit than to perform major repairs.

Should further information be desired or should particular problems arise which are not cov-
ered sufficiently in this manual, the matter should be referred to manufacturer.

Conponent Locations
The following pages highlight the major components and their locations on the drill. Due to the
variety of drill options and requirements, each drill may vary from the configurations shown.

Introduction iii
SKF Component Locator

FRONT OF MACHINE

COMPRESSOR OIL COOLER

ENGINE RADIATOR HYDRAULIC OIL COOLER

ENGINE AIR FILTER COMP. AIR CLEANER

RH FRONT JACK
LH FRONT JACK

COMPRESSOR AIR/OIL SEPARATOR

MAST ACCESS LADDER

AIR COMPRESSOR
FUEL TANK
DIESEL ENGINE
MUFFLER FUEL FILL

DRIVELINE
PUMP DRIVE

RETURN FILTERS

DUST COLLECTOR

HYDRAULIC OIL RESERVOIR

CHARGE FILTERS
(LOOP FILTERS OPTIONAL) MAIN ELECTRIC CABINENT

PRESSURE/VACUUM FILTER
MAST ELEVATING CYLINDERS
RH REAR JACK

LH REAR JACK

WINDOW WASHER BOTTLE

PIPE CAROUSEL
OPERATOR’S CAB
IN DECK PLENUM CHAMBER

A/C CONDENSER

IN DECK TOOL BOX

CRANE (OPT)

DRILLING PLATFORM CRANE CONTROLS (OPT)

VIEWING HATCH

Fig. i-1 SKF Top View

iv Introduction
 SKF Component Locator
TOP MAST SHEAVE

ROTARY DRIVE

CAROUSEL

BATTERY BOX

TRACK FINAL DRIVE

CRAWLER

HYDRAULIC OIL FILL PUMP

LIGHTS

DUST CURTAINS

A/C/ UNIT

Fig. i-2 SKF Side View

Introduction v
SKFX Component Locator
FRONT OF MACHINE

MAST REST

WATER TANKS
BOLTED UNDER DECK
AIR/OIL RECEIVER TANK

LEFT FRONT JACK

COMPRESSOR RIGHT FRONT JACK

AIR CLEANER
ENGINE AIR CLEANER

OIL INJECTION TANK

AIR COMPRESSOR
FRONT FUEL TANK

ENGINE MUFFLER

ENGINE COOLER

COMPRESSOR OIL COOLER

ENGINE
BATTERY BOX

CENTRAL LUBE
SYSTEM PUMP

REAR FUEL TANK

FLEX DRIVE COUPLING
(COVER REMOVED)

PUMP DRIVE GEARBOX HYDRAULIC FILL

HAND PUMP
FUEL TANKS MAIN RETURN FILTER
BOLTED UNDER DECK
CASE DRAIN FILTER

MAIN HYDRAULIC PUMPS HYDRAULIC TANK

DRILL STEM THREAD

LUBRICATOR
RIGHT REAR JACK
LEFT REAR JACK

DRILLING PLATFORM
OPERATOR’S CAB

vi Introduction
 SKFX Component Locator
TOP SHEAVES

ROTARY DRIVE
GEARBOX

TRAVELING SHEAVES

FINAL DRIVE

MAST CARRIER ROLLERS

TRACK ROLLERS
CRAWLER ASSEMBLY

HYDRAULIC FILL
HAND PUMP TENSIONER
IDLER
MAST ELEVATING
CYLINDERS FRONT IDLER

BOTTOM SHEAVES

Introduction vii
Contents

INTRODUCTION

SECTION 1 .................................................................................... SAFETY

SECTION 2 ................................................. OPERATOR'S CAB/CONTROLS

SECTION 3 .......................................................... MAINFRAME/CRAWLERS

SECTION 4 ..................................................... DRIVETRAIN/COMPRESSOR

SECTION 5 ....................................................... DUST CONTROL SYSTEMS

SECTION 6 ............................................ MAST/ROTARY DRIVE/PIPE RACK

SECTION 7 .............................................................. HYDRAULIC SYSTEMS

SECTION 8 ..................................................... ELECTRICAL COMPONENTS

SECTION 9 ....................... LUBRICATION AND PREVENTIVE MAINTENANCE

SECTION 10 .......................................................... OPTIONAL EQUIPMENT

viii Introduction
 Section 1

Safety

Maximum Wind Speed = 75 MPH (120.8 Km/h) at which time drilling must be
stopped, mast lowered and machine shutdown.

Safety 1-1
Hazard Classification

The Rotary Blasthole Drill is a heavy moving machine with a mast which raises vertically for drilling.
Like all moving objects and reach extending devices, there are potential hazards associated with its use.
These hazards will be minimized if the machine is properly operated, inspected and maintained. Operator's
must read this manual and have been trained to use the machine in an appropriate and safe manner.
Non-English speaking persons must have an interpreter explain all safety and operating procedures in this
manual. Should any questions arise concerning the maintenance or operation of the machine contact the
manufacturer at 1-800-258-0009.

Safety Alert Symbol

The safety alert symbol is used to alert you to potential personal injury hazards. Obey all safety messages
that follow this symbol to avoid possible injury or death.

Safety Alert Symbol

Hazard Classification
A multi-tier hazard classification system is used to communicate potential personal injury hazards. The
following signal words used with the safety alert symbol indicate a specific level of severity of the potential
hazard. All are used as attention-getting devices on decals and labels fixed to the machine to assist in
potential hazard recognition and prevention.

Indicates an imminently hazardous situation which, if not avoided, will result in

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

Indicates a potentially hazardous situation which, if not avoided, may result in

minor or moderate injury.
Yellow

Indicates a potentially hazardous situation which, if not avoided, may result in

property or equipment damage.
Blue

1-2 Safety
 Overview of Potential Hazards

Potential Hazard Prevention

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

Crush Hazard. Falling pipe car- Place carousel against lower

ousel can cause severe injury stops before servicing hydraulic
or death. circuit. Purge air from circuit after
servicing carousel circuit.

Entanglement Hazard. Death Keep clear of rotating drivelines.

or serious injury can result from Switch off engine before perform-
contact with rotating drivelines. ing service. Do not operate with
guard removed.

Entanglement Hazard. Rotat- Keep away from fan and belt

ing parts can cause personal when engine is running. Stop
injury. engine before servicing.

Crush Hazard. Falling mast can Purge air from circuit after servic-
cause severe injury or death. ing mast raising cylinder(s).

Burn Hazard. Hot pressurized Allow to cool before opening.

fluid can cause severe burns.

Safety 1-3
Overview of Potential Hazards
Potential Hazard
Fall Hazard. Death or serious
injury may result from climbing
raised mast.
Improper operation or mainte-
nance can result in serious injury
or death.
Electrocution Hazard. Death
or serious injury can result from
contacting electric power lines.
Crush / Fall Hazard. Riding
rotary head can cause severe
injury or death.
Flying Object & Spray Hazard.
Death or serious injury can re-
sult from release of pressurized
liquids.
Entanglement Hazard. Rotating
parts can cause severe injury.
Crush Hazard. Falling rotary
head can cause severe injury
or death.
1-4
Prevention
Do not climb raised mast. Lower
mast completely to service.
Read and understand operator's
manual and all safety signs before
using or maintaining machine.
If you do not understand the in-
formation in the manuals, consult
your supervisor, the owner or the
manufacturer.
Maintain required clearance.
Always contact the electric power
line owner. The electric power
shall be disconnected or the pow-
er lines moved or insulated before
machine operations begin.
Do not ride rotary head. Lower
mast completely to service.
Shut off live air at source, and re-
lieve all pressure before removing
filler plug.
Do not operate with guard re-
moved. Keep all guards in
place.
Purge air from circuit after servic-
ing feed cylinder(s).
Safety
 Overview of Potential Hazards

Potential Hazard Prevention

Explosion / Burn Hazard. Can Keep all open flames and sparks
cause death, burns or blindness away. Wear personal protective
due to ignition of explosive gases equipment, including face shield,
or contact with corrosive acid. gloves and long sleeve shirt.

READ MANUALS
Read all manuals prior to opera-
tion.

DO NOT OPERATE equipment if

you do not understand the infor-
mation in the manuals.

Consult your supervisor, the

owner or the manufacturer.

Explosion Hazard. Combustible Do not spray "High Energy" start-

gas can cause severe injury or ing aid into compressor air inlet or
death. engine grid heaters.

Fall Hazard. Death or serious Use the access system provided

injury can result from falling. when servicing the machine.

Crush Hazard. Standing on Keep clear of moving stairway.

stairway when raising or lower-
ing can cause severe injury or
death.

Electrical Shock Hazard. Can Disconnect battery prior to electrical system service
cause severe injury or death. work or any welding to avoid electrical shock and ma-
chine damage. Refer to service operator manual.

Safety 1-5
Safety Guidelines

Before Operation
• Do study this manual and fully understand the controls.
• Do be sure all safety guards are securely in place and all access doors are closed and locked.
• Do wear safety helmet, glasses and hearing protection when operating or working on machine.
• Do be sure all personnel are clear of the machine and work area before starting the engine or oper-
ating machine.
• Do be sure drill area is clear of all obstructions before operating and know the size limitations of the
machine.
• Do attach safety chain when using towbar.
• Do Not operate machine with:
• A hydraulic leak
• Broken or damaged electrical wiring
• Damaged hydraulic hoses or fittings
Operation
• Do provide sufficient ventilation when running the engine in an enclosed area. Exhaust gasses
contain carbon monoxide, a deadly poison, which is colorless and odorless.
• Do make sure the drill pipe is secured in the loader before raising or lowering the mast, if your
machine is equipped with a drill pipe loader.
• Do make sure the mast lock pins are engaged in the mast base before starting drilling operations.
• Do examine the surface before drilling to determine the possible presence of unfired explosives.
• Do use PPE (personal protection equipment) appropriate for the conditions you are working in; e.g.
safety helmet, safety glasses, hearing protection, gloves, respirator.
• Do Not wear jewelry or loose fitting clothing when working on machinery. Keep clothing, hands
and hair clear of moving parts.
• Do Not drill into or near a "bootleg" hole or any hole that may contain explosives.
• Do Not use the machine for any other purpose than what it was designed for. This machine is de-
signed for rotary blasthole drilling operations only.
• Do Not travel on steep inclines soft or unstable ground or close to unsupported excavations.
• Do Not move machine if drill is in a potentially unstable position.

After Operation
Normal Shut Down
1. Be sure machine is on solid level ground. Lower jacks, so the jack pads just touch the ground, but
do not lift machine up.
2. Be sure all controls are in the OFF or NEUTRAL position.
3. Allow engine to idle for a minimum of five (5) minutes before stopping.
4. Turn the ignition key to OFF position.
5. Check machine for any unusual conditions.
6. Report any defects to your immediate supervisor.

1-6 Safety
 Safety Guidelines

Maintenance
• Do be sure two people are present when performing service work, both being fully trained on the
safety issues. One person shall supervise from the operator's position and have immediate access
to an emergency stop in all situations. Visual, audible or verbal communication signals must be
established and understood by both persons.
• Do be sure each person is adequately trained to perform service and maintenance procedures.
• Do place a warning tag on starting controls to alert personnel that someone is working on the ma-
chine and disconnect battery before making repairs or adjustments to machine.
• Do be sure you have adequate lighting when performing service work at night.
• Do relieve pressure on hydraulic or pneumatic systems before loosening connections or parts.
• Do be sure machine and components are well supported before servicing or replacing parts.
• Do maintain a metal-to-metal contact between the fill nozzle and fuel tank when filling the fuel tank.
This will prevent sparks and the possibility of an explosion.
• Do Not hammer bit or drill pipe. Use only proper tools to make repair or adjustments.
• Do Not weld or grind near oil lines.
• Do Not attempt to remove radiator cap when engine is hot or has overheated.
• Do Not smoke or use an open flame near batteries, when servicing the batteries. Batteries can
give off hydrogen which is a highly explosive gas.
• Do Not leave tools or other loose objects on the engine, drive mechanisms or drilling platform.
They could be thrown by this equipment with a powerful force.

Equipment Transfer
• If all or part of the equipment is shipped to a new destination, always include a complete instruction
manual or a copy of the following topics from the operator's manual:
• Safety Section
• Operation Instructions including:
• Pre-Start Checks
• Start-up
• After Start Checks
• Shutdown Procedure Clearances from High Voltage Lines
• Propelling Machine Line Voltage Minimum Clearance
0 to 50 kv 10 ft (3 m)
50 to 200 kv 15 ft (4.6 m)
200 to 350 kv 20 ft (6.1 m)
350 to 500 kv 25 ft (7.6 m)
500 to 750 kv 35 ft (10.7 m)
750 to 1000 kv 45 ft (13.7 m)
Table 1-1

Safety 1-7
Safety Sign List

Refer to Figures 1-1 and 1-2 for locations

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

(ref. 429469)

Safety Sign Maintenance

Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap
and water to clean safety signs. Do not use solvent-based cleaners as they may damage the safety sign
material.

1-8 Safety
 Safety Sign Locator

Fig. 1-1

Safety 1-9
Safety Sign Locator

Fig. 1-2

1-10 Safety
 Safety Signs

WARNING WARNING
Entanglement
Hazard
Rotating parts can
cause personal injury.

3500 lbs/
1587 kg

Do not exceed hoist Keep away from fan

Crush Hazard
Falling objects can cause
severe injury or death.
capacity & stay away and belt when engine
from lifted loads. is running. Stop engine
(3500 lbs./1587 kg.) before servicing.
Do not use damaged 428893
cable. 429414

428893
429414

WARNING WARNING

Crush Hazard
Falling pipe carousel can
cause severe injury or death.
Crush Hazard
Purge air from circuit
Place carousel against after servicing mast
Falling mast can cause
lower stops before raising cylinder(s).
severe injury or death.
servicing hydraulic circuit.
Purge air from circuit after
servicing carousel circuit. 429418

429448
429418
429448

WARNING
WARNING

Entanglement Hazard Keep clear of rotating drivelines.

Switch off engine before performing
Death or serious injury
service. Do not operate with guard
can result from contact
removed. Burn Hazard
with rotating drivelines.
429406
Allow to cool before
Hot pressurized fluid can opening.
429406 cause severe burns.
429449

429449

Safety 1-11
Safety Signs

WARNING DANGER

Maintain required clearance.

Line voltage Required clearance
Electrocution Hazard
Death or serious injury can result from contacting 0 to 50 kv 10 ft (3 m)
electric power lines. 50 to 200 kv 15 ft (4.6 m)
Fall Hazard 200 to 350 kv 20 ft (6.1 m)
Always contact the electric power line owner.
Death or serious injury The electric power shall be disconnected or the 350 to 500 kv 25 ft (7.6 m)
may result from climbing power lines moved or insulated before machine 500 to 750 kv 35 ft (10.7 m)
raised mast. operations begin.
429437 750 to 1000 kv 45 ft (13.7 m)

429437

WARNING
Do not climb raised
mast. Lower mast
completely to
service.
429404

429404
Crush / Fall Hazard
Do not ride rotary head.
Riding rotary head can Lower mast completely
cause severe injury or to service.
death.
429420

429420

WARNING
WARNING
Flying Object & Spray Hazard
Improper operation or Read and understand Death or serious injury can
maintenance can result operator's manual and all result from release of
in serious injury or safety signs before using
death. or maintaining machine. pressurized liquids.
If you do not understand
the information in the Shut off live air at source, and
manuals, consult your
supervisor, the owner or
relieve all pressure before
the manufacturer. removing filler plug.
429445

429141
429445
429141

1-12 Safety
 Safety Signs

WARNING WARNING
Explosion / Burn Hazard
Can cause death, burns or blindness due to
Entanglement Hazard ignition of explosive gases or contact with
corrosive acid.
Rotating parts can cause
severe injury.

Keep all open flames and sparks away. Wear

personal protective equipment, including face
shield, gloves and long sleeve shirt.
READ MANUALS
Do not operate with Read all manuals prior to operation.
guard removed. DO NOT OPERATE equipment if you do not
Keep all guards in place. understand the information in the manuals.
Consult your supervisor, the owner or the
429431 manufacturer.

429431 429439

429439

WARNING WARNING

Crush Hazard
Purge air from circuit Explosion Hazard
Do not spray "High Energy"
after servicing feed
Falling rotary head can starting aid into
cylinder(s). Combustible gas can
cause severe injury or compressor air inlet
cause severe injury
death. or engine grid heaters.
or death.
429426 429444

429426 429444

Safety 1-13
Safety Signs (International)

429740

Flying Object & Spray Hazard (429740)

429720

Explosion/Burn Hazard (429720) Fall Hazard–Mast (429712)

T104915

Fall Hazard (T104915)

429713

Explosion Hazard–Ether (429713)

429705

Entanglement Hazard (429705)

1-14 Safety
 Safety Signs (International)

3500 lbs/
1587 kg

429718

429721
Crush Hazard–Carousel (429718)

Crush Hazard–Winch (429721)

429715 429719

Crush Hazard–Mast (429715) Crush Hazard–Rotary Head (429719)

Safety 1-15
Safety Signs (International)

429709

Electrocution Hazard (429719)

429722

Modification or Alter Hazard (429722)

429717

Burn Hazard–Pressurized Fluids (429717)

429714

Crush/Fall Hazard–Rotary Head (429714)

429710

Entanglement Hazard (429710)

429738

Entanglement Hazard (429738)

1-16 Safety
 Section 2

Operator Controls

Operator Controls 2-1

Graphic Symbol Legend

The following is a listing of the graphic symbols found on the cab control consoles and their basic descrip-
tion. The control functions are described in detail following the symbol descriptions.

Drill Functions

HOBO Swing HOBO Lock Deck Wrench

Auto Pulldown Holdback Hoist Pulldown

Winch Drill Pipe Support Oil Injection

Pipe Rack Swing Pipe Rack Rotate Pipe Rack Lock

Thread Lube Mast Lock Dust Curtain/Blower

ON

OFF

Main Air Drill/Propel Dust/Water

Mast Lower/Raise Front Jack–UP/DOWN Left Rear/Right Rear Jack–Up/Down

2-2 Operator Controls

 Graphic Symbol Legend

Drill Functions

Rotation/Left Track Pressure Pulldown Pressure Drilling Air Pressure

Hydraulic System Pressure Rotation–Forward/Reverse Pulldown Pressure–Increase/Decrease

Water Injection–Increase/Decrease

Operator Controls and Indicators

Compressor Discharge Temperature Engine Coolant Temperature Engine Oil Pressure

Fuel Level Battery Charge Engine Hourmeter

Engine Tachometer Engine Start Drill Hourmeter

Ether Injection Engine Stop Ignition–On/Off

Throttle–Fast/Slow

Operator Controls 2-3

Operator Control Panel (standard)

Fig. 2-1 Operator Control Panel

NOTE "PUSH" LEVER - Move lever AWAY FROM OPERATOR

"PULL" LEVER - Move lever TOWARDS OPERATOR

NOTE Options are used along with or in place of standard equipment on some machines.
Although every effort has been made to be as complete and thorough as pos-
sible in the following pages, not every photo and item described herein may be
used on each machine and your machine may have different controls than those
shown. Consult with manufacturer if unsure about any function or control prior to

1. Level Indicator
Indicates when the machine is level.
2. Throttle
Used to control the engine speed. Minimum engine speed is 1300 RPM, Maximum speed is 2100
RPM.
3. Jack Levers
Used for lowering and raising the jacks to level the machine. Pull the levers to lower the jacks.
Push the levers to raise the jacks.
3a. Right Rear Jack
3b. Front Jacks
3c. Left Rear Jack

2-4 Operator Controls

 Operator Control Panel (standard)
4. Mast Lever
Controls the lowering and raising of the mast.
• Pull lever to raise mast.
• Push lever to lower mast.
DO NOT raise mast close to power lines. See Section 1 for Clearances from High
Voltage Lines.

5. Propel Levers - Hydraulic pilot operated

Control the speed and the direction of the tracks.
• Push levers to propel forward (radiator end).
• Pull levers to propel in reverse (cab end).
5a. Right Track Lever
5b. Left Track Lever
6. Rotation Lever - Hydraulic pilot operated
Controls rotary head speed and direction.
• Push lever for forward rotation.
• Pull lever for reverse rotation.
7. Hoist/Pulldown System Lever - Hydraulic pilot operated
Controls the raising and lowering of the rotary head.
• Push lever to raise the rotary head.
• Pull lever to lower the rotary head.
8. Engine Diagnostic Lamp
Light flashes to indicate engine fault.
Refer to engine manual for fault codes and remedy.
9. Remote Pulldown Relief
Controls the pressure to the feed system to increase or decrease the weight on bit.
• Turn control clockwise to increase pressure.
• Turn counterclockwise to decrease pressure.
9a. Holdback System Pressure Control
This valve is used on high pressure machines using down the hole hammers and is used in con-
junction with the Holdback System Switch (see switch panel detail) which activates the solenoid
valve. Normally this valve is wide open (all the way out, counterclockwise) when drilling begins. As
pipe sections are added, the weight on the bit increases. To avoid too much pressure on the bit turn
valve IN (clockwise) to increase oil restriction from pulldown cylinder to tank.
• Turn control clockwise to decrease pressure on bit.
• Turn counterclockwise to increase pressure on bit.
10. Compressor Start-Run Valve–not shown (cold weather option)
Low Pressure Machines:
When starting machine, valve should be in the "Start" position so compressor is unloaded or in low
pressure mode. When machine is warmed up, turn valve to "Run" position.
High Pressure Machines:
When starting machine, valve should be in the "Low" position. When machine is warmed up, turn
valve to "High" position.

NOTE Machines without cold weather package do not use this valve.

Operator Controls 2-5

Operator Control Panel (standard)

Fig. 2-1 Operator Control Panel

Fig. 2-2 Instrument Panel

2-6 Operator Controls

 Operator Control Panel (standard)
11. Main Circuit Breaker Panel
Pull to disconnect, push to reset breakers.
11a. Circuit Breaker Panel
For Air Conditioner and Heater.
12. Light Switches
Used to turn on and off outside drill and cab interior lights.
13. Compressor Air Filter Indicator
Shows RED when filter element needs to be changed. Indicates differential pressure across filter
element.
14. Engine Air Filter Indicator
Shows RED when filter element needs to be changed. Indicates differential pressure across filter
element.
15. Ignition
The ignition key is used to turn the electrical power ON/OFF.
(a) Turn key ON to supply electrical power.
(b) Turn key OFF to stop engine.
16. Starter
The Start button is used to start the engine.
(a) Press Start button to start the engine.
(b) Release button once engine is running.
17. Ether Injection (optional)
Aids in starting cold engine.
(a) Press for 3 seconds.
(b) Release to discharge.
(c) Wait 3 seconds to start engine.
18. Drill Hourmeter
Meter records actual drilling hours.
19. Engine Hourmeter
Meter records total engine hours.
20. Engine Oil Pressure
Gauge indicates engine oil pressure.
21. Engine Tachometer
Gauge indicates engine revolutions per minute.
22. Engine Coolant Temperature
Gauge indicates the temperature of the engine coolant.
23. Compressor Discharge Temperature
Gauge indicates the temperature of the compressor discharge air.
24. Fuel Level
Gauge indicates fuel level in tank.
25. Voltage
Gauge indicates voltage output of the electrical charging system.
Operator Controls 2-7
Operator Control Panel (optional)

Fig. 2-3 Optional Control Panel

Fig. 2-4 Water Injection Pump Motor Flow

Control
Controls hydraulic flow to water pump motor.
Turn counterclockwise to increase flow.
2-8 Operator Controls
 Operator Control Panel (optional)

1. Auto Lube Controller

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

Operator Controls 2-9

Cat EMS Panel

Engine Monitoring System (EMS) The main gauge module has ten indicators (two
Display rows offi ve) that are used to display the system
diagnostics. A digital LCD readout displays the
parameters that are monitored. When metric values
Overview are displayed, the units of measurement are
also displayed. When US values are displayed,
the units of measurement are not displayed. For
example, if metric values are being displayed, the
readout would be “35 kPa”. If US values are being
displayed, the readout would be “5”. (The unit of
measurement “psi” is NOT displayed.)

The following parameters are monitored:

• Auxiliary pressure
• Auxiliary temperature
• Battery voltage
• Coolant temperature
• Engine hours
• Engine load (percent)
g00746960
Illustration 53 • Engine oil pressure
The EMS display is used to display various engine • Engine speed
parameters. The EMS display supports backlighting
in order to provide excellent visibility in various light • Fuel pressure
conditions.
• Fuel rate
The engine ECM processes the operating
parameters and diagnostic information before • Fuel temperature
sending this information to the EMS display via the
CAT data link. The main gauge module displays • Inlet air temperature
the information that is received from the ECM. Only
two wires are required from the ECM to the display • Turbocharger outlet pressure (boost)
for communication of all of the engine operating
parameters. The quad gauge module has graduated warning
zones that display information in an analog format.
The EMS display incorporates three individual The quad gauge module displays the following
gauge modules which can be installed in various information:
locations in order to enhance operation. One main
gauge module is required for each desired operator • Battery voltage
station. The tachometer module and the quad
gauge module are optional. These optional modules • Coolant temperature
will NOT operate without being connected to a main
gauge module. • Engine oil pressure
The following information describes the function • Fuel pressure
and the requirements for installation of each gauge
module: The tachometer module displays engine speed
(rpm) on an analog gauge.

2-10 Operator Controls

 Operator Control Panel (optional)

Fig. 2-5 Instrument Panel with optional Murphy Fig. 2-6 Cummins Engine Panel
Power View display.

14. Murphy Power View (optional)

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

Operator Controls 2-11

System Pressure Gauge Panel

Fig. 2-7 System Pressure Gauge Panel

2-12 Operator Controls

 System Pressure Gauge Panel

26. Rotation / Left Track Pressure

Maximum pressure 5000 PSI (344.7 bar). Avoid stalling the rotary head for extended
periods.

Gauge indicates hydraulic pressure required to rotate the drill string and when in propel mode, indi-
cates pressure to left track motor.
27. Pulldown Pressure

Maximum pressure 2600 PSI (179 bar). Higher pressures may cause the machine to
tip.

Gauge indicates hydraulic pressure at feed cylinder.

28. Hydraulic System Pressure
Indicates auxiliary pump pressure.
29. Drilling Air Pressure
Gauge indicates the air pressure in the drilling air line.

When the drilling air is turned OFF, there should be zero pressure on this gauge.

Operator Controls 2-13

Switch Panel (standard)

HOLD BACK

HOBO CLAMP THREAD LUBE

HOBO SWING OIL INJECTION

POSITIONER DUST CURTAIN

DUST/WATER MAST LOCK

PIPE RACK SWING PIPE RACK LOCK

AUX. PUMP MAIN AIR

FAST PULLDOWN AUTO TOOL

AUTO PULLDOWN DRILL/PROPEL

WINCH PIPE RACK INDEX

Fig. 2-8 Switch Panel

2-14 Operator Controls

 Switch Panel (standard)

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

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

Operator Controls 2-15

Switch Panel

38. Mast Lock

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

39. Used for Optional Functions

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

45. Fast Down

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

2-16 Operator Controls

 Switch Panel

47. Tool (Deck) Wrench

Switch retracts or extends the deck wrench to hold the drill pipe when breaking thread joints or
when multiple pass drilling is required.
• Push and hold switch up to retract tool wrench.
• Push and hold switch down to engage tool wrench.
48. Drill / Propel Switch
Engages the drill controls or propel system.
• Push switch up to engage the propel system.
• Push switch down to engage the drilling controls.

Drill mode must be selected if not propelling the machine or when the machine is
unattended. Drill mode engages the propel brakes.

49. TRAM High/Low Switch

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

Operator Controls 2-17

Lights, Circuit Breakers

ADDITIONAL DRILL CAB ROTATING

LIGHTS LIGHTS LIGHTS BEACON

FRONT CAB BEACON

LIGHTS LIGHTS

ADDITIONAL ECM IGN-24V WIPERS

LIGHTS

CIRCUIT
BREAKERS
DRILL LIGHTS MAIN POWER

CONTROL
PANEL

12 VOLT HEATER &

DRILL LIGHTS NOTE: Not all switches and circuit breakers are used on every
machine. See parts manual for specific switches and breakers.

PULL TO PUSH
DISCONNECT TO RESET
STARTER

Fig. 2-9 Control Panel - Left Side

Fig. 2-10 Control Panel - Right Side

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

2-18 Operator Controls

 Remote Mounted Cameras

There are two remotely mounted cameras on the machine that allow the operator greater visibility while
tramming. The cameras are switched on by a toggle switch on the cab circuit breaker panel.
The cameras can be positioned for best view but as a minimum should optimize the operator's visibility to
the front and far left side of the machine.
The display is located in the cab so that the operator has full view of the display when the machine is being
trammed. Only one camera is able to be viewed at a time.

9 8

Fig. 2-11 Camera Display Controls

1. POWER LED–indicates that the monitor has power

2. DAY/NIGHT SENSOR–senses available light and adjusts
monitor brightness accordingly
3. MENU BUTTON–initiates display of onscreen user controls
for image contrast, brightness and speaker volume
4. + BUTTON– UP button-increases the value for setup menu
items, such as volume
5. - BUTTON–DOWN button-decreases the value for setup
menu items, such as volume
6. POWER/CAM SELECT BUTTON–when pressed and held
for one second, turns the monitor ON or OFF; when pressed
briefly, switches image input
7. NORMAL/MIRROR SWITCH–switches image display to
Normal or Reverse (as it would appear in a rear-view mirror)
8. MONITOR CABLE–receives power and camera images
from the control box
9. BRACKET SLOT–accepts the adjustable mounting bracket
Operator Controls 2-19
Heater/AC/Pressurizer

Fig. 2-12 Heater/Air Conditioner Unit

1. Heater - A/C Temperature Control

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

Pressurizer w/Air Filter

Backpack Combo

2-20 Operator Controls

 AC/Heater

Cab Heater Fault Isolation

Check out the heater as follows:

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

Fig. 2-13 Heater Connections and Cutoff Valves (Cat.

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

Operator Controls 2-21

Air Conditioner

Maintenance and Servicing Schedule

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

Daily Weekly Monthly Every 3 Every 6 Yearly

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

Check Compressor Clutch:

1. Fixing screws & bracket
2. Clutch electrical connections X X X X X
3. Belt tension and wear
Check for Cleanliness of Condensing
Coil. X X X X

Clean Condenser Fan Motor With Dry

Compressed Air. X X X X

Check for Correct Setting of Thermo-

X X X X
stat.
Check Refrigeration and Water Lines
for Damaged Lines X X X X

Check Condensing Coil:

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

2-22 Operator Controls

 Air Conditioner

Maintenance and Servicing Schedule

Daily Weekly Monthly Every 3 Every 6 Yearly

Service Service Service Months Months Service

Check Liquid Receiver/Drier

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

Check Evaporator Coil

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

Check Electrical Connections of Ther-

mostat X X X

Check Control Switch

1. Electrical connections X X X
2. Operation

Check Heater Control Valve

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

Operator Controls 2-23

Air Conditioner

Maintenance and Servicing Schedule

Daily Weekly Monthly Every 3 Every 6 Yearly

Service Service Service Months Months Service

Check Condensate Drip Tray

1. For cleanliness X X X
2. For drain pipe blockage

Check Securing Screws & Bolts for

Tightness on Main Frame & Panels X X X

Check for Leakage of Refrigeration

and Water Lines X X X

Check Evaporator Pressure Regulator

1. For leakage X X X
2. Evaporator pressure setting

Check Fresh Air Fan Motor

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

2-24 Operator Controls

 Air Conditioner

DO NOT brush fins of coil with wire brush or irreparable damage will occur. If fins are
bent, use a correct coil fin comb to realign them.

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

Operator Controls 2-25

Air Conditioner

Servicing (cont.)
Changing Compressor:
1. Connect pressure gauge to suction gauge port on suction service valve stem one to two turns
clockwise. If gauge shows a pressure above zero gauge pressure and compressor can be oper-
ated, close suction service valve and operate compressor until compressor suction pressure is
reduced to approximately 2 psig.
2. Stop compressor and immediately close discharge service valve by turning clockwise.
3. Remove suction and discharge service valves from compressor.
4. Remove mounting bolts from compressor and remove compressor from engine.
5. Remove clutch.
6. Check to see that new replacement compressor:
a. Is of the same model and bill of material or an approved replacement for the one being re-
moved.
b. Oil level meets compressor manufacturer's specifications.
7. Install clutch removed from defective compressor with "non-Rok" key in place after checking to see
that the clutch has no objectionable imperfections in it. Tighten hexhead bolt in end of shaft.
Carefully lower, do not drop, clutch or compressor shaft. In most instances it is a
NOTE
good idea to replace clutch assembly as well.

8. Mount compressor using specified torque for mounting bolts, making sure that belts are properly
aligned and tightened to recommend belt tension (120 pounds for new belts, 100 pounds for used
belts).
9. Securing service valves to compressor:
a. If valves are of the flat pad type, check to see that valve mounting surfaces on both valves and
cylinder head are clean, free of nicks, gaskets and foreign material. Using new mounting gasket
mount valves to compressor and tighten mounting bolts.
b. If valves are of the Rotalock type, check to see that valve mounting surfaces on both valves
and compressor are clean and that o-ring valve mounting gasket is properly positioned and in good
condition. If deformed, broken or split, replace with new gasket. Properly align valve to cylinder
head and tighten Rotalock nuts.
c. Special care should be used so that no dirt or foreign material enters compressor during instal-
lation. The new replacement compressor should not be left unsealed to the atmosphere longer
than is absolutely necessary for preparation and actual installation. In no case should compressor
be open to atmosphere for more than five minutes.

2-26 Operator Controls

 Air Conditioner

Servicing (cont.)
Changing Compressor (continued):

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

Seal Assembly Replacement Procedure (Optional, HG 1000 Only):

Parts required: Seal Assembly Kit. This assembly includes front seal plate, seal nose and spring
assembly, o-ring for front plate and when required, a seal plate retainer and dust shield.
1. Remove compressor from engine in accordance with procedure under "Changing Compressor,"
Items 1 thru 4, inclusive. Place compressor on bench with shaft in up position.
2. Remove hex nut from end of crankshaft and remove flywheel or clutch by use of a 5/8-11 bolt. Do
not tap on shaft or clutch.
3. Wash or clean seal plate and adjoining surfaces of all dirt and foreign material.
4. Remove shaft key.
If the compressor being repaired has a dust shield, carefully remove it to avoid
NOTE
marring the shaft and discard.

5. Remove seal plate assembly by removing the six bolts in plate and gently pry plate loose, being
careful not to scratch, mar, or nick crankcase mating surface or edges.
6. Remove carbon nose and spring assembly from shaft by a seal puller. When pulling the seal assembly
from the shaft, do not scratch crankshaft. If rubber seal around shaft does not come out with carbon
nose and spring assembly, remove same with long nose pliers, pulling on edge of grommet.
7. Remove all gasket material, dirt and foreign material from crankcase mating surface to seal plate,
exposed crankshaft, and adjacent surfaces.
8. Coat exposed surface of crankshaft with clean refrigeration oil. Dip bellows seal assembly and shaft
seal washer in clean refrigeration oil. Place bellows seal assembly over shaft with end for holding
shaft seal washer going on last. With hand, push bellows seal assembly on shaft to a position beyond
taper of shaft. Do not push into seal cavity.

Operator Controls 2-27

Air Conditioner

Servicing (cont.)
Seal Assembly Replacement Procedure (continued):
9. Assemble shaft seal washer in bellows seal assembly, assuring before doing so to see that bellow
seal assembly and notches in washer line up with the tabs in bellow seal assembly. Cover exposed
surface of shaft seal washer with clean refrigeration oil.
10. Insert new o-ring in crankcase groove on mating surface for seal plate.
11. Place new front seal plate or seal plate and retainer over the shaft. Properly line up mounting holes
with seal and seal plate. When aligned, place plate and seal assembly up against crankcase. Insert
the six capscrews and screw in squarely and evenly. Tighten capscrews in a circular sequence to a
torque of 6–7.5 ft-lb.
12. Rotate shaft by hand 15 to 20 revolutions to seat seal. Clean off excess oil.
13. Install the key. Replace the clutch and tighten the clutch mounting bolt.

NOTE In general, it is more cost effective to replace the compressor.

Liquid Receiver/Drier - In the event that the system is contaminated, or has lost all its charge, or is
down for extensive maintenance, the receiver/drier should be replaced. It is a low cost item and
provides a great deal of protection. If the system has lost its charge completely, replacement should
be effected immediately prior to final leak testing and charging. This prevents contaminants being
drawn into the desiccant and thereby decreasing its capacity.

NOTE If the system is charged, the refrigerant MUST be recovered into a refrigerant
recovery device.

High Pressure and Low Pressure Controls - Follow Maintenance Schedule. If found faulty, replace
completely. Do not attempt to repair any part. Connection is via access ports so minimal refrigerant
is lost.
Filters - Clean regularly as per Maintenance Schedule with low pressure water or clean compressed air.
Replace if found that they cannot be cleaned.

2-28 Operator Controls

 Air Conditioner

Servicing (Cont.)
DO NOT brush fins of coil with wire brush or irreparable damage will occur. If fins are
bent, use a correct coil fin comb to realign them.

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

Operator Controls 2-29

Air Conditioner

Servicing (Cont.)
Setting of TX Valve Superheat & Evaporator Pressure Regulators (continued)
The following table has been provided for your convenience:

SUCTION PRESSURE SATURATED 10oF

TEMPERATURE SUPERHEAT

psi kPa oF oC oF oC

28.4 196 30 -1 40 5
30.0 207 32 0 42 6
31.7 219 34 1 44 7
33.4 230 36 2 46 8
35.1 242 38 3 48 9
36.9 254 40 5 50 11

How to set - Ensure that coils and filters are clean and system fully charged. Run through normal
checks and ensure pressures, etc., are within expected levels and no blockages in supply line to
TX valve.
Check that the bulb or coil is securely and cleanly clamped to the suction line.
Fit a thermometer probe to the suction line adjacent to the bulb or coil.
Connect up pressure gauge at the EPR port.
Operate the unit under a stable load and calculate the superheat, then adjust the TX valve slowly.
After adjustment, please allow time for the system to stabilize as 'hunting' will occur for some time.
Evaporator Pressure Regulator - This device modulates according to pressure in the evaporator. Its
purpose is to keep pressure, and therefore temperature, above a set figure to prevent ice build-
ing-up on the coil, and water in the heating circuit from freezing and possible rupture of the water
pipes.
If the pressure falls, it will restrict the flow, therefore the evaporator pressure and temperature rise,
but the suction pressure to the compressor falls. Operation is reversed if pressure rises.
In normal air conditioning applications, it should be set at 28-30 psi.
How to Set - Once the TX valve has been adjusted to correct superheat the EPR valve can be adjusted
by screwing the adjusting screw beneath the knurled cap. The Lp gauge line is left in position.

2-30 Operator Controls


Troubleshooting
I. System Produces No Cooling
CAUSE
Fuse blown or circuit breaker tripped
Broken or disconnected electrical wire
Broken or disconnected ground wire
Clutch coil burned out or disconnected
Electric switch contacts in pressure
switches burned excessively, or clutch
relay not working
Blower motor disconnected or burned
out
Mechanical:
Loose or broken drive belt
Compressor partially or completely
frozen
Compressor reed valves inoperative
Expansion valve stuck in open position
Refrigeration:
Broken refrigeration line
Safety valve
Leak in system
Compressor shaft seal leaking
Clogged screen or screens in receiver
dehydrator or expansion valve; plugged
hose or coil
Operator Controls
INDICATIONS
Electrical components will not operate.
Electrical components will not operate.
Electrical components will not operate.
Compressor clutch inoperative.
Compressor clutch inoperative.
Blower motor inoperative.
Visual inspection.
Compressor pulley slips on belt or will
not turn when clutch is engaged.
Only slight variations of both gauge
readings at any engine speed.
Head pressure normal, suction pressure
high evaporator flooding.
Complete loss of refrigerant.
Complete or partial refrigerant loss.
No pressure on high and low gauges
(applies to any system having complete
loss of refrigerant).
Clutch and front of compressor oily;
system low or out of refrigerant.
High gauge normal or may read high.
Low gauge usually shows vacuum or
very low pressure reading. Frosting usu-
ally occurs at point of blockage.
Air Conditioner
REMEDY
Replace fuse or reset circuit breaker.
Check all terminals for loose connec-
tions; check wiring for hidden breaks.
Check ground wire to see if loose, bro-
ken, or disconnected.
Check current flow to clutch; replace if
inoperative.
Replace low pressure or high pressure
switches or clutch relay.
Check current flow to blower motor;
repair or replace if inoperative.
Replace drive belts and/or tighten to
specifications.
Remove compressor for service or
replacement.
Service or replace compressor reed
valves.
Replace expansion valve.
Examine all lines for evidence of break-
age by stress or rubbing wear.
Examine valve on drier.
Evacuate system, apply static charge
leak test system, & repair leak as neces-
sary.
Replace compressor shaft seal.
Repair as necessary.
2-31
Air Conditioner
Troubleshooting
II. System Will Not Produce Sufficient Cooling
CAUSE
Electrical:
Blower motor sluggish in operation
Mechanical:
Compressor clutch slipping
Obstructed blower discharge passage
Clogged air intake filter
Insufficient air circulation over condens-
er coils; fins clogged with dirt or bugs.
Evaporator clogged
Evaporator pressure regulator defective
or improperly adjusted
Refrigeration:
Insufficient refrigerant in system
Clogged screen in expansion valve
Expansion valve thermal bulb has lost
charge
Clogged screen in receiver
Excessive moisture in system
NOTE After completing repairs above, system MUST have dehydrator replaced purged, evacuated and charged.
2-32
INDICATIONS
Small displacement of air from dis-
charge duct; blower motor possibly
noisy.
Visual inspection.
Blower operates at high speed but air
displacement very small.
Insufficient air displacement by blower.
Insufficient cooling at discharge outlet;
excessive high pressure gauge reading.
Fins clogged with lint, dust, or coated
with cigarette tars.
High pressure gauge readings normal;
low gauge usually reads too high.
Bubbles in sight glass; high gauge read-
ings excessively low.
Gauge pressures may be normal or may Purge system, remove screen, clean
show slightly increased head pressure
and low suction pressure; discharge out-
put temperature higher than specified.
Excessively high or low gauge readings;
may cool in excess or not enough.
High pressure gauge usually higher than Purge system; replace receiver.
normal; receiver cold to touch and may
frost.
Excessive high and low gauge reading.
Lack of cooling.
REMEDY
Remove blower motor for service or
replacement.
Remove clutch assembly for service or
replacement.
Examine entire discharge passage
for kinks, waddings or failure to open
passage during installation. Correct as
necessary.
Replace air filter screens and service, or
replace if necessary.
Clean condenser.
Remove cover and clean with
compressed air. Use cleaning solvent to
remove cigarette tars.
Repair or adjust as necessary.
Test for leaks. Repair as necessary.
Recharge system until bubbles
disappear and gauge readings stabilize
to specifications.
and replace.
Purge system; replace expansion valve.
Inspect system for refrigerant
overcharge. Correct.
If gauges still read high, inspect con-
denser for oil clogging.
Operator Controls

Troubleshooting
II. System Will Not Produce Sufficient Cooling (cont.)
CAUSE
Refrigeration (cont.):
Air in system
Evaporator pressure control valve im-
properly set
NOTE When a unit must be removed from the system for service or replacement, the system must
have the dehydrator replaced also, and the system must be purged, evacuated and recharged
to remove excess moisture.
III. System Cools Intermittently
CAUSE
Electrical:
Defective fuse or circuit breaker, blower
switch, or blower motor
Partially open, improper ground or loose
connections in compressor clutch coil
Mechanical:
Compressor clutch slipping
Refrigeration:
Unit icing up may be caused by exces-
sive moisture in system, incorrect super-
heat adjustment in expansion valve or
thermostat adjusted too low
Thermostat defective
Stuck regulator valve
Operator Controls
Air Conditioner
INDICATIONS
Excessive high and low gauge reading.
Sight glass shows bubbles or is cloudy.
System contaminated.
High air temperature off of evaporator
coil, high evaporator coil temperature.
INDICATIONS
Electrical units operate intermittently.
Clutch disengages prematurely during
operation.
Visual inspection operates until head
pressure builds up (as viewed on high
pressure gauge) at which time clutch
begins slipping, may or may not be
noisy.
Unit ices up intermittently.
Low side pressure may be low or exces-
sively high; adjustments will not correct.
Both head and suction pressures low;
moisture in system usually indicated.
REMEDY
Purge system, replace filter/drier,
evacuate and charge system with new
refrigerant.
Adjust pressure setting on valve to
28–30 psi. (1.9–2.1 bar).
REMEDY
Remove defective part for service or
replacement.
Check connections or remove clutch coil
for service or replacement.
Slippage over a prolonged period will
require that clutch be removed for
service; may require readjustment for
proper spacing.
Replace expansion valve if excess
moisture present, adjust thermostat.
Purge system, evacuate, recharge.
Replace thermostat.
Purge system and evacuate and replace
dehydrator to remove moisture; if still
stuck, replace regulator valve.
2-33
Air Conditioner

Troubleshooting

IV. Excessively Noisy System

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

2-34 Operator Controls

 Operator's Seat

Operator Controls 2-35

Operator's Seat

2-36 Operator Controls

 Section 3

Fig. 3-0 Electronic Control Module - Caterpillar C15

Electronic Engine
1. Electronic Control Module (ECM)
2. Plug-Ins - Disconnect from ECM BEFORE welding.
Mainframe / Crawlers
using Intertractor Tracks
CAUTION:
DO NOT weld on any part of the machine without first
disconnecting the negative battery cable or place the
battery disconnect switch in the open position. On ma-
chines equipped with electronic engine, disconnect the
connections to the Electronic Control Module (ECM) on
the engine before welding.

Fig. 3-0a Electronic Control Module - Cummins QST30-
Left Side
1. Electronic Control Module (ECM)
2. Plug-Ins - Disconnect from ECM BEFORE welding.
Mainframe / Crawlers
Fig. 3-0b Electronic Control Module - Cummins QST30-
Right Side
1. Electronic Control Module (ECM)
2. Plug-Ins - Disconnect from ECM BEFORE welding.
3-1
Leveling Jacks

Fig 3-1 Leveling Jack Cylinder Fig 3-2 Main Frame Top View

3-2 Mainframe / Crawlers

 Leveling Jacks

Leveling Jacks
Detecting Leveling Jack Troubles - Faulty leveling jacks may be detected
through inspection, through operating difficulties encountered, or during hydraulic
pressure tests outlined in Section 7.

Leveling Jack Cylinders

Remove
1. Lower jack pad to ground, but do not have weight of machine on jacks.
2. Shutdown machine.

WARNING:
Relieve pressure on hydraulic and pneumatic systems before
loosening connections or parts.

3. Remove lower pin that holds cylinder to inner casing.

4. With hydraulic pressure relieved, disconnect upper hose fittings to cylinder and remove adapters
from cylinder. Cap or plug all openings and fittings.
5. Remove capscrew and cap from top of cylinder outer casing.
6. Remove upper pin that holds cylinder to outer casing.
7. Install a lifting eye in place of the capscrew removed in step 5. This is a 1/2-13 UNC thread.
Using a suitable crane or heavy lifting device lift cylinder out of casing. Weight of cylinder is about
270 lbs. (122.8 kg).

Repair
Refer to parts manual for specific cylinder and repair parts. Refer to cylinder repair information in
Section 7 of this manual.

Replace
1. Replacement is reverse of removal procedure.
2. Rotate jack pad to align bolt hole with cylinder.
3. Cycle cylinder several times to remove trapped air before putting machine into service.

Lubricating Jack Casings

If jack casings are equipped with a grease fitting, grease it by applying a small quantity of grease.
If cylinder is not equipped with a grease fitting, extend the jack fully and apply grease directly to the
inner casing.

Mainframe / Crawlers 3-3

Mast Elevating Cylinders

Fig. 3-3 Mast Raising Cylinders

Fig. 3-4 Upper Cylinder Pin

1. Pin
2. Pin Retaining Bolt
3. Grease Line

3-4 Mainframe / Crawlers

 Mast Elevating Cylinders

Removal
1. Removal of mast cylinders is easier with mast in up position.

WARNING:
BE SURE mast lock pins are engaged before removing mast
elevating cylinders.
Relieve pressure on hydraulic and pneumatic systems before
loosening connections or parts.

2. With mast lock pins engaged and machine shut down, tag and remove hydraulic hoses. Cap
fittings and hose ends.
3. Support cylinder with suitable lifting device and remove upper and lower pins. Lift cylinder free of
mountings.

Repair
Refer to parts manual for specific cylinder and repair parts. Refer to cylinder repair information in
Section 7 of this manual.

Replace

1. With cylinder supported, install lower pivot pin, retaining plate and capscrews.

WARNING:
BE SURE to cycle cylinder at least six times to remove
trapped air before installing on mast, otherwise mast may fall
suddenly when lowered.

2. Connect hoses, start up machine and cycle cylinders at least six times to remove trapped air,
then slowly extend cylinder to line up rod end with clevis on mast.
3. Install upper pivot pin and retaining bolt on each side (fig. 3-4).
4. Install the grease lines (item 3, fig. 3-4) on each side, if machine is equipped with a central lube
system.

Mainframe / Crawlers 3-5

 Crawler Assembly

Fig. 3-5 Crawler Assembly

1. Steel Frame Complete 9. Track Roller
2. Sprocket 10. Screw (4)
3. Screw (32) 11. Washer (2)
4. Washer (32) 12. Idler Unit
5. Gear Unit 13. Screw (52)
6. Screw (32) 14. Washer (52)
7. Washer (32) 15. Tensioner Group
8. Track with Shoes

3-6 Mainframe / Crawlers

 Crawler Wear Limits

How to Measure Undercarriage Wear

The following information serves to establish wear measurement criteria for B6 undercarriage
components. Before measuring wear, all the parts must be properly cleaned. All measurements are in
millimeters (mm).

NOTE Always refer to the manufacturer's information for the latest updates.

C
BUSHING WEAR

New
10% 20% 25% 30% 40% 50% 60% 70% 75% 80% 90% 100%
C
66.5 66.1 65.85 65.6 65.3 64.9 64.5 64.0 63.5 63.2 62.9 62.3 61.7

TRACK PAD
A

New
10% 20% 25% 30% 40% 50% 60% 70% 75% 80% 90% 100%
A
26.5 24.7 22.9 22.0 21.1 19.3 17.4 15.6 13.7 12.8 11.9 9.9 8.0

PIN AND BUSHING WEAR / CHAIN STRETCH

Ln

New
10% 20% 25% 30% 40% 50% 60% 70% 75% 80% 90% 100%
Ln
811.2 812.8 814.5 815.4 816.3 818.2 820.2 822.3 824.6 825.8 826.9 829.6 832.3

Mainframe / Crawlers 3-7

Crawler Wear Limits

SPROCKET TOOTH PROFILE

Sprocket
Measurement method: visual
Wear on the sprockets affects the entire tooth contour without leaving any reference point on which the measurements can be based.
Moreover, each machine manufacturer has its own measurement specifications.
In the absence of clearly defined measuring methods, it would be practically impossible to set a common spec for all types of sprockets.
Therefore the only recommendation that can be given is to inspect the sprockets periodically and assess the wear patterns.
Also bear in mind that the sprocket must be replaced as soon as the tooth tips are completely worn to a point and best practice is to
replace the sprockets when new track chains are installed.

TRACK LINK HEIGHT MEASUREMENT

A
New
10% 20% 25% 30% 40% 50% 60% 70% 75% 80% 90% 100%
A
117.5 116.8 116.1 115.7 115.3 114.5 113.6 112.7 111.7 111.2 110.7 119.6 108.4

Idler Assembly
A

New
10% 20% 25% 30% 40% 50% 60% 70% 75% 80% 90% 100%
A
26.0 26.5 26.9 27.2 27.4 28.0 28.6 29.2 29.8 30.2 30.5 31.2 32.0

3-8 Mainframe / Crawlers

 Crawler Wear Limits

B
Track Rollers

A
CALIPER METHOD
New
10% 20% 25% 30% 40% 50% 60% 70% 75% 80% 90% 100%
A

180 179.2 178.2 177.6 177.1 175.9 174.7 173.4 171.9 171.2 170.4 168.7 167

DEPTH GAUGE METHOD

New
10% 20% 25% 30% 40% 50% 60% 70% 75% 80% 90% 100%
B
15 15.4 15.9 16.2 16.5 17 17.7 18.3 19 19.4 19.8 20.7 21.5

CARRY ROLLER POSITION

X1 X2

Mainframe / Crawlers 3-9

Crawler Wear Limits

Track Rollers

A
CALIPER METHOD
New
10% 20% 25% 30% 40% 50% 60% 70% 75% 80% 90% 100%
A

168 166.8 165.5 164.8 164.2 162.7 161.2 159.6 157.8 157 156.1 154.1 152

DEPTH GAUGE METHOD

New
10% 20% 25% 30% 40% 50% 60% 70% 75% 80% 90% 100%
B
18.5 19.1 19.7 20.1 20.4 21.1 21.9 22.7 23.6 24 24.5 25.5 26.5

TRACK ROLLER POSITION

X1 X2 X3 X4 X5 X6 X7 X8 X9 X10

CARRY ROLLER POSITION

X1 X2 X3

3-10 Mainframe / Crawlers

 Crawler Assembly

WARNING:
DO NOT attempt to replace the recoil spring.
Replacement of the recoil spring must be done by an
authorized Intertractor dealer.
The recoil spring assembly is assembled with a force of
several tons.
DO NOT put the recoil spring assembly under compres-
sion or release the tension with the nut that holds the unit
together.
Damaged threads on the spring carrier rod or nut can
cause the assembly to come apart with force, resulting in
personal injury or death.

Crawler Component Repair

It is recommended not to repair component parts of the crawler assembly. NEVER attempt to
repair the track tensioner unit. The track tension spring is assembled in a fixture with several tons of
force. For your safety and that of others DO NOT attempt to repair this unit. Replace the worn or
damaged components with new ones. Refer to the following Intertractor B6 Operating and Mainte-
nance Manual.
When ordering parts for the crawler, give the serial number of the unit to be sure to get the
correct parts. The serial number is stamped on the side frame adjacent to the final drive sprocket.

Fig. 3-6 Crawler Serial Number Location

Mainframe / Crawlers 3-11

Notes

3-12 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-13

Crawler Repair

3-14 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-15

 Crawler Repair

3-16 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-17

 Crawler Repair

3-18 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-19

 Crawler Repair

3-20 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-21

 Crawler Repair

3-22 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-23

Crawler Repair

3-24 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-25

 Crawler Repair

3-26 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-27

 Crawler Repair

3-28 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-29

 Crawler Repair

3-30 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-31

 Crawler Repair

3-32 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-33

Crawler Repair

3-34 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-35

 Crawler Repair

3-36 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-37

Crawler Repair

3-38 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-39

Crawler Repair

3-40 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-41

Crawler Repair

3-42 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-43

Crawler Repair

3-44 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-45

Crawler Repair

3-46 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-47

Crawler Repair

3-48 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-49

 Crawler Repair

3-50 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-51

 Crawler Repair

3-52 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-53

Crawler Repair

3-54 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-55

Crawler Repair

3-56 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-57

 Crawler Repair

3-58 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-59

Crawler Repair

3-60 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-61

Crawler Repair

3-62 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-63

Crawler Repair

3-64 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-65

Crawler Repair

3-66 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-67

 Crawler Repair

3-68 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-69

 Crawler Repair

3-70 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-71

 Crawler Repair

3-72 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-73

 Crawler Repair

3-74 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-75

 Crawler Repair

3-76 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-77

 Crawler Repair

3-78 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-79

 Crawler Repair

3-80 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-81

 Crawler Repair

3-82 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-83

 Crawler Repair

3-84 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-85

 Crawler Repair

3-86 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-87

 Crawler Repair

3-88 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-89

 Crawler Repair

3-90 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-91

 Crawler Repair

3-92 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-93

 Crawler Repair

3-94 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-95

 Crawler Repair

3-96 Mainframe / Crawlers

 Crawler Repair

Mainframe / Crawlers 3-97

Notes

3-98 Mainframe / Crawlers

 Section 4

Fig. 4-0 Electronic Control Module - Caterpillar C-15

Electronic Engine
1. Electronic Control Module (ECM)
2. Plug-Ins - Disconnect from ECM BEFORE welding.

Drivetrain / Compressor
CAUTION:
DO NOT weld on any part of the machine without first
disconnecting the negative battery cable or place the
battery disconnect switch in the open position. On ma-
chines equipped with electronic engine, disconnect the
connections to the Electronic Control Module (ECM) on
the engine before welding.

Fig. 4-0a Electronic Control Module - Cummins QST30-
Left Side
1. Electronic Control Module (ECM)
2. Plug-Ins - Disconnect from ECM BEFORE welding.
Drivetrain / Compressor
Fig. 4-0b Electronic Control Module - Cummins QST30-
Right Side
1. Electronic Control Module (ECM)
2. Plug-Ins - Disconnect from ECM BEFORE welding.
4-1
Engine and Drivetrain Service Procedures

Fig. 4-1 SKF Air Cleaner (ref. 415802)

1. Upper Body Assembly
2. Safety Element
3. Gasket
4. Nut
5. Primary Element
6. Wing Nut
7. Gasket
8. Cover Assembly
9. O Ring
10. Clamp Assembly
11. Shroud Assembly
12. Lower Body Assembly
13. Clamp Assembly
14. Dust Cup
15. Vacuator Valve
16. Pin

4-2 Drivetrain / Compressor

 Engine and Drivetrain Service Procedures

Service procedures outlined in this section include:

1. Diesel Engine
2. Air Cleaners
3. Drive Shaft
4. Pump Drive and Pumps
5. Compressor Drive Coupling
6. Air Compressor System

For hydraulic pump adjustment see Section 7.

Engine Service Procedures

Lubrication requirements, fluid levels and general service requirements are covered in Section 9.
Refer to the engine manufacturer's manual on the specific engine for more detailed service requirements.

Engine and Compressor Air Cleaner Service

Service for the disposable-filter type air cleaner (fig. 4-1) includes general inspection and replacing
the elements as required.

A. Inspection and General Service

1. Inspect air transfer duct between air cleaner and engine to be sure all clamps and joints are tight
and there are no cracks in ducting.
2. Verify that air cleaner mounting bolts and clamps are tight, holding air cleaner securely.
3. Check dust cup to make sure it is sealing completely around air cleaner body.
4. Be sure vacuator valve is in place (if so equipped), not inverted or damaged, and free from
obstruction.
5. Check body of air cleaner for dents and damage which could cause a leak or damage the ele-
ments.
6. Make sure all inlet accessories are free from obstruction and securely mounted.

Drivetrain / Compressor 4-3

Engine and Compressor Air Cleaners

Engine and Compressor Air Cleaner Service (continued)

B. Air Cleaner Service
Proper air cleaner servicing will result in maximum engine protection against the ravages of dust,
and can also save time and money by increasing filter life and dust cleaning efficiency.

Two of the most common servicing problems are:

Over-Servicing - New filter elements increase in dust cleaning efficiency as dust builds up on the
media. Don't be fooled by filter appearance, it should look dirty. By using proper filter restriction
measurement tools, you will use the full life of the filter at maximum efficiency.
Improper Servicing - Your engine is highly vulnerable to abrasive dust contaminants during the
servicing process. The most common cause of engine damage is careless servicing procedures.
By following the steps shown, unnecessary dust contamination to the engine can be avoided.

1. A filter indicator is used to measure the filter restriction. There are two indicators mounted on the
operator control console to monitor the right and left filters.
2. Dust cup should be dumped when 2/3 full. Make sure it seals all around the air cleaner body. On
vacuator valve equipped models, dust cup service is cut to a minimum; a quick check to see that
the vacuator valve is not inverted, damaged, or plugged is all that is necessary.

C. Element Servicing
1. When restriction indicates that element servicing is required, remove primary element. Before
installing new element, inspect the element and gasket for shipping or storage damage. Carefully
install element and wing nut. Reset the restriction indicator to green. For minimum downtime,
replace dirty filter with new or properly cleaned filter element. If element is to be serviced for
immediate re-use, reinstall outer cover to protect induction system while cleaning element.
2. Inspect and tighten all air cleaner induction system connections.
3. Inspect all gaskets. Replace if worn or damaged. Annual replacement of all gaskets is recom-
mended.

4-4 Drivetrain / Compressor

 Engine and Compressor Air Cleaners

Engine and Compressor Air Cleaner Service (continued)

D. Safety Element Service
The safety element is not to be cleaned. For maximum engine protection and air cleaner service
life, replace the safety element with a new safety element every third primary element change or
cleaning, or as indicated by the Safety Signal Service Indicator (this is the special nut that holds
the safety element in place).

E. Element Replacement
To replace the elements refer to fig. 4-1 and proceed according to the steps below.
1. Release the lower clamp (13) and remove dust cup (14). Remove and wash lower body (12) and
dust cap.
2. Remove cover (8), check condition of gasket (7).
3. Remove primary element.
4. Remove inside nut and gasket and remove small (safety) element.
5. Clean or replace primary element as required. Do not clean safety element

F. Element Cleaning Methods

Clean the primary element either by using compressed air or by washing. Compressed air is recom-
mended when element will be re-used immediately because a washed element must be dried before re-
use. However, washing does a better job and must be used when exhaust soot has lodged in fine pores of
the filter media. Use filter manufacturer's detergent which contains a special additive for removing soot
and carbon.

Replace element after 6 cleanings or annually, whichever occurs first.

Compressed Air - Direct air through element in the direction opposite to normal air flow through
the element. Move nozzle up and down while rotating element. Keep nozzle at least one inch from
pleated paper. Maximum air pressure to prevent damage of element is 100 PSI (7 bar).
Washing - Soak element 15 minutes or more in filter manufacturer's detergent and water solu-
tion. See carton for instructions. Rinse until water is clear. Maximum water pressure is 40 PSI (2.8
o o
bar). Air dry or use warm flowing air, max. 160 F (71.7 C). Do not use compressed air or light
bulbs.
Inspection - Place bright light inside element and rotate element slowly. If any rupture, holes or
damaged gaskets are discovered - replace.

Drivetrain / Compressor 4-5

Flexible Drive Coupling

Flexible Drive Coupling Service

Normally the flexible drive coupling requires no maintenance, however it may be necessary to re-
move the flexible drive coupling to service another component such as pump drive or engine. Follow the
steps below for repair or removal and installation of flexible drive coupling.
Removal
1. Remove flex drive cover.
2. Remove the socket head capscrews (items 5, 7 & 9) and slide the flexible flanges (3 & 8) back
far enough to be able to move the inner plate (2) back away from the outer plate (1). When the lip
of the inner plate clears the outer plate, you can lift the complete assembly out.

Installation
NOTE Use a torque wrench when installing the radial and axial capscrews.
DO NOT use anaerobic adhesives, such as LoctiteTM as they have a detrimental
effect of the bond between the rubber and the inserts.
Pre-coated capscrews provided can be used up to three (3) times. Recommended
adhesives are 3MTM 2353 or Nylok Precote 80.

Mounting Screws and Adhesive

The axial and radial mounting screws are treated for corrosion resistance (minimum grade DIN 8.8,
SAE Grade 8). The threads are coated with micro-encapsulated adhesive. The adhesive is released at
assembly and further enhances the performance and safety of the coupling. For adequate effect, the
adhesive should be allowed to harden for 4 to 5 hours prior to installation.

Fig. 4-2 Flex Drive Coupling (ref. 420382)

1. Outer Plate (2) 6. Tube
2. Inner Plate (2) 7. Axial Socket Head Capscrew (4)
3. Flexible Flange 8. Flexible Flange
4. Sleeve (4) 9. Radial Socket Head Capscrew (4)
5. Axial Socket Head Capscrew (4)
4-6 Drivetrain / Compressor
 Flexible Drive Coupling

Installation - continued

Fig. 4-3 Correct and Incorrect installation of axial and radial capscrews.

1. Be sure the flange hubs on the engine and pump drive are not damaged. Be sure they are free of
nicks and burrs and that all mounting bolts are tight.
2. Place a small amount of grease under the head of each capscrew. This reduces the possibility of
twisting the rubber element (see fig. 4-3). Install all pre-coated axial capscrews (longer) finger
tight. Be sure the flexible flange with the steel sleeves is on the engine side (fig. 4-2).
3. Rotate the tube (item 6, fig. 4-2) so all radial capscrews (shorter) can be installed finger tight.

NOTE Use caution when tightening capscrews to prevent twisting of the flexible flange, see
fig. 4-3. This is particularly important for the radial capscrews. If the part is twisted,
the cylindrical surface between the insert and the hub does not carry the load with
the whole surface, but with the two corners only. If this happens the other radial
bolts can loosen and the coupling will be destroyed.
4. Tighten all axial capscrews first, torque to 370 ft. lbs. (503 Nm), then tighten all radial capscrews
to same torque value.
5. Install flex drive cover.

Drivetrain / Compressor 4-7

Notes

4-8 Drivetrain / Compressor

 Pump Drive

Pump Drive Assembly - Removal & Replacement

WARNING:
Be sure to relieve pressure from hydraulic and pneumatic
systems before loosening connections or parts.

1. Remove drive shaft cover.

2. Disconnect drive shaft from pump drive unit.
3. Drain oil from pump drive gearbox before removing pumps. Support hydraulic pumps with a
suitable lifting device. Remove mounting bolts and separate from pump drive.

For pump drive service only, it is not necessary to remove hoses from hydraulic
NOTE
pumps. Move pumps back far enough to clear pump drive unit for removal. Pro-
vide adequate support for hydraulic pumps.
DO NOT let pumps hang from hydraulic hoses.

4. Support pump drive assembly with a suitable lifting device.

5. Remove mounting bolts from each side and lift out pump drive assembly.
Refer to parts manual for pump drive repair parts.
Replacement is reverse of removal.

Fig. 4-4 Pump Drive Assembly

1. Pump Drive
2. Mounting Bolts (8)
3. Drive Shaft Cover

Drivetrain / Compressor 4-9

Pump Drive

Fig. 4-6 Pump Drive Gearbox (ref. 412082)

1. Housing 10. Dipstick Tube 19. Adapter Stud (12)
2. Magnetic Plug 11. Dipstick 20. Hex Nut (12)
3. Pipe Plug (4) 12. Input Gear, 56 tooth 21. Flanged Input Assembly
o
4. Elbow 90 13. Driven Gear, 56 tooth (3) 22. Capscrew (8)
5. Reducer Bushing 14. Ball Bearing (6) 23. Tag - "No Oil"
6. Breather 15. Ball Bearing
7. I.D. Plate 16. Ball Bearing
8. Drive Screw (2) 17. Pump Adapter (3)
9. Expansion Plug 18. O Ring (3)

4-10 Drivetrain / Compressor

 Pump Drive

Pump Drive Gearbox - Repair

Disassembly (refer to fig. 4-6):
1. After removing pump drive from machine as outlined previously, place unit on a workbench so that
pump adapter pads are facing up.
2. Remove nuts from studs (or capscrews) that secure pump mounting pads to gearbox.
3. Lift the driven gears and their bearings from the gearbox.
4. Turn gearbox over so input adapter is facing up. Remove the capscrews that hold the input
adapter to the gearbox housing. Lift up the input adapter with input shaft, bearings and gear.
Inspection and Repair:
1. Check gears and bearings for damage, look for metal particles or flaking from bearings.
2. Check splines on output shafts for excessive wear.
3. Check bearing bores, the O.D. of the ball bearings are a slip fit. If there is excessive play, the
bearing bores will have to be built up and re-machined
4. Check condition of input shaft oil seal. Its always a good idea to replace seals when overhauling
the unit.
5. Clean mounting surfaces of old sealant, clean and remove any debris from inside of gearcase.
Assembly:
1. Assembly is basically the reverse of disassembly procedure. Remember to follow the notes with
the assembly drawing.
2. If bearings need to be replaced, press them onto both sides of gears as far as they will go. There
is no bearing pre-load, as the O.D. of the bearings are a slip fit.
3. Apply anti-seize compound or a good grade of wheel bearing grease to the splines of the output
shafts.
4. Apply silicone sealant to mounting flanges of pump adapter plates and input adapter.
5. Apply medium strength adhesive to input adapter and pump adapter plate capscrews and studs.
6. Pump adapter studs or capscrews should not be reused. Install new ones and torque to 150 ft.
lbs. (204 Nm). Torque nuts on studs to 150 ft. lbs. (204 Nm).
Installation:
1. Refer to "Removal & Replacement" procedures as outlined previously.
Lubrication:
1. After installing pumps, fill gearbox with proper lubricant (see Section 9). Oil level should be to
bottom of plug on side of gearbox or to FULL mark on dipstick. Oil volume is 6 3/4 quarts (6.8
liters) .DO NOT OVERFILL, this will result in overheating and possible malfunction of the unit.
o o
2. Maximum operating oil temperature is 225 F (107.2 C).

Drivetrain / Compressor 4-11

Hydraulic Pumps

Hydraulic Pump Identification

OUT
5

IN
4

5
2

OUT

OUT

4 3

Fig. 4-7 Pump Arrangement (ref.439365)

1. Left Track & Rotation (Closed Loop)
2. Charge Relief Valve (for Left Track/Rotation and Right Track pumps)
3. Pulldown & Auxiliary Functions (Open Loop)
4. Right Track (Closed Loop)
5. Fan & Dust Collector

4-12 Drivetrain / Compressor

 Hydraulic Pumps–Rexroth

The following pages reflect the installation and repair of Rexroth hydraulic pumps. For detailed pump
adjustments, see Section 7.

AA4VG125/32

Drivetrain / Compressor 4-13

Hydraulic Pumps–Rexroth

Hydraulic Piston Pumps - Removal and Replacement

WARNING:
Be sure to relieve pressure from hydraulic and pneumatic
systems before removing hoses, or loosening parts or
connections.

1. Tag and remove hoses from pump unit.

2. Cap or plug all connections.
3. Support pump with a suitable lifting device.
4. Remove mounting bolts and lift pump out.
5. Be sure to fill case of pump with oil before starting.
Replacement is the reverse of removal. See pump startup procedure before starting a new pump.

Model AA4VG Hydraulic Piston Pumps - Repair

Right Track Pump
Left Track & Rotation Pump

Overhaul of hydraulic piston pumps in the field is not recommended. Special tools, expert knowl-
edge and absolute cleanliness are essential. It is usually best to exchange the pump for a new or factory
rebuilt unit. However, replacement of shaft seals, control units, charge pump and external adjustments
may be done without difficulty. Refer to parts manual for your specific machine and Section 7 of this
manual for pump adjustments.

Shaft Seal Replacement

1. Remove the retaining ring with snap ring pliers.
2. Screw sheet metal screws into the two holes in the rubber seal and pull seal out by pulling on
screws with pliers.
3. Press in new shaft seal to the inner retaining ring, then install outer retaining ring.

Charge Pump Inspection and Replacement

1. Before removing capscrews, mark the position of the charge pump housing and separator plate in
relation to the port block.
2. Loosen the four capscrews with an allen wrench (6 mm for 28 - 125 size pumps, 10 mm for 180
- 250 size pumps).
3. Remove charge pump housing and inspect for wear or damage to gear set and o-ring seals.
Grease o-rings prior to assembly and be sure they are completely seated in the grooves.
4. Remove pinion shaft and inspect gear teeth and bearing surfaces for abnormal wear. When
assembling, make sure chamfer on outer edge of driven gear and drive gear is installed into
housing as shown in the illustration. Gears must be replaced as a matched set.
5. Torque capscrews to 18 ft. lbs. (24 Nm) for 29 - 125 size pumps or 62 ft. lbs. (84 Nm) for 180 -
250 size pumps.

4-14 Drivetrain / Compressor

 Hydraulic Pumps–Rexroth

AA4VG Shaft Seal Replacement AA4VG Charge Pump Inspection & Replacement

Fig. 4-7e AAVG Pump Shaft Seal Installation

Fig. 4-7f AAVG Charge Pump Removal & Installation

Drivetrain / Compressor 4-15

Hydraulic Pumps–Rexroth

Hydraulic Piston Pumps - Removal and Replacement

WARNING:
Be sure to relieve pressure from hydraulic and pneumatic
systems before removing hoses, or loosening parts or
connections.

1. Tag and remove hoses from pump unit.

2. Cap or plug all connections.
3. Support pump with a suitable lifting device.
4. Remove mounting bolts and lift pump out.
5. Be sure to fill case of pump with oil before starting.
Replacement is the reverse of removal.

Model A11VLO Hydraulic Piston Pumps - Repair

Auxiliary Functions & Feed Pump
Overhaul of hydraulic piston pumps in the field is not recommended. Special tools, expert knowl-
edge and absolute cleanliness are essential. It is usually best to exchange the pump for a new or factory
rebuilt unit. However, replacement of shaft seals, control units and external adjustments may be done
without difficulty. Refer to Section 7 for pump adjustments.

Shaft Seal Replacement

1. Protect pump shaft by wrapping with tape.

2. Remove capscrews from seal retainer and pry out with screwdrivers.

NOTE If pump has single shaft seal, the seal retainer will be held in by a snap ring.
Remove snap ring and pry out seal retainer.
3. Remove old seals and check shaft for deep grooves in seal contact area. If deep grooves exist,
you will need to add shims behind the seals so they will not be positioned in the grooves on the
shaft.
4. Install new seal(s), seal housing and snap ring or capscrews.

4-16 Drivetrain / Compressor

 Hydraulic Pumps–Rexroth

Fig. 4-8 A11VLO Pump Shaft Seal Installation

Drivetrain / Compressor 4-17

Hydraulic Pumps–Linde

The following pages reflect the installation and repair of Linde hydraulic pumps. For detailed pump
adjustments, see Section 7.

4-18 Drivetrain / Compressor

 Hydraulic Pumps–Linde

HPR Series (Open Loop) Pump

Drivetrain / Compressor 4-19

Hydraulic Pumps–Linde

4-20 Drivetrain / Compressor

 Hydraulic Pumps–Linde

Drivetrain / Compressor 4-21

Hydraulic Pumps–Linde

4-22 Drivetrain / Compressor

 Hydraulic Pumps–Linde

Drivetrain / Compressor 4-23

Hydraulic Pumps–Linde

HPV Series (Closed Loop) Pump

4-24 Drivetrain / Compressor

 Hydraulic Pumps–Linde

Drivetrain / Compressor 4-25

Hydraulic Pumps–Linde

4-26 Drivetrain / Compressor

 Hydraulic Pumps–Linde

Drivetrain / Compressor 4-27

Hydraulic Pumps–Linde

4-28 Drivetrain / Compressor

 Hydraulic Pumps–Linde

Drivetrain / Compressor 4-29

Hydraulic Pumps–Linde

4-30 Drivetrain / Compressor

 New or Rebuilt Hydraulic Pump - Startup

Startup Procedure
The following procedure has been developed based on experience with most types of applications,
however certain applications may require a departure from or variation to this procedure.
For the startup of new or overhauled installations:
1. If the prime mover is:
Internal combustion engine: (Diesel, gasoline or LP) - Remove the coil wire, close the injector rack
or leave the gas turned off and turn the engine over until the charge pressure reaches 50 psi (3.5
bar) or more.
Electric Motor: Jog the starting circuit until the charge pressure reaches 50 psi or more.
2. Start the prime mover, and if possible, maintain a pump speed of approximately 750 rpm for 5
minutes. This will allow the system to be filled.
3. Listen for any abnormal noises.
4. Check for oil leaks.
5. Run prime mover to 1800 rpm. (Adjust to the design speed if less than 1800 rpm.)
6. Set charge and pilot pressure as required for the application (refer to circuit schematic).
7. Retighten all connections.
8. Operate the control to work the hydrostatic transmission at approximately 20% of maximum
speed.
9. Deaerate system by venting a bleed valve or by cracking the highest connection until fluid seeps
out without bubbles.
10. Check fluid level and add fluid if necessary.
11. Continue operating transmission and gradually increase to full speed, still with no load.
12. With controls neutralized, check for creep in neutral. If evident, center the control in accordance
with the instructions in the pump service manual.
13. Check that the controls are connected so that the transmission operates in the correct direction
related to the control input.
14. Continue to monitor all pressure gauges and correct any irregularities.
15. Apply brakes and set high pressure relief valves (and pressure override if installed) to level
required for the application by stroking the pump to approximately 20% of maximum displace-
ment.
16. Check security of high pressure connections.
17. Check oil level and temperature.
18. Remove and inspect high pressure filter elements, if so equipped. Replace with new elements.
19. Operate transmission under no load conditions for about 15 minutes to stabilize the temperature
and remove any residual air from the fluid.
20. Again remove and inspect high pressure filter elements, if so equipped. If clean, the high pres-
sure, bi-direction filters may be removed from the circuit. If contamination is still evident, fit new
elements and continue flushing until the system is clean.

Drivetrain / Compressor 4-31

New or Rebuilt Hydraulic Pump - Startup

21. Replace the elements in the charge pump suction or pressure filter, whichever is installed.
22. Operate the transmission under full and normal load conditions.
23. Erratic operation may indicate there is still air trapped in the system. By working the pump control
to one or both sides the remaining air can be eliminated. The system is free of air when all func-
tions can be operated smoothly and when the oil in the reservoir is no longer aerated. (Usually
less than 1 hour of operation).
If, after following the Pre-Start and Startup procedures, the transmission does not
NOTE
perform correctly, refer to the relevant sections of the following troubleshooting
procedures.

4-32 Drivetrain / Compressor

 Hydraulic Piston Pumps - Maintenance

The hydraulic variable pumps are relatively maintenance free. Maintenance work is confined to the
system, by way of oil changes and renewal of filter elements. Both of these measures promote system
cleanliness. Monitoring and periodic maintenance of the system can prevent premature breakdowns and
repairs.

Under normal application conditions, the following maintenance intervals are suggested:
1. Renewal of Filter Elements
a. After commissioning.
b. At every 500 operating hours, or when filter indicator shows a dirty element.
c. With suction filtration, the filter element should be renewed as soon as a charge pump inlet
pressure of less than -3.2 psi (0.8 bar absolute) becomes evident with the transmission in
warm running condition (indicates contamination).
d. With charge flow filtration, watch for high pressure differential across the filter element (Refer
to filter manufacturer’s specifications).
Paper inserts cannot be cleaned; use throwaway cartridges (maintain a good
NOTE
supply).
2. Hydraulic Oil Change
a. After 500 operating hours (1st oil change).
b. Thereafter every 1000 operating hours or annually irrespective of operating hours achieved.
The oil change should be carried out with the system in warm running condition. Before refilling,
the reservoir should be cleaned to remove any sludge.
Caution: Rags or other threading material must not be used.
The recommended interval between oil changes is based on various factors and
NOTE
should be carried out according to the type of fluid, the degree of aging and
contamination of the fluid. The water content is also a contributory factor. Under
application conditions with a heavy occurrence of dust or severe temperature
fluctuations the intervals between oil changes should be shortened accordingly.

Practical experience shows that most maintenance errors occur during an oil change due to:
a. Use of an unsuitable hydraulic oil.
b. Use of oil contaminated due to faulty storage.
c. Failure to clean reservoir.
d. Inadequate cleanliness when filling (dirty drums or containers).
3. Leakage Inspection
a. After commissioning.
b. The complete transmission (pump, motor and all pipelines, filters, valves, etc.) should be
checked for leakage at regular intervals.

Drivetrain / Compressor 4-33

Hydraulic Piston Pumps - Maintenance

Caution: Leaking joints and connections must only be tightened with system pressure relieved.
4. Cleanliness Inspection
The oil tank breather should be regularly cleaned of dirt and dust to prevent clogging. The cooling
surfaces should be cleaned at the same time.
Caution: If hose couplings are used in the high pressure lines, it is imperative that the utmost care be
taken that no foreign bodies infiltrate the oil circuit when coupling and uncoupling (danger of
damage to rotary group, and even possibility of total breakdown).
5. Oil level Inspection
Inspect oil level in reservoir after commissioning, thereafter daily.
Caution: Top up only with specified oil type. Do not mix fluids.
Hydraulic Fluid
Most good quality, mineral oil based, hydraulic fluids exhibiting the following characteristics are
suitable for use in a Rexroth hydrostatic transmission.
• Good anti-wear performance
• Resistant to oxidation depredation
• Protection against rust and corrosion
• Resistance to foaming
• Ability to separate water rapidly
• Suitable for widely varying temperature conditions
• Good low temperature flow properties
• Retains viscosity-temperature characteristics in service
• Universally available
The prime consideration in the selection of hydraulic fluid is the expected oil temperature extremes
that will be experienced in service. The extremes should be considered when selecting a fluid, so that the
most suitable temperature-viscosity characteristics are obtained.
The fluid chosen should permit the system to operate within the following viscosity ranges.
Maximum viscosity at startup ........................................................................... 4600 SUS (1000 cSt)
Normal operating viscosity range ............................................................ 66–464 SUS (12–100 cSt)
Optimum viscosity range ........................................................................... 81–141 SUS (16–30 cSt)
Absolute minimum viscosity ..................................................................................... 60 SUS (10 cSt)
When the fluid viscosity is greater than 1000 SUS (216 c St) the transmission should be operated
at reduced speed until the oil has been warmed to a temperature of 40°F (4.5°C).
For applications that will operate near the extremes of viscosity and/or temperature, the fluid
manufacturer should be consulted for assistance in selection of the most suitable type and grade of fluid
for your application.
The selection and use of fluids from reputable and established suppliers is strongly recommended.

4-34 Drivetrain / Compressor

 Hydraulic Piston Pump - Troubleshooting
NOTE This troubleshooting procedure applies to the AA4VG series pumps. All reference
to settings and port locations refer to the AA4VG pumps. However the basic
troubleshooting procedure will apply to all hydraulic piston pumps.

Drivetrain / Compressor 4-35

Hydraulic Piston Pump - Troubleshooting

4-36 Drivetrain / Compressor

 Hydraulic Piston Pump - Troubleshooting

Drivetrain / Compressor 4-37

Hydraulic Piston Pump - Troubleshooting

4-38 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-39

Hydraulic Pump Repair - Linde

4-40 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-41

Hydraulic Pump Repair - Linde

4-42 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-43

Hydraulic Pump Repair - Linde

4-44 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-45

Hydraulic Pump Repair - Linde

4-46 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-47

Hydraulic Pump Repair - Linde

4-48 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-49

Hydraulic Pump Repair - Linde

4-50 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-51

Hydraulic Pump Repair - Linde

4-52 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-53

Hydraulic Pump Repair - Linde

4-54 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-55

Hydraulic Pump Repair - Linde

4-56 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-57

Hydraulic Pump Repair - Linde

4-58 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-59

Hydraulic Pump Repair - Linde

4-60 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-61

Hydraulic Pump Repair - Linde

4-62 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-63

Hydraulic Pump Repair - Linde

4-64 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-65

Hydraulic Pump Repair - Linde

4-66 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-67

Hydraulic Pump Repair - Linde

4-68 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-69

Hydraulic Pump Repair - Linde

4-70 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-71

Hydraulic Pump Repair - Linde

4-72 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-73

Hydraulic Pump Repair - Linde

4-74 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-75

Hydraulic Pump Repair - Linde

4-76 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-77

Hydraulic Pump Repair - Linde

4-78 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-79

Hydraulic Pump Repair - Linde

4-80 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-81

Hydraulic Pump Repair - Linde

4-82 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-83

Hydraulic Pump Repair - Linde

4-84 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde (HPV)

Drivetrain / Compressor 4-85

Hydraulic Pump Repair - Linde

4-86 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-87

Hydraulic Pump Repair - Linde

4-88 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-89

Hydraulic Pump Repair - Linde

4-90 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-91

Hydraulic Pump Repair - Linde

4-92 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-93

Hydraulic Pump Repair - Linde

4-94 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-95

Hydraulic Pump Repair - Linde

4-96 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-97

Hydraulic Pump Repair - Linde

4-98 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-99

Hydraulic Pump Repair - Linde

4-100 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-101

Hydraulic Pump Repair - Linde

4-102 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-103

Hydraulic Pump Repair - Linde

4-104 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-105

Hydraulic Pump Repair - Linde

4-106 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-107

Hydraulic Pump Repair - Linde

4-108 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-109

Hydraulic Pump Repair - Linde

4-110 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-111

Hydraulic Pump Repair - Linde

4-112 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-113

Hydraulic Pump Repair - Linde

4-114 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-115

Hydraulic Pump Repair - Linde

4-116 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-117

Hydraulic Pump Repair - Linde

4-118 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-119

Hydraulic Pump Repair - Linde

4-120 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-121

Hydraulic Pump Repair - Linde

4-122 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-123

Hydraulic Pump Repair - Linde

4-124 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-125

Hydraulic Pump Repair - Linde

4-126 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-127

Hydraulic Pump Repair - Linde

4-128 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-129

Hydraulic Pump Repair - Linde

4-130 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-131

Hydraulic Pump Repair - Linde

4-132 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-133

Hydraulic Pump Repair - Linde

4-134 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-135

Hydraulic Pump Repair - Linde

4-136 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-137

Hydraulic Pump Repair - Linde

4-138 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-139

Hydraulic Pump Repair - Linde

4-140 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-141

Hydraulic Pump Repair - Linde

4-142 Drivetrain / Compressor

 Hydraulic Pump Repair - Linde

Drivetrain / Compressor 4-143

Hydraulic Pump Repair - Linde

4-144 Drivetrain / Compressor

 Hydraulic Gear Pump - Repair

Hydraulic Gear Pumps - Removal & Replacement

WARNING:
Be sure to relieve pressure from hydraulic and pneumatic
systems before removing hoses, or loosening parts or
connections.

1. Tag and remove hoses from pump unit.

2. Cap or plug all connections.
3. Support pump with a suitable lifting device.
4. Remove mounting bolts and lift pump out.
Replacement is the reverse of removal.

Auxiliary Pump - Repair

• P365 Fan & Dust Collector Pump (Used with Rexroth Pumps)
Refer to the following P330/P350/P365 Service Manual for repair of gear pumps, used for the fan
and dust collector circuits. Refer to parts manual for your specific machine for repair part numbers.

Drivetrain / Compressor 4-145

Notes

4-146 Drivetrain / Compressor

 Auxiliary Pump

Drivetrain / Compressor 4-147

Auxiliary Pump

4-148 Drivetrain / Compressor

 Auxiliary Pump

Drivetrain / Compressor 4-149

Auxiliary Pump

4-150 Drivetrain / Compressor

 Auxiliary Pump

Drivetrain / Compressor 4-151

Auxiliary Pump

4-152 Drivetrain / Compressor

 Auxiliary Pump

Drivetrain / Compressor 4-153

Auxiliary Pump

4-154 Drivetrain / Compressor

 Auxiliary Pump

Drivetrain / Compressor 4-155

 Auxiliary Pump

4-156 Drivetrain / Compressor

 Auxiliary Pump

Drivetrain / Compressor 4-157

Auxiliary Pump

4-158 Drivetrain / Compressor

 Auxiliary Pump

Drivetrain / Compressor 4-159

Auxiliary Pump

4-160 Drivetrain / Compressor

 Auxiliary Pump

Drivetrain / Compressor 4-161

Notes

4-162 Drivetrain / Compressor

 Compressor Service Procedures

Compressor Drive Coupling - Removal & Replacement

The compressor is driven off the rear of the engine via a Torsional Drive Coupling (fig 4-9). The
coupling consists of a rubber element, flange and taper lock bushing. Usually no service is required other
than replacement when the rubber element is worn out. You can inspect the coupling through the opening
in the side of the bell housing / adapter plate.

WARNING:
Be sure to relieve pressure from hydraulic and pneumatic
systems before loosening parts or connections.

Compressor Unit - Removal:

1. Support the compressor unit with a suitable lifting device.
2. Remove bolts that attach compressor to engine and lower compressor mounting bolts (fig. 4-10).

NOTE Be sure not to lose shims at lower mounting.

Some couplings have a negative reaction to thread lock chemicals.

3. Loosen main air connection so compressor unit can be moved back far enough to allow access
to drive coupling.
4. Inspect drive coupling and taper lock bushing. Replace parts as required, refer to parts manual
for specific machine for part numbers.
5. See compressor installation procedure on following page.

Fig. 4-9 Torsional Drive Coupling

1. Rubber Element
2. Flange
3. Taper Lock Bushing

Drivetrain / Compressor 4-163

Compressor Service Procedures

Before Installation and Start-Up of New or Rebuilt Compressor:

1. Drain all lubricant from receiver tank and system.
2. Replace compressor oil filter element.
3. Remove separator and check receiver tank for foreign material, metal cuttings, varnish and
sludge. The system must be completely cleaned out.
4. Flush out compressor oil cooler.
5. Check all valves for foreign material and proper operation.
6. Install new filter elements and separator element. Install compressor unit (see "Compressor Unit -
Installation" below).
7. Reconnect all hoses and valves that were removed.
8. Fill system with new, clean lubricant (see section 9 for lubricant specifications) and pour 2 quarts
(1.9 liters) of lubricant down the inlet.
9. Start compressor and set the full load RPM and the idle RPM (refer to Sullair service manuals in
this section).
10. Set the controls at the rated pressure and RPM.
11. Check engine and compressor operating temperature. The engine water temperature should not
o o
be above 200 F (93.3 C) in radiator top tank. Compressor discharge temperature should not be
o o
above 210 F (98.9 C).
12. Check all shutdown devices for proper operation and temperature range.

Compressor Unit (low pressure) - Installation:

1. Support compressor with a suitable lifting device and align with engine flywheel housing.
2. Install capscrews (6) and lock washers (7) to flywheel housing. Move lifting straps to rear of
compressor to support weight.
3. Place a .060" shim (9) between the compressor mounting feet and the support bar (16). Install
capscrews (10 & 17) and flat washers (11) as shown in fig. 4-10. DO NOT tighten yet. Note that
capscrew (10) is 5" long and capscrew (17) is 6" long.
4. Loosen the capscrews (6) around the flywheel housing. Use capscrew (12) to support compres-
sor (fig. 4-10c). DO NOT over tighten capscrew (12) as this may overload the flywheel housing.
Turn capscrew no more than 1/4 turn after screw contacts compressor housing. Remove shims
(9).
5. Slide compressor back away from engine flywheel housing .015" to .030".
6. Use feeler gauges to check compressor alignment, measuring between engine flywheel housing
face and compressor housing face. A .001" difference at the flywheel housing will require .001"
shim at the compressor mounting feet. Turn capscrew (12) to adjust. After correct adjustment,
measure gap between compressor mounting feet and support bar (16). Install shims required to
take up gap.
7. Recheck alignment at the flywheel housing. The difference between the top and bottom of the
housing should be as close to zero as possible, but not more than .001". Repeat alignment and
shimming as necessary.

4-164 Drivetrain / Compressor

 Compressor Service Procedures

8. Slide compressor to engine flywheel housing and tighten the 24 capscrews (6). Torque capscrews
according to standard fastener torque values.
9. Loosen capscrew (12) so that the compressor is only supported by the shims (9). There should
be a 1/8" gap between the capscrew and compressor housing. Lock capscrew (12) in place with
nut (13).
10. Tighten the mounting capscrews (10 & 17).

Fig. 4-10 Compressor Installation - Low Pressure (ref. 416678)

Drivetrain / Compressor 4-165

Compressor Service Procedures

Fig. 4-10a Compressor Installation - Fig. 4-10b Compressor Installation -

Low Pressure Low Pressure

Fig. 4-10c Compressor Installation - Low Pressure

4-166 Drivetrain / Compressor

 Compressor Service Procedures

Compressor Unit (high pressure) - Installation:

Ref. figure 4-11a
1. With engine mounted to supports (14 & 15), use an overhead crane to support compressor and
align compressor to flywheel housing. Slide the compressor against the flywheel housing. Adjust
the crane support such that the compressor housing contacts the flywheel housing all the way
around.
2. Estimate the shim thickness that is required between the compressor feet and the support with a
feeler gauge. Install the measured amount of shims (9) under the compressor feet and install
capscrews and lockwashers (6 & 7).
3. Move crane slings to support rear of compressor (1) as the compressor CG is located to the rear
of the front compressor mounting feet.
4. With the rear of the compressor supported with the crane, loosen, but do not remove, the
capscrews (6) securing the compressor to the flywheel housing. Slide the compressor away from
the flywheel housing approximately 0.015 in to 0.030 in, depending on feeler guage used.
5. Use feeler gauge to check compressor alignment, measuring between flywheel housing face and
compressor face. A 0.001 in difference at the flywheel housing will require approximately 0.001
in adjustment at the compressor foot. Install appropriate shims.
6. Recheck alignment at flywheel housing. The difference between the top and bottom flanges
should be as close to zero as possible, but not more than 0.001 in.
7. Repeat alignment and shimming as necessary.
8. Slide compressor to flywheel housing and tighten capscrews (6) to 50 ft. lbs. (68 Nm).
9. The purpose of this method of installation is to minimize the overhung load (bending) that the
compressor applies to the flywheel housing. The maximum allowable bending moment at the
flywheel housing is 12,000 in. lbs. (1356 Nm). The unsupported compressor will produce a
bending moment of approximately 48,000 in. lbs. (5425 Nm).

Drivetrain / Compressor 4-167

Compressor Service Procedures

Fig. 4-11 Compressor Installation - High Pressure (ref. 430513)

Fig. 4-11a Compressor Installation - High Pressure

4-168 Drivetrain / Compressor

 Compressor Service Procedures

Fig. 4-11b Compressor Installation - High Pressure

Fig. 4-11c Compressor Installation - High Pressure

Drivetrain / Compressor 4-169

Notes

4-170 Drivetrain / Compressor

 Main & Auxiliary Air

The physical and functional aspects of the compressed air system are described briefly in the
following paragraphs. However, you should refer to the parts manual for installation details and to the
Sullair manual for technical information and troubleshooting.

Compressed Air Subsystem Components (low pressure)

Fig. 4-12 Low Pressure Compressor Cooling and Lubrication System Functional Diagram.

The compressed air subsystem consists of an engine driven air compressor, a separator tank, and
the miscellaneous control and plumbing elements required to control the operation of the subsystem and
to direct the air flow as desired. Figure 4-12 illustrates the compressor lubrication and cooling functions.
Although the following topics briefly describe the functions of the compressor and separator tank, you
should refer to the Sullair manual for functional details of these units.

1. Air Compressor - A single-stage, positive-displacement, oil-flood-lubricated type air compressor

is located behind the engine. The compressor operates in association with the separator tank to
provide compressed air at a given CFM to the rotary drill and to other air operated components
as required. The air compressor is engine driven by means of a torsional drive coupling.
In operation, the compressor unit receives oil from the separator tank sump. Besides acting as a
coolant for the compressor, the oil seals the leakage paths between the rotor and stator and
between the rotor meshes. Forming a lubricating film between the rotors, the oil allows one rotor
to directly drive the other. As the air is compressed, it becomes mixed with oil which must be
separated out before the air is used.
2. Separator Tank - The separator tank is both a sump for the compressor oil and a reservoir for
the compressed air. The tank serves to separate the cooling and lubricating oil from the air in the
air/oil mixture delivered by the compressor. A built-in filter in the separator tank filters the oil from
the air, and the recovered oil is returned to the compressor. A sight gauge in the return line
enables the operator to see that oil is flowing in the line. A blow-down valve is located in a com-
mon line between the compressor and tank.

Drivetrain / Compressor 4-171

Main & Auxiliary Air

Compressed Air Functions

The main function of the compressed air system is to provide air to the drill bit to propel the par-
ticles out of the hole. A secondary function of the system is to provide auxiliary air for control functions
and for operation of air tools, etc.

An air cleaner assembly on the intake to the air compressor cleans the air before it goes into the
compressor. Similar to the air cleaner for the diesel engine, the unit has the same type of filter elements.
The lower element traps the larger particles and a double filter unit that filters out the fine particles. Both
the safety (inner) element and the primary (outer) element are disposable. The lower permanent element
is designed to be removed for cleaning, while the upper safety (inner) element and the primary (outer)
element are disposable. Although cleaning of these elements is possible, replacement is recommended.
Refer to the parts manual for installation and assembly details and to the beginning of this section for
service instructions.

1. Main Air System - Filtered air to the drill bit passes through a check valve and the butterfly
control valve, then through the main air header to an air hose that connects with a stand pipe.
From the stand pipe the air is applied through a hose and swivel connector to the rotary element
where it passes into the drill stem to emerge from the drill bit, blowing out the particles from the
blast hole. Water is injected into the main air manifold by means of an air loop to the water
injection system.
2. Auxiliary Air - The auxiliary air is used to control the main air butterfly valve, and is also avail-
able for special tool applications such as indexing the optional pipe rack and operating the
automatic tool wrench.
3. AirSubsystem Control Functions - The main air control valve, controlled by a switch on the
control console, can be operated in two directions.
4. Air System Indicators - Three pressure gauges indicate the various air pressures in the sys-
tem. The air "T" tank pressure gauge indicates the pressure in the tank itself, while the filter
pressure gauge indicates the air pressure on the delivery side of the filter. The difference between
the filter pressure gauge and the "T" pressure gauge readings indicates the condition of the filter.
A pressure differential greater than ten PSI indicates incomplete air/oil separation, and thus
indicates the need to service the air compressor. The bit pressure gauge indicates the pressure
at the main air header, and hence the air pressure of the air delivered to the drill bit.
A pressure switch on the main air header completes the circuit to the drill hour meter. Thus, when
air is applied for drill operation the hour meter begins to count, measuring the time of operation.
When the air is cut-off, the hour meter ceases to run, thereby indicating the number of hours the
engine has operated (as indicated on the engine hour meter).

4-172 Drivetrain / Compressor

 Sulliscrew Compressor Unit

Functional Description
This unit provides continuous pulse-free compression to meet your needs. With a Sullair Compres-
sor, no internal inspection of the compressor unit is required.

Fluid is injected into the compressor unit and mixes directly with the air as the rotors turn, compress-
ing the air. As a coolant, it controls the rise of air temperatures normally associated with the heat of
compression. The fluid also seals the leakage paths between the rotors and the stator and also between
the rotors themselves. It acts as a lubricating film between the rotors allowing one rotor to directly drive
the other, which acts as an idler. After the air/fluid mixture is discharged from the compressor unit, the
fluid is separated from the air. At this time, the air flows to your service line and the fluid is cooled in
preparation for reinjection.

Control System
The purpose of the compressor control system is to regulate the compressor air intake to match
the amount of compressed air being used. The inlet valve consists of a butterfly valve controlled by an air
cylinder as shown in fig. 4-13. For high pressure machines refer to Sullair Drill Compressor manual for high
pressure units in this section. Fig. 4-12a shows the high pressure control circuit.

Fig. 4-12a High Pressure Compressor Control System.

Drivetrain / Compressor 4-173

Butterfly Inlet Control System (low pressure)

Butterfly System Initial Set-up Procedure

Perform steps 1 - 6 with machine shutdown and pressure relieved.
1. Align air cylinder (item 1, fig. 4-13). Be sure cylinder is in line and rods are not bent or damaged.
2. Using shop air at the base of the cylinder, extend the large rod all the way out.
3. With cylinder extended place a wrench on the butterfly lever and move back to fully closed position
(the small cylinder rod has a spring behind it). You should be able to close the butterfly valve before
the spring bottoms out. If not, adjust cylinder base or stop screw (2).
4. Shut off shop air supply and remove hose from cylinder. Push the butterfly lever all the way back so
large cylinder rod is fully retracted and butterfly valve is closed. Install hose from return manifold to
base of cylinder.
5. Using the stop screw (2), adjust butterfly inlet so it is just barely open, just enough to build 50 - 60
PSI (3.5 to 4.1 bar) after starting machine.
6. Back out the reducing regulator and the system regulator (fig. 4-13a).
7. Place compressor Start/Run valve in START position, and start machine and leave in low idle and
watch pressure build. Loosen running blowdown outlet to muffler (fig. 4-13a) and verify when blowdown
opens. Pressure should build to approx. 50 to 60 PSI (3.5 to 4.1 bar). This should be a steady
pressure. If not, adjust butterfly open or closed to get 50 to 60 PSI (3.5 to 4.1 bar). Check at high
idle and re-adjust if necessary.
8. Return to low idle and turn compressor vStart/Run valve to RUN position.
9. Adjust the system regulator to approx. 90 to 100 PSI (6.2 to 6.9 bar).
10. Shift to high idle and check, re-adjust if necessary.

Fig. 4-13 Butterfly Inlet Valve

1. Air Cylinder 2. Stop Screw 3. Butterfly Valve 4. Return Manifold 5. Grease Fitting (2)

4-174 Drivetrain / Compressor

 Butterfly Inlet Control System (low pressure)

11. Open main air partially and let the butterfly open and close.
12. Adjust reducing regulator (fig. 4-13a) to 20 PSI (1.4 bar).

Maintenance
1. Keep linkage and area around inlet clean.
2. Be sure clamps are tight and rubber inlet boot has no tears or holes.
3. Grease the butterfly valve weekly at the grease fittings (5) located at each end of the shaft.

Fig. 4-13a Low Pressure Air Control Piping (ref. 425365)

Drivetrain / Compressor 4-175
Butterfly Inlet Control System (high pressure)
Refer to Sullair Drill Compressor Model 20/12 500 - 1350 CFM (high pressure 250 - 500 PSIG)
Operator's Manual #02250136-659 in this section. This manual covers instructions for compres-
sor set-up and inlet valve adjustment.

Fig. 4-13b High Pressure Air Control Piping (ref. 411237)

4-176 Drivetrain / Compressor

 Compressor Oil Filter Service Bulletin

Drivetrain / Compressor 4-177

Compressor Oil Filter

Fig. 4-14 Compressor Filter Assembly

1. Visual Service Indicator
2. O-Ring
3. Locking Screw
4. Cannister Assembly
5. Filter Element
6. Filter Bowl
7. Filter Head

4-178 Drivetrain / Compressor

 Compressor Oil Filter

Routine Maintenance
The compressor oil filters does not normally require special attention except for periodic monitoring
of the differential pressure warning device.

1. If external leakage is noted, replace o-ring at leak. For bowl seal leaks, replace o-ring (2). If
leakage persists, check sealing surfaces for scratches or cracks; replace any defective parts.
2. Differential pressure devices actuate when the element needs changing or because of high fluid
viscosity in "cold start" conditions. If visual indicator is fitted and actuates during "cold start",
reset by depressing the rubber button when the normal operating temperature is reached. If
indicator actuates after resetting, replace element.

Changing Filter Elements

WARNING:
Relieve pressure on hydraulic and pneumatic systems before
loosening connections or parts.
Failure to depressurize system before proceeding could result
in explosive loss of fluid, damage to equipment, or possible
personal injury.

1. Turn off and depressurize the system. Open bleed plug (if fitted) 1 1/2 turns.
2. Unscrew and remove filter cover bowl (6) from head assembly (7), counterclockwise when viewed
from above. It may be necessary to use a lever on the "Rotolok Ring" of the filter bowl (6) to
loosen the bowl initially.
3. Remove filter element (5) and carefully inspect the surface for visible contamination. Normally no
dirt should show, but visible dirt or particles can be an early warning of system component break-
down and can indicate potential failure. Discard both the filter element and its o-ring. The filter
element is not cleanable. Any attempt to clean the filter element can cause degradation of the
filter medium and allow contaminated fluid to pass through the filter element.

CAUTION:
DO NOT attempt to clean or reuse element.

Drivetrain / Compressor 4-179

Compressor Oil Filter

Fig. 4-15 Compressor Oil Filter Assembly

4-180 Drivetrain / Compressor

 Compressor Oil Filter

Changing Filter Elements (continued)

4. DO NOT run the system without a filter element (5) installed. Check that the o-ring (2) on the head
assembly (7) is not damaged. Use replacement filter element part number called for on the
element change label or in the parts book.
5. Lubricate element o-ring (2) with clean system fluid and push open end of filter element (5)
straight onto the nipple in the head assembly (7). Clean out filter bowl (6) and lightly lubricate
threads of filter cover assembly with clean system fluid. Screw cover assembly onto head
assembly until it bottoms. O-ring sealing in not improved by overtightening.

CAUTION:
DO NOT use pipe wrench, hammer, or any other tool to tighten
bowl.

6. Bleed the system and check for leaks. To bleed filter, open bleed plug, if fitted, one and one half
turns. Jog system and fill filter until all air bleeds through plug, then tighten plug. Pressurize system
fully and check for leaks; if leaks occur, check o-rings and sealing surfaces.
7. After element change, ensure differential pressure device is reset by pushing in the button; electri-
cal switches reset automatically. When system reaches normal operating temperature, check
that the electrical switch has not actuated and/or the visual warning button has remained de-
pressed. If visual indicator rises due to a cold start condition, reset again as outlined in "Routine
Maintenance".

Drivetrain / Compressor 4-181

Compressor Maintenance

Please refer to the following Sullair manuals for proper operation and maintenance of the compressor:

250 to 2000 CFM Single Stage Low Pressure Manual No. 02250150-154
or
500 to 1350 CFM High Pressure (250 - 500 PSI) Manual No. 02250136-569

4-182 Drivetrain / Compressor

Drivetrain / Compressor 4-183
4-184 Drivetrain / Compressor
Drivetrain / Compressor 4-185
4-186 Drivetrain / Compressor
Drivetrain / Compressor 4-187
4-188 Drivetrain / Compressor
Drivetrain / Compressor 4-189
4-190 Drivetrain / Compressor
Drivetrain / Compressor 4-191
4-192 Drivetrain / Compressor
Drivetrain / Compressor 4-193
4-194 Drivetrain / Compressor
Drivetrain / Compressor 4-195
4-196 Drivetrain / Compressor
Drivetrain / Compressor 4-197
4-198 Drivetrain / Compressor
Drivetrain / Compressor 4-199
4-200 Drivetrain / Compressor
Drivetrain / Compressor 4-201
4-202 Drivetrain / Compressor
Drivetrain / Compressor 4-203
4-204 Drivetrain / Compressor
Drivetrain / Compressor 4-205
4-206 Drivetrain / Compressor
Drivetrain / Compressor 4-207
4-208 Drivetrain / Compressor
Drivetrain / Compressor 4-209
4-210 Drivetrain / Compressor
Drivetrain / Compressor 4-211
4-212 Drivetrain / Compressor
Drivetrain / Compressor 4-213
4-214 Drivetrain / Compressor
Drivetrain / Compressor 4-215
Notes

4-216 Drivetrain / Compressor

Drivetrain / Compressor 4-217
4-218 Drivetrain / Compressor
Drivetrain / Compressor 4-219
4-220 Drivetrain / Compressor
Drivetrain / Compressor 4-221
4-222 Drivetrain / Compressor
Drivetrain / Compressor 4-223
4-224 Drivetrain / Compressor
Drivetrain / Compressor 4-225
4-226 Drivetrain / Compressor
Drivetrain / Compressor 4-227
4-228 Drivetrain / Compressor
Drivetrain / Compressor 4-229
4-230 Drivetrain / Compressor
Drivetrain / Compressor 4-231
4-232 Drivetrain / Compressor
Drivetrain / Compressor 4-233
4-234 Drivetrain / Compressor
Drivetrain / Compressor 4-235
4-236 Drivetrain / Compressor
Drivetrain / Compressor 4-237
4-238 Drivetrain / Compressor
Drivetrain / Compressor 4-239
4-240 Drivetrain / Compressor
Drivetrain / Compressor 4-241
4-242 Drivetrain / Compressor
Drivetrain / Compressor 4-243
4-244 Drivetrain / Compressor
Drivetrain / Compressor 4-245
4-246 Drivetrain / Compressor
Drivetrain / Compressor 4-247
4-248 Drivetrain / Compressor
Drivetrain / Compressor 4-249
4-250 Drivetrain / Compressor
Drivetrain / Compressor 4-251
4-252 Drivetrain / Compressor
Drivetrain / Compressor 4-253
4-254 Drivetrain / Compressor
Drivetrain / Compressor 4-255
4-256 Drivetrain / Compressor
Drivetrain / Compressor 4-257
4-258 Drivetrain / Compressor
Drivetrain / Compressor 4-259
4-260 Drivetrain / Compressor
Drivetrain / Compressor 4-261
4-262 Drivetrain / Compressor
Drivetrain / Compressor 4-263
4-264 Drivetrain / Compressor
Drivetrain / Compressor 4-265
4-266 Drivetrain / Compressor
Drivetrain / Compressor 4-267
4-268 Drivetrain / Compressor
Drivetrain / Compressor 4-269
4-270 Drivetrain / Compressor
Drivetrain / Compressor 4-271
4-272 Drivetrain / Compressor
Drivetrain / Compressor 4-273
Notes

4-274 Drivetrain / Compressor

 Radiator/Oil Cooler Assembly

Unauthorized service will void the warranty. Read the following service information carefully before
performing any repair work. Refer to parts manual for your particular machine for correct parts ordering.

Fig. 4-16 L&M Radiator/Oil Cooler Assembly used with Low Pressure Compressor 1050/125 (ref. 423540 rev. E).

Drivetrain / Compressor 4-275

Radiator/Oil Cooler Assembly

Fig. 4-16a L & M Radiator/Oil Cooler used with High Pressure Compressor 1150/350 (ref. 423842)

4-276 Drivetrain / Compressor

 Double Fan Plumbing Circuit

Fig. 4-16b Double Fan Plumbing used with High Pressure Compressor 1350/350 (ref. 420822 rev. -)

Drivetrain / Compressor 4-277

Radiator/Oil Cooler Assembly

Square Tube Installation Tools - L&M Radiator (Mesabi)

Use of proper tools makes radiator/oil cooler repair faster and reduces risk of damage to tubes.
Following is a list of installation tools for square and round tubes, other special tools are available, if
needed. Refer to the L&M Radiator service information at the end of this section.

Fig. 4-17 Square Tube Installation Tools (L&M Radiator)

4-278 Drivetrain / Compressor

 Radiator/Oil Cooler Assembly

Refer to the following Mesabi service manuals for detailed repair information on the L&M Radiator
(Mesabi) units:
Mesabi Radiators & Cores
Mesabi Aluminum Tube Air To Oil Coolers
Mesabi Copper Tube Air To Oil Coolers

NOTE Be sure to check whether your machine has copper or aluminum tube oil coolers.
Copper tube units are good to 150 PSI (10.3 bar).
Aluminum tube units are good to 350 PSI (24.1 bar).

Round Tube Installation Tool - L&M Radiator (Mesabi)

Fig. 4-18 Round Tube Installation Tool (L&M Radiator)

Drivetrain / Compressor 4-279

Notes

4-280 Drivetrain / Compressor

Drivetrain / Compressor 4-281
4-282 Drivetrain / Compressor
Drivetrain / Compressor 4-283
4-284 Drivetrain / Compressor
Drivetrain / Compressor 4-285
4-286 Drivetrain / Compressor
Drivetrain / Compressor 4-287
Notes

4-288 Drivetrain / Compressor

Drivetrain / Compressor 4-289
4-290 Drivetrain / Compressor
Drivetrain / Compressor 4-291
4-292 Drivetrain / Compressor
Drivetrain / Compressor 4-293
4-294 Drivetrain / Compressor
Drivetrain / Compressor 4-295
Notes

4-296 Drivetrain / Compressor

Drivetrain / Compressor 4-297
4-298 Drivetrain / Compressor
Drivetrain / Compressor 4-299
4-300 Drivetrain / Compressor
Drivetrain / Compressor 4-301
4-302 Drivetrain / Compressor
Drivetrain / Compressor 4-303
Notes

4-304 Drivetrain / Compressor

 Section 5

Dust Control Systems

WARNING:
HEALTH HAZARD
Always use dust collector or water suppression to control dust
when drilling.
Avoid breathing airborne dust particles.
Prolonged inhalation of silica dust can cause silicosis, a serious
and sometimes fatal disease.

Dust Control Systems 5-1

Dust Control System Functions

The dust control system includes a dust curtain around the drilling platform and a blower type dust
collector which acts as a vacuum to gather the dust trapped within the dust curtain. The dust control
system also contains a water injection system that injects water into the main air stream to help control
dust accumulation.

The general functions of the dust control subsystem units are described below.

Dust Curtains - The dust curtains are attached to a framework underneath the drilling platform. Part
of the drilling platform forms the base for the mast assembly.
Dust Collector Subsystem Function - The dust collector subsystem consists of a dust collector
assembly connected by a hose to an outlet of the enclosure formed by the dust curtains.
The dry filter type dust collector uses a series of filters and retention rod elements to entrap and
dump the dust into the bottom of the unit to be funneled to the outside. Significant to the effec-
tiveness of this unit is a compressed air filter-cleaning system that automatically blows reverse
flow air through the filters during operation. This reverse flow cleaning is facilitated through use of
manifold system and a timer box. Auxiliary compressed air is applied to the manifold which routes
compressed air through each filter in an endless sequence. Sequence control is a function of the
timer, which sequentially operates control valves at the individual filter elements. Compressed air
for dust collector operation is plumbed in from the auxiliary air system.
Water Injection Subsystem Function - Water is injected into the main air stream to control dust
from the drilling operation. The water injection system consists of a water tank and a hydraulically
driven water pump that injects water into the main air header. The pump provides water from the
tank at a flow rate controlled by an adjustable flow control valve on the control console. The
water is directed to an air control valve which meters the water into the air stream at the main air
header.

Dust Control System Control Functions

The operator controls for the dust control system consist of a switch and a water flow control
valve on the control console. Because the water injection system and the dry dust control system
are not operated at the same time, a single switch operates the water pump hydraulic motor and
the dust collector hydraulic motor. Pushing the switch up engages the water pump motor, and
pushing the switch down engages the dust collector motor. The water flow control operates a
needle valve that controls the amount of water being injected into the main air stream.

5-2 Dust Control Systems

 Dust Collector

Basic Specifications
The SKF series blasthole drills are equipped with either the FC-3000 or FC-4500 dust collector.
Specifications are listed below.

TECHNICAL DATA
FC-3000 FC-4500
Air Capacity (suction) 3000 SCFM 4500 SCFM
No. Filters / Area (sq ft) 4 / 548 6 / 822
Hydraulic Power Reqd. 23 GPM @ 1300 PSI 23 GPM @ 1500 PSI
Suction Hose Dia. (in.) 8.0 10.0
Cross Section (in. x in.) 25.0 x 51.0 28.0 x 75.0
Height (in.) 88.5 89.4
Shipping Weight (lbs) 1300 1600

Fig. 5-1 FC-3000 Fig. 5-2 FC-4500

Dust Control Systems 5-3

Dust Collector

Fig. 5-3 Dust Collector (Model FC-3000)

1. Filter Access Doors
2. Air Valve Access Doors
3. Timer Box
4. Blower Housing
5. Flow Control Valve
6. Hydraulic Motor
7. Air Pressure Regulator/Filter

Fig. 5-4 Manometer Connections

1. Upper Tap
2. Lower Tap

5-4 Dust Control Systems

 Dust Collector

Initial Startup
If the Filter/Clone dust system was installed on your drill at the factory, the unit should be set up
ready to run. However, to make yourself familiar with the operation of the unit, it is advisable for you to go
through the following setup procedures.

The dust system is divided functionally into two separate subsystems:

A. The blower assembly which provides the vacuum source.

B. The compressed air supply which cleans the filter elements.

Blower Assembly - The blower assembly consists of an aluminum blower wheel, an aluminum
blower housing, and a hydraulic motor (fig. 5-3). For the unit to operate as it was designed, the blower
wheel must turn at both the right speed and the right direction to produce the level of vacuum required.

Fan Speed Adjustment -

The proper speed of the blower wheel is:
3000 RPM (12-13 inches of water) - without precleaner
3300 RPM (12-13 inches of water) - with precleaner

Although this speed can be set directly by use of a tachometer, the preferred method is to set the
speed to give the desired vacuum as measured with a water manometer. A water manometer is a very
simple device consisting of a clear plastic tube bent into a "U" shape. The tube is partially filled with water
so that two columns appear side by side and extend approximately half way up the length of the manom-
eter (fig. 5-5). If both ends of the tube are open to the atmosphere, then the water level in each leg of the
manometer will be equal. However, if one leg is connected to a vacuum source, the air pressure in the
other leg will be greater and will push the water column down on the side connected to atmosphere. At
the same time, the column connected to the vacuum will rise. The distance in inches between the two
water columns is the measurement of the vacuum in inches of water.

There are two places on the dust collector to measure the vacuum produced by the blower system
(fig. 5-4).
1. The upper tap is connected to the clean air side of the filter element.
2. The lower tap is connected to the dirty air side of the filter element.

Dust Control Systems 5-5

Dust Collector

Setting The Fan Speed - continued

Figure 5-5 shows the manometer connected to both taps at the same time. This measurement
would reflect the pressure drop across the filter element. To measure the clean air vacuum, connect one
side of the manometer to the upper tap and the other side to atmosphere (fig. 5-5). Likewise, to measure
the dirty air side of the filter, connect one hose to the lower tap and the other hose to atmosphere.
Normal readings (in inches of water) for the various configurations are shown at the top of fig. 5-5. Using
clean filters, adjust the fan speed by using the flow control valve (item 5, fig. 5-3) to achieve these
readings.

Direction of Fan Rotation

WARNING:
ALWAYS wear safety glasses when working on or around
equipment.
NEVER look directly into blower housing exhaust as small
particles could fly out at high speed, causing personal injury.

The blower wheel rotates in a clockwise direction when viewing the unit from the top. It is imperative
that the blower turn in the right direction. It will not always be immediately obvious when the blower is
turning backwards because the unit will still pull a vacuum of 2-3 inches of water. There are two methods
to ensure that the fan is turning clockwise. The first is to make the measurements above. However, the
easiest method is to physically view the fan as it is either starting or stopping and note the direction it is
turning. Always wear safety glasses and stand to one side of the blower housing exhaust, as small par-
ticles could fly out at high speed causing personal injury.
NORMAL MANOMETER READINGS:

MODEL UPPER TAP LOWER TAP PRESSURE DROP

FC3000 12-13 inches 9-10 inches 2-3 inches
FC4500 12-13 inches 9-10 inches 2-3 inches

Fig. 5-5 Manometer Setup

5-6 Dust Control Systems

 Dust Collector

Compressed Air Supply

The compressed air supply is used to back blow the filter elements to clean the filter material. The
outside section of the top of the dust collector is a compressed air reservoir. This air tank is connected
directly to the impulse valves which supply the air pulse to clean the filter. The lines should be drained
daily using the petcock next to the timer (fig. 5-8).

Air Regulator/Filter
Adjust the air regulator/filter to 40 PSI (2.8 bar). Lift up the cap and turn to adjust, then push back
down to lock. If air pressure is too high the filter elements will be damaged. The air regulator/filter is
located on the side of the dust collector opposite the timer (fig. 5-7). The air regulator/filter is equipped
with a water separator which automatically drains the water off as it accumulates in the bowl.

Fig. 5-7 Air Regulator/Filter

Fig. 5-6 FC3000 Dust Collector

1. Air Impulse Valves (4)
2. Filters (4)

Fig. 5-8 FC3000 Dust Collector

1. Relief Valve
2. Water Drain Petcock

Dust Control Systems 5-7

Dust Collector

Fig. 5-9 Electric Timer and Air Impulse Valve

Fig. 5-10 Electric Timer

1. Off Time Switch 5. Power Light
2. Last Out Switch 6. Pulse Sequence Lights (for number of filters)
3. First Out Switch 7. Fuse, 3 amp
4. Reset Button

5-8 Dust Control Systems

 Dust Collector

Compressed Air Supply (continued)

The impulse valve is connected directly to the air tank through a short threaded pipe nipple. Pres-
sure builds in the air tank and the impulse valve is held closed as long as the port on top of the valve is
closed. Under this condition, air from the tank is allowed to flow to both the top and bottom of a rubber
diaphragm. A light weight spring is used to ensure that the diaphragm stays seated in the closed position.

When air is exhausted from the top of the valve, the pressure from air on the bottom of the dia-
phragm causes it to be lifted momentarily. A small orifice connecting the air tank supply to the top of the
diaphragm causes the diaphragm to re-seat within approximately 0.1 second.

There is one impulse valve for each filter and these valves are made to sequentially pulse approxi-
mately every four seconds. The pulse rate is controlled by an electric timer.

Electric Timer
The electric timer (fig. 5-10) is a 24 Volt controller designed to sequentially activate 24V solenoid
directional air valves shown in Figure 5-9. The solenoid valve, when activated, exhausts to atmosphere
the air from the top of the impulse valve. Exhausting this air causes the impulse valve to pulse. The
electric timer is set up at the factory and should need no adjustment. However, to suit your particular
drilling situation you may wish to increase or decrease the interval between pulses.
The numbers on the FIRST OUT and LAST OUT dials indicate the order in which the impulse valves
fire. Do not change these settings. The red sequence lights indicate which impulse valve is firing. If only
four filters are used, then only four lights will flash. Always check that the green POWER ON light is on and
that the fuse is not blown. Push the RESET BUTTON if power has been interrupted.

Setting Time Interval Between Pulses

Use the OFF TIME switch (item 1, fig. 5-10) to set time between pulses. Each number on the dial
represents 0.5 seconds, so 1 equals 0.5 seconds, 2 equals 1 second and so on. The factory setting is
18 pulses per minute (about 3.2 seconds between pulses).

Filter Maintenance
If dust appears at blower housing, this indicates a filter has ruptured. Shutdown machine and change
filters immediately.
To check filter performance, connect manometer to upper and lower taps. With dust collector run-
ning, the difference between the two legs of the manometer should be about 3 in. (76.2 mm) of water for
a clean filter. When the water difference is more than 4 in. (101.6 mm), filters need to be changed.

Ground Water
Shut off dust collector if ground water is encountered, so filter will not plug up.

Dust Control Systems 5-9

Dust Collector

Routine Maintenance
In order to insure that your Filter/Clone Dust Control system is operating to its design specifications,
the following visual inspections should be performed on a periodic basis.

1. Verify that the dropout hose located at the bottom of the dust collector is securely fastened to the
dropout cone. This hose should be free of any holes and should form a tight seal during the period
when the collector is pulling a vacuum. The hose will open momentarily during each back-pulse of
compressed air when the filter elements are being cleaned.
2. The suction hose leading from the deck to the collector should be clear of obstructions such as
build-up of dirt or mud. There should be no kinks or extremely sharp bends in the suction hose.
3. Inspect the dust curtains surrounding the hole to be sure there are no holes or gaps.
4. Listen to the back-pulsing of filter elements. There should be a sharp pulse of air every 2-3 seconds.
If a pressure gauge is installed in the air supply line to the collector, verify that the air is pulsed at a
peak pressure of approximately 40 PSI (2.8 bar).
5. Observe the discharge of the blower assembly. NEVER look directly into the discharge of the
blower, as small particles could come out at high speed, causing personal injury. There
should be no visible dust emerging from the outlet of the blower housing. If there is, the filter ele-
ments and/or filter gaskets should be replaced immediately to avoid damage to the blower wheel.
6. The filters should be cleaned whenever possible by pulsing the elements with the blower system
turned off. This can be done at the end of any drilling cycle, while changing drill pipe sections, and
possibly between each hole.

MANOMETER
READING:

UPPER LOWER INDICATION CAUSE CURE

High Low Loss of suction. Plugged Filter. Check Pulse Air

High reading across (faulty timer, impulse valves
filter. or low pressure).

High High Loss of suction. Plugged Hose. Clear obstruction

Reading of zero across
filter.
Poor filter life. Fan speed too high. Reduce hydraulic flow to
fan motor.

Low Low Loss of suction. Fan speed too low. Adjust hydraulic flow to fan
motor.
Fan runs backwards. Check hydraulic hookup.
Dump hose missing. Replace dump hose.

5-10 Dust Control Systems

 Dust Collector

Troubleshooting Guide
If, upon inspection of your dust control system, it is obvious that the unit is not operating properly,
the following discussion should help you to troubleshoot the problem.

All the problems with the Filter/Clone Dust Control System can be isolated through the use of a
single test instrument, namely the water manometer discussed earlier. Measurements should be made
separately on the upper and lower vacuum taps located on the dust collector housing (See fig. 5-4).
Typical readings for proper operation are listed in fig. 5-5. Depending on whether your readings are higher
or lower than the normal values, the following explanations will apply.
Upper Tap HIGH - Lower Tap LOW
This situation indicates that the blower assembly is being "choked off," causing the vacuum in the
clean air section to go up. The fact that the area around the filter elements (lower tap) is low
indicates that air is not moving through the filters (i.e. plugged filter elements). The main reason that
this occurs is failure of the back-pulsing system of compressed air. Three probable causes are:
1. The incoming air pressure is too low. This pressure should be maintained at approximately 40
PSI. Insert a gauge at the point where air enters the collector to make your measurement.
2. The timer could be malfunctioning. Check the timer to see that each station is being fired at the
set timer interval of about 2-3 seconds between stations.
3. The impulse valves over the filter elements may themselves be faulty. If one of the diaphragms of
the impulse valves develops a hole or a rock becomes lodged in the valve causing the diaphragm to
seat improperly, the compressed air may never be allowed to build up to the required 40 PSI pres-
sure and/or the valve may not fire properly. Also, the electric-air solenoid valve operating the im-
pulse valve may be faulty.
Upper Tap HIGH - Lower Tap HIGH
This condition indicates that the system is being "choked off" prior to the filter elements. This gener-
ally results from a plugged suction hose due to the build-up of dirt and mud or obstruction by a
foreign obstacle such as a shot-sack.
Upper Tap LOW - Lower Tap LOW
This condition points to a loss in suction capacity. The primary concern here is fan speed. The fan
may be turning below the suggested 3000 RPM because of a problem in hydraulic oil supply. An-
other situation often occurs when the motor is changed out or repaired. The motor may be recon-
nected incorrectly to cause the blower wheel to turn in a reverse direction. When this happens, a
vacuum will be produced and some air-flow will occur. The best way to verify proper rotation of the
wheel is to observe it visually upon start-up or shut-down. NEVER look directly into the blower
discharge, as small particles could come out at high speed causing personal injury. The
blower wheels on all Filter/Clone units should turn clockwise when viewed from the top looking down
at the collector.
As a final comment, one should note that the dust collector fan should be run as close to 3000 RPM
as possible. Although the fan can easily tolerate higher speeds and the system will indeed pull more
air at higher speeds, operating the system at such speeds can cause unnecessary wear of filter
elements, dust collector housing, and suction hose.

Dust Control Systems 5-11

Water Pump (vertical)

Item No. Description Qty.

1 Hex Capscrew, 1/2"-13 x 1-1/2 1

2 Clamp, Valve Cover 1
3 Valve Cover 2
4 O-Ring, 1-3/16" OD 6
5 Spring & Disc 4
6 Valve Cage 4
7 Valve Seat 4
8 Hex Capscrew, 3/8"-16 x 5" 3
9 Valve Chamber 1
10 Gasket Cylinder 4
10A Ring Seal 2
10B O-Ring 2
11 Cylinder 2
12 Capscrew, 5/16"-18 2
14 Packing Washer 2
15 Packing 2
16 Packing Holder 2
17 O-Ring, 3/4" OD 2
18 Umbrella 2
19 Washer, Umbrella 2
20 Sleeve, Crosshead 2
21 Case, Pump 1
22 Pipe Plug, 3/4" 1
23 Crosshead 2
24 Wrist Pin 2
25 Connecting Rod Assembly 2
26 Bearing Insert, Con. Rod 4
27 Machine Screw, #10-24 x 1/2" 2
28 Speed Nut 1
29 Oil Slinger 1
30 Crankshaft 1
31 Bearing 2
32 Oil Seal 2
33 Snap Ring 2
34 Gasket, Pump Base 1
35 Mounting Base, Pump 1
36 Cup Washer, 3/8" 6
37 Capscrew, 3/8"-16 x 3/4" 6
38 Pipe Plug, 1/4" 1
39 Valve Seat Remover 1

Fig. 5-8
5-12 Dust Control Systems
 Water Pump (vertical)

Servicing Instructions
WARNING:
Relieve pressure on hydraulic and pneumatic sys-
tems before loosening connections or parts.

General Care of the Pump

a. Drain and refill the pump crankcase with clean SAE 30 API service classification MM or better oil
after the first 100 hours of operation. Following the first 100 hours of operation, for best results
always change the oil every 750 hours of operation.
b. Keep all piping and mounting bolts tight.
c. Replace all worn parts promptly with exact factory replacement parts.
d. The water relief valve mounted on the discharge of the water pump should be set 50 PSI higher
than air pressure in order to inject water into the air stream (e.g., Low Pressure = 150-200 PSI,
High Pressure = 400-450 PSI).
Care in Freezing Weather

NOTE Precautions must be taken to avoid damage to the pump from liquid allowed to
freeze in the valve chamber.

a. Drain all connecting piping.

b. Remove capscrew (1), clamp (2), valve cover (3) and valve disc and spring (5) to drain the valve
chamber (9) when freezing temperatures are expected (See Fig. 5-8). Remove "top" discharge
valves or raise them to be sure that no liquid is trapped under the "inner" suction valves.

Servicing the Plunger Packings

1. Release the valve vhamber (9) from the pump case by removing the three capscrews (8).
2. Lift the chamber free of the cylinders (11). Remove the capscrews (12), cup washers (14), and
plunger packings (15).
3. Lift the cylinders (11) from the pump case (21).
4. Inspect the o-rings (17) and the umbrellas (18). If either of these parts are damaged, they should
be replaced. A pocket knife can be used for easiest removal of the umbrellas. Clean all parts
thoroughly - replace worn parts with exact replacement parts.

Dust Control Systems 5-13

Water Pump (vertical)

Item No. Description Qty.

1 Hex Capscrew, 1/2"-13 x 1-1/2 1

2 Clamp, Valve Cover 1
3 Valve Cover 2
4 O-Ring, 1-3/16" OD 6
5 Spring & Disc 4
6 Valve Cage 4
7 Valve Seat 4
8 Hex Capscrew, 3/8"-16 x 5" 3
9 Valve Chamber 1
10 Gasket Cylinder 4
10A Ring Seal 2
10B O-Ring 2
11 Cylinder 2
12 Capscrew, 5/16"-18 2
14 Packing Washer 2
15 Packing 2
16 Packing Holder 2
17 O-Ring, 3/4" OD 2
18 Umbrella 2
19 Washer, Umbrella 2
20 Sleeve, Crosshead 2
21 Case, Pump 1
22 Pipe Plug, 3/4" 1
23 Crosshead 2
24 Wrist Pin 2
25 Connecting Rod Assembly 2
26 Bearing Insert, Con. Rod 4
27 Machine Screw, #10-24 x 1/2" 2
28 Speed Nut 1
29 Oil Slinger 1
30 Crankshaft 1
31 Bearing 2
32 Oil Seal 2
33 Snap Ring 2
34 Gasket, Pump Base 1
35 Mounting Base, Pump 1
36 Cup Washer, 3/8" 6
37 Capscrew, 3/8"-16 x 3/4" 6
38 Pipe Plug, 1/4" 1
39 Valve Seat Remover 1

Fig. 5-8
5-14 Dust Control Systems
 Water Pump (vertical)

Reassembling Plunger Packings

1. Inspect bottom gasket (10) and replace if necessary. (Torque capscrews to 15 to 20 ft. lbs.)

NOTE If it is necessary to replace one gasket at either top or bottom of the cylinders,
then both bottom and top cylinder gaskets should be replaced.
For easier installation of the umbrella, immerse in hot water for approximately
two to three minutes to soften.

2. Fold the plastic umbrellas (18) to insert them through openings and over ends of crosshead rods.
3. Press tops of umbrellas to place pilot washers (19) over ends of rods with groove up.
4. Place o-rings (17) and packing holders (16) in position on ends of crosshead rods.
5. Place cylinders (11) in position in the mounting plate recess.
6. Oil the plunger packings (15) and place them in the open end of the cylinders, with the cup "up".
Use the thumb to press the packings into each cylinder, firmly and squarely on the plunger rod
end.
7. Turn the pump by hand to raise each plunger rod to the top of the stroke, as needed.
8. Place the cup washers (14), with the ribbed side against the plunger packing inside the cups of
the packing.
9. Secure packing and washers to plunger rods with capscrews (12), tightening them until the
washers and cups seat firmly on the plunger rods.
10. Inspect top cylinder gaskets (10) and replace both if either shows defect, holding them in place in
the valve chamber by using heavy oil or grease if necessary.
11. Return the valve chamber to position over the cylinder, making sure that gaskets (10) and cylin-
ders (11) are properly positioned in the recesses top and bottom.
12. Retighten capscrews (8) alternately and evenly until the parts are snugly seated. Torque
capscrews to 20-25 ft. lbs.

Servicing the Pump Valves

1. Remove the capscrew (1) and clamp bar (2) from the rear of the valve chamber (9) and lift out
valve covers (3) and o-rings (4) attached.
2. Remove the discharge valve springs and seat assemblies (5) and valve cages (6).
3. Insert the round end of valve seat puller (tool 39) through the opening at the center of the valve
seats (7) and loosen the seats from the valve chamber (9) with a "rocking" motion of the tool (39).
4. Remove the valve seats from the recesses with the opposite end (curved end) of the tool (39).
5. Repeat the four preceding steps to remove the suction valve parts which are identical to the
discharge valve parts and are located immediately under them in the valve chamber.
6. Clean all parts and inspect them - replace all worn parts as needed.

Dust Control Systems 5-15

Water Pump (vertical)

Item No. Description Qty.

1 Hex Capscrew, 1/2"-13 x 1-1/2 1

2 Clamp, Valve Cover 1
3 Valve Cover 2
4 O-Ring, 1-3/16" OD 6
5 Spring & Disc 4
6 Valve Cage 4
7 Valve Seat 4
8 Hex Capscrew, 3/8"-16 x 5" 3
9 Valve Chamber 1
10 Gasket Cylinder 4
10A Ring Seal 2
10B O-Ring 2
11 Cylinder 2
12 Capscrew, 5/16"-18 2
14 Packing Washer 2
15 Packing 2
16 Packing Holder 2
17 O-Ring, 3/4" OD 2
18 Umbrella 2
19 Washer, Umbrella 2
20 Sleeve, Crosshead 2
21 Case, Pump 1
22 Pipe Plug, 3/4" 1
23 Crosshead 2
24 Wrist Pin 2
25 Connecting Rod Assembly 2
26 Bearing Insert, Con. Rod 4
27 Machine Screw, #10-24 x 1/2" 2
28 Speed Nut 1
29 Oil Slinger 1
30 Crankshaft 1
31 Bearing 2
32 Oil Seal 2
33 Snap Ring 2
34 Gasket, Pump Base 1
35 Mounting Base, Pump 1
36 Cup Washer, 3/8" 6
37 Capscrew, 3/8"-16 x 3/4" 6
38 Pipe Plug, 1/4" 1
39 Valve Seat Remover 1

Fig. 5-8
5-16 Dust Control Systems
 Water Pump (vertical)

Pump Specifications
Stroke --- 1" Oil Capacity --- 1 quart
Oil Type --- SAE 30 GPM --- 9
Direction of Rotation --- either Maximum Pressure --- 550 PSI
Number of Pistons --- 2 RPM --- 500
Crankcase Material --- Cast iron

Torque Requirements
Valve Chamber Studs --- 15 ft. lb. Conn Rod Nuts --- 7 ft. lb.
Rear Cover HHCS --- 15 ft. lb. Packing Assembly Nut --- 10 ft. lb.
Reassembling Valve Parts
NOTE Valve seats are used with the thin seating area pointing toward the valve disc.

1. With the o-ring (4) in place on each valve seat (7), place a few drops of light oil on the ring and
seat and place each squarely in the bottom of the recess in the valve chamber.
2. Place the valve cages (6) on the valve seats (7) and the spring and disc (5) inside each cage.
3. Repeat steps 1 and 2 to install the outer discharge valve parts.
4. Place the valve covers (3) (with o-rings on bottom groove) over each valve assembly.
5. Replace clamp bar (2) and capscrew (1), tightening capscrew (1) only snugly. Overtightening
capscrew (1) can damage valve parts. Torque to 30 ft. lbs.

Servicing the Crankshaft

1. Remove pipe plug (38) and drain oil from pump case.
2. Disconnect piping and remove pump from mounting.
3. Remove capscrews (37), cup washers (36) and mounting base (35) carefully to protect gasket
(34).
4. Remove capscrews from rod assemblies (25). Use a center punch or other suitable instrument to
mark caps and rods for proper rematching when they are reassembled.
5. Remove oil slinger (29) from the crankshaft (30).
6. Push the connecting rods and crosshead assemblies into the pump case to clear the crankshaft
(30).
7. Remove the driven sheave from the crankshaft extension.
8. Remove the snap rings (33).

Dust Control Systems 5-17

Water Pump (vertical)

Item No. Description Qty.

1 Hex Capscrew, 1/2"-13 x 1-1/2 1

2 Clamp, Valve Cover 1
3 Valve Cover 2
4 O-Ring, 1-3/16" OD 6
5 Spring & Disc 4
6 Valve Cage 4
7 Valve Seat 4
8 Hex Capscrew, 3/8"-16 x 5" 3
9 Valve Chamber 1
10 Gasket Cylinder 4
10A Ring Seal 2
10B O-Ring 2
11 Cylinder 2
12 Capscrew, 5/16"-18 2
14 Packing Washer 2
15 Packing 2
16 Packing Holder 2
17 O-Ring, 3/4" OD 2
18 Umbrella 2
19 Washer, Umbrella 2
20 Sleeve, Crosshead 2
21 Case, Pump 1
22 Pipe Plug, 3/4" 1
23 Crosshead 2
24 Wrist Pin 2
25 Connecting Rod Assembly 2
26 Bearing Insert, Con. Rod 4
27 Machine Screw, #10-24 x 1/2" 2
28 Speed Nut 1
29 Oil Slinger 1
30 Crankshaft 1
31 Bearing 2
32 Oil Seal 2
33 Snap Ring 2
34 Gasket, Pump Base 1
35 Mounting Base, Pump 1
36 Cup Washer, 3/8" 6
37 Capscrew, 3/8"-16 x 3/4" 6
38 Pipe Plug, 1/4" 1
39 Valve Seat Remover 1

Fig. 5-8
5-18 Dust Control Systems
 Water Pump (vertical)

Servicing the Crankshaft (continued)

CAUTION:
NEVER pound directly on bearings (31) when removing
or replacing them on the crankshaft.

9. Place a wood block against either end of the crankshaft and drive the shaft from the pump case
(21). A block of wood, with a suitable sized opening or block supports to assure reasonably equal
support around the bearing, in a press is best for this important work.
10. After inspecting and replacing all worn parts, press new bearings (if needed) against the shoulders
of the crankshaft.
11. With the crankshaft and bearings assembly in place in the pump case, carefully place the oil seals
(32) over the ends of the crankshaft with the "lip" of the seals facing the inside of the pump case.
12. Seat the snap rings (33) in the grooves in the bearing housings against the oil seals and tap the
crankshaft to allow a slight end play in the crankshaft.
13. Reassemble the connecting rods and crossheads, being sure to re-match the rod and cap prop-
erly as marked when disassembled. Use 6 to 8 ft. lbs. of torque on capscrews.
14. Complete the reassembly by reversing steps 1-8, being sure to replace drain plug (33).
Torque mounting base capscrews 20-25 ft. lbs.
Remove plug (22) and fill the crankcase with clean SAE 30 API service classification MM or better
oil, to the filler plug level.
Turn the pump a few revolutions by hand to be sure all parts are running freely before use.

Servicing the Crossheads

1. Remove the valve chamber, cylinders, and plunger packings.
2. Remove o-ring seal (17), back-up washer (19), and the crosshead umbrellas (18).
3. Remove the mounting base and the connecting rods as described in "Servicing the Crankshaft".
4. Turn the crankshaft by hand to allow removal of the crossheads through the pump case opening.
5. Reverse steps 1-3 when reassembling the crossheads, be sure that all parts are reassembled in
their EXACT former positions.

Dust Control Systems 5-19

Dust Collector/Water Injection Circuit

• The dust collector and water injection circuit are supplied by a open loop gear pump.
• The pump supplies the control valve (410089) which controls both functions, water and dust.
• With the control valve in neutral, water pump motor pressure blocked at control valve, the supply
to the dust collector is open to tank for fan spin down.
• Water injection
Flow from the control valve is directed to a flow control valve (81239) at which the flow to
the motor is adjusted as needed.
• Dust Collector
Flow from the control valve is directed to the dust collector motor and the motor speed is
controlled by a by-pass flow control. This by-pass flow control also serves as a anti-cavita-
tion check for motor spin down.

Fig. 5-9 Dust Collector / Water Injection Circuit - SKF Machines

5-20 Dust Control Systems
 Dust Collector/Water Injection Circuit

Pressure Adjustment
1. Shutdown machine and relieve standing pressure (see beginning of Section 7).
2. Block flow to dust collector and/or water injection pump.
3. Install a 6000 PSI (414 bar) gauge in the relief valve (410089) or, if machine is equipped with a
hydraulic pressure test station, turn knob to DUST COLLECTOR.
4. Start machine and allow time for system to warm up. Loosen lock nut on relief valve and turn
adjusting screw (fig. 5-11a) to get a reading of 2000 PSI (138 bar). Tighten lock nut.
5. Shut down machine and relieve standing pressure. Hook up hoses that were removed in step 2
and remove gauge. Tighten all connections and fittings.

Fig. 5-11 Dust Collector/Water Injection Valve 410089. Fig. 5-11a Dust Collector/Water Injection Valve
Adjustment

Dust Control Systems 5-21

5-22
Water Injection System (vertical pump)

Fig. 5-12 Water Injection System with John Bean Vertical Pump (ref. 410845)

Dust Control Systems

Dust Control Systems
Fig. 5-12a Water Injection System with Cat Horizontal Pump (ref. 403868)
Water Injection System (horizontal pump)

5-23
Water Injection Pump (horizontal)

Water Pump Repair:

Refer to the following CAT Pumps Service Manual which covers the Model 1050 for repair and
maintenance information. Refer to machine parts manual for parts ordering.

Water Pump Drive Motor Repair:

Refer to the Char-Lynn 2000 Series Repair Manual which covers the Model 104-1002 Hydrau-
lic Motor for repair. Shuttle Valve Option and Speed Sensor are not used on this model. Refer to machine
parts manual for parts ordering.

5-24 Dust Control Systems

Dust Control Systems 5-25
5-26 Dust Control Systems
Dust Control Systems 5-27
5-28 Dust Control Systems
Dust Control Systems 5-29
5-30 Dust Control Systems
Dust Control Systems 5-31
5-32 Dust Control Systems
Dust Control Systems 5-33
5-34 Dust Control Systems
Dust Control Systems 5-35
5-36 Dust Control Systems
Dust Control Systems 5-37
5-38 Dust Control Systems
Dust Control Systems 5-39
5-40 Dust Control Systems
 Section 6

Mast / Rotary Drive / Pipe Rack

CAUTION:
DO NOT weld on any part of the machine without first
disconnecting the negative battery cable or place the
battery disconnect switch in the open position. Discon-
nect the connections to the Electronic Control Module
(ECM) on the engine before welding.

Mast/Rotary Drive/Pipe Rack 6-1

SKF Mast Assembly
33 6
18

16
16

27
4
18 27 Fig. 6-1 SKF 11.5 Meter Mast (ref. 428646 rev 10)
1. Rotary Drive
2. Hoist/Pulldown Cylinder
3. Hoist/Pulldown Pin
4. Hoist/Pulldown Cylinder Clamp
5. Sheave Guide Assembly
6. Top Sheave w/Bearing (3)
16. Hoist Cable (2)
17. Pulldown Cable (2)
17 17 18. Hex Nut (8)
27. Grease Fitting (8)
33. Modified Sheave (DEI)

2
3

6-2 6 Mast/Rotary Drive/Pipe Rack

 SKFX Mast Assembly
28 5

47
11

11
WELD
UNDERNEATH
OVERHANG
1

64

2
Fig. 6-1a SKFX 12 Meter Mast (ref. 428190 rev 6)
1. Rotary Drive
2. Hoist/Pulldown Cylinder
5. Top Sheave w/Bearing (3)
11. Hoist Cable (2)
12. Pulldown Cable (2)
20. Hoist/Pulldown Counterbalance Valve
28. Sheave 20"
47. Hex Nut (8)
63. Chock Bar (2)
2 3/4 12 2 NOTE: See fig. 6-5 for travleing sheave/tensioning
12 12 assembly. This arrangement applies only to the
SKFX drills.

47 12
ANCHOR DETAIL P

20

63
2X
WELD THIS
SIDE ONLY

Mast/Rotary Drive/Pipe Rack 6-3

SKF Feed Cylinder

SAE NO 24
PORT
2X

17 8 7
12 5 3

3.500-12UN-2
24 TORQUE
1450-1800 ft-lbs

PRIOR TO INSTALLATION
SEE DETAIL A-A APPLY GREASE TO I.D OF
FOOTMOUNT ASS'Y AND WIRE
25 19 18 23 FOOTMOUNT ASSY TO FLANGE
4 9 20 22 ON BOTH SIDES
1 2

13 SEAL KIT 1
12 WEAR RING 2 25 SPACER (4.25 LONG) 1
11 WEAR RING 2 24 NUT 1
16 DETAIL A-A
10 INGRESSION RING 2 23 HEADCAP 1
9 O-RING 1 22 HEAD 1
8 SEAL 1 21 PISTON 1
14 21 10
11 6 7 BACK-UP 2 20 FOOTMOUNT ASSY 1
6 SEAL 1 19 ROD 1
5 SEAL 1 18 TUBE ASSY (4V151) 1
4 BACK-UP 1 17 PORT PLUG 2
NOTES:
APPROX CYLINDER DRY WEIGHT= 2,806 lbs. 3 WIPER 1 16 NYLON PLUG 2
MAX OPERATING PRESSURE- 3,000 PSI EXTEND; 5,000 PSI RETRACT 2 BACK-UP 1 15 SETSCREW 2
LUBE ALL SEALS BEFORE ASSY 1 O-RING 1 14 SETSCREW 4
NO DESCRIPTION QTY NO DESCRIPTION QTY

Fig. 6-2 SKF Feed Cylinder (ref. 423475 for 11.5 Meter Mast)

6-4 Mast/Rotary Drive/Pipe Rack

 SKFX Feed Cylinder

NOTES:
TORQUE PISTON NUTS 200-220 ft lbs
APPLY LOCTITE 242 (BLUE)
INSTALL LOCKWIRE BETWEEN ADJACENT PARTS
APPROX CYLINDER WEIGHT DRY= 2,489 LBS
CYLINDER WILL BE USED SOLELY IN TENSION
LUBE ALL SEALS BEFORE ASSY

14 SEAL KIT 1
13 WEAR RING 4
12 WEAR RING 4
11 SEAL 2
10 BACK-UP 2 24 CAPSCREW 12
9 CONTAMINATION RING 2 23 NUT 2
8 BACK-UP 4 22 HEADCAP 2
7 SEAL 1 21 HEAD 2
6 BACK-UP 2 20 ROD-TUBE ASSY 1
5 BACK-UP 4 19 ROD-TUBE ASSY 1
4 O-RING 4 18 TUBE ASSY 1
3 O-RING 1 17 PORT PLUG (STEEL) 2
2 SEAL 2 16 PORT PLUG (STEEL) 2
1 WIPER 2 15 SETSCREW 2
NO DESCRIPTION QUAN NO DESCRIPTION QUAN

TOP OF MAST

32.13 46.63

38.00

50.63

64.13

82.63

16.50 114.75

Fig. 6-2a SKFX Feed Cylinder (ref. 417188 for 12 Meter Mast)

Mast/Rotary Drive/Pipe Rack 6-5

 Feed Cylinder

Feed Cylinder - Removal & Installation

WARNING:
BEFORE removing feed cylinder pins, relieve tension from hoist/pull-
down cables.
Secure rotary head to mast crown with a chain to prevent it
from moving once the feed cylinder is disconnected.
BE SURE to relieve pressure on hydraulic or pneumatic systems
before loosening connections or parts.

NOTE Two people are needed for this procedure.

1. Remove drill pipe from rotary head and place in pipe rack, swing pipe rack out. Place mast in
horizontal position. Be sure machine is on level ground.
2. Lower rotary head about 2 ft. (0.6m) and place a suitable spacer bar between the rotary head
and crown block of mast. Spacer bar must be able to withstand the force of the feed cylinder
(5000 PSI [345 bar]) without breaking or bending.

NOTE Place chain around rotary head and crown block of mast to keep rotary head
from moving after feed cylinder is removed.
3. With spacer bar installed, place hoist/pulldown lever in HOIST position to force rotary head
against spacer bar. This will relieve tension from pulldown cables so nuts can be removed where
cables attach to cylinder. With one person holding the hoist/pulldown lever in HOIST position, the
other person must be sure there is slack in the pulldown cables BEFORE loosening the pulldown
cable adjusting nuts. When the pulldown cable adjusting nuts are loosened, the hoist/pulldown
lever may be returned to neutral.
4. Remove the two bolts that secure the feed cylinder clamp to the cylinder. Remove clamp and
retract cylinder so rod is clear of sheave guide assembly.
5. Shut down machine and be sure hydraulic pressure is relieved, then remove upper and lower hose
connections to feed cylinder. Cap hose ends and plug cylinder ports.
6. Remove the four capscrews and washers that secure the upper end of the cylinder to the mast.
7. Place lifting straps around the upper and lower ends of the cylinder. Use an adequate lifting device
to support the weight of the cylinder.
8. Remove the capscrew and pin from lower end of cylinder.
9. Move cylinder forward to clear the pipe support. Reposition rear lifting strap in front of pipe
support. Be sure cylinder is balanced and lift free of mast.
Installation
1. Installation is basically the reverse of removal.
2. Be sure hoist/pulldown cables are adjusted properly. Refer to Hoist/Pulldown Cable Adjustment in
this section.

6-6 Mast/Rotary Drive/Pipe Rack

 Feed Cylinder

General Information
This section describes those teardown and rebuild practices that are common to all standard Texas
Hydraulics cylinder designs. Specific practices are available based on the component to be rebuilt.

Standard Texas Hydraulics cylinders are designed to operate with fluids per MIL-L-2104 or equiva-
lent. Fluid cleanliness should be maintained at an ISO 18/15 for maximum life.

Teardown
1. Remove the cylinder and drain hydraulic fluid. Clean away all dirt or other foreign substance from
openings, particularly at the head.

NOTE If excessive wear due to side-loads or binding is a possibility, mark or note the
piston and head relationship to the rod and tube. This condition will usually show
up as a highly polished surface on the piston and head 90o to the pin rotation axis.

2. Remove the head retaining device. See specific procedure for your head design.
3. Extend the rod until the piston bottoms out on the head. Gently tap the piston against the head to
drive the rod assembly out. Place the rod assembly on a surface that will not damage the
chrome. Remove the piston locknut and separate the piston from the rod. Slide the head off the
rod from the piston end.
4. Discard all old seals.

Mast/Rotary Drive/Pipe Rack 6-7

Feed Cylinder

General Information

Inspection
1. Inspect Rod: There should be no scratches or pits deep enough to catch the fingernail. Pits that
go to the base metal are unacceptable. Scratches that catch the fingernail, but are not to the
base metal, less than 0.5 in. long and primarily in the circumferential direction are acceptable
provided they cannot cut the rod seal. Chrome should be present over the entire surface of the
rod and the lack thereof is unacceptable. In the event that an unacceptable condition occurs, the
rod should be repaired or replaced.
2. Inspect Head: Visually inspect the inside bore for scratches or polishing. Deep scratches are
unacceptable. Polishing indicates uneven loading and when this occurs, the bore should be
checked for out-of-roundness. If out-of-roundness exceeds 0.007 in., this is unacceptable. Check
the condition of the dynamic seals looking particularly for metallic particles embedded in the seal
surface. It is normal to cut the static seal on the retaining ring groove upon disassembly. Remove
the rod seal, static o-ring and backup and rod wiper. Damage to the seal grooves, particularly on
the sealing surfaces, is unacceptable. In the event that an unacceptable conditions occurs, the
head should be replaced.
3. Inspect Piston: Visually inspect the outside surface for scratches or polishing. Deep scratches
are unacceptable. Polishing indicates uneven loading and when this occurs, the diameter should
be checked for out-of-roundness. If out-of-roundness exceeds 0.007 in., this is unacceptable.
Check the condition of the dynamic seals and bearings looking particularly for metallic particles
embedded in the bearing and in the piston seal surface. Remove the seals and bearings. Damage
to the seal grooves, particularly on the sealing surfaces, is unacceptable. In the event that an
unacceptable condition occurs, the piston should be replaced.
4. Inspect Tube Assembly: Visually inspect the inside bore for scratches and pits. There should
be no scratches or pits deep enough to catch the fingernail. Scratches that catch the fingernail
but are less than 0.5 in. long and primarily in the circumferential direction are acceptable pro-
vided they cannot cut the piston seal. The roughness of the bore should be between 10 and 20
microinches RMS. Significant variations (greater than 8 microinches difference) are unacceptable.
In the event that an unacceptable condition occurs, the tube assembly should be repaired or
replaced.

6-8 Mast/Rotary Drive/Pipe Rack

 Feed Cylinder

General Information

Rebuild
1. Thoroughly rinse the inside of the tube and allow to drain. A high-pressure rinse followed by a wipe
with a lint-free rag is preferable. Clean all internal components of any foreign material.
2. Visually inspect for material defects and contamination.
3. Lubricate the head and all seals with hydraulic fluid. Rebuild the head and seals per the specific
practice for this design.
4. Lubricate the piston and all components with hydraulic fluid. Rebuild the piston and seals per the
specific practice for this design.
5. Place the rod on a clean table. Install the static o-ring per the recommended practice. Install the
head followed by the piston onto the rod noting the proper orientation of each component. Torque
the piston nut to the proper torque.
6. When the rod assembly is ready to be installed in the tube, liberally apply an anti-seize lubricant
to the head outer surface, especially the static seal.
7. Dip the entire rod assembly into hydraulic fluid and stuff this assembly into the tube. Watch the
seals as they pass over the rod port (if visible) to be sure they are not nicked or cut.
8. Tighten the head per the specific procedure for this design.

Test
1. Set test stand pressure to the recommended test pressure and attach hose fittings to cylinder.
2. The cylinder shall be stroked its full length in both directions to fill it with oil and remove trapped
air.
3. Pressurize to recommended test pressure at each end, beginning with the rod end, for a minimum
of 10 seconds per end. While under pressure, cylinder shall be checked for leaks at welds, pipe
fittings, and at all external static and dynamic seals.
4. When testing is complete, retract the cylinder using air in the rod port to remove oil.
5. Seal ports with port plugs to prevent contamination from entering cylinder.

Mast/Rotary Drive/Pipe Rack 6-9

Feed Cylinder

Texas Hydraulics "H" Type Head Repair

The H series head uses aluminum material and has a polyurethane u-cup as the primary sealing
element. The wiper is a standard type D polyurethane. The head is retained within the tube by means of an
internally threaded headcap.

Teardown
Remove the head retaining device as follows: Locate the setscrew in the headcap (a headcap is the
internally threaded head retaining nut threaded onto the tube external threads). Remove this setscrew
and insert a spanner wrench into the holes provided. Turn the headcap counter-clockwise (it is a right-
hand thread) to remove it. If the headcap is stuck or moves erratically, tap the headcap with a brass or
plastic mallet while turning it. Wrap the headcap with a soft cloth or provide some other means to insure
that the inner diameter of the headcap does not contact the chromed surface of the rod.

Rebuild
Lubricate the head and all seals with hydraulic fluid prior to installation. Using round-nose pliers or
special installation tools, twist the dual lip u-cup seal into a "C" shape and allow it to snap into groove. Use
a similar technique for installing the wiper. Install the static o-ring and backup into the static seal groove
verifying that the backup is closest to the headcap retaining lip. If possible, the head/seal assembly
should sit for at least one hour to allow the seals to elastically restore.

Place the rod on a clean table. Slide the headcap onto the rod. Wrap it so that it does not damage
the chromed surface. Install the head followed by the piston onto the rod noting the proper orientation of
each component. Slide the headcap onto the tube and engage it with the threads. Turn the headcap
counter-clockwise until the first thread just passes the engagement point (The headcap will move notice-
ably) then turn the headcap clockwise until it is hand-tight or fully seated. Insert a spanner wrench into the
holes provided and tighten 1/8 to 1/4 turn past fully seated. Insert the nylon plug and setscrew into the
setscrew hole and tighten the setscrew securely.

6-10 Mast/Rotary Drive/Pipe Rack

 Feed Cylinder

Texas Hydraulics "Z" Type Piston Repair

The Z series is used on Jack Cylinders as well as Mast Elevating Cylinders. The Z series piston uses
ductile iron material and glass-filled nylon wear rings (bearing rings). It is available in two basic design
styles. The first uses a groove sized for a specially designed teflon seal called the AQ seal. The teflon
sealing ring has a small groove on its outside diameter that houses a quad ring seal. The entire ring is
energized by a square section rubber loader. The second series uses an interference fit split nylon sealing
ring with an oval section rubber loader and is called a Chemcast seal. A small static o-ring seal is fitted to
a groove in the piston and is held in place by the shoulder of the rod.

STOP
Teardown
After removing the piston, remove and discard the PRS static o-ring from the rod shoulder. Remove
the AQ seal by means of blunt instruments of bronze or aluminum. Be sure there are no sharp edges on
these tools. Be particularly careful of scratching the groove surface finish.

Rebuild
Separate the three components of the seal assembly. For easiest installation, warm the teflon outer
ring in 120-150 oF hydraulic fluid or water. Lubricate the piston and all components with hydraulic fluid.
Stretch the inner rubber expander into the seal groove. Do not use sharp edged tools and verify that it has
not twisted. Likewise, stretch the teflon outer ring into the groove. Be extremely careful to avoid damag-
ing the seal grooves during installation. Scratching the groove may cause by-pass leakage. The teflon
ring will have a memory and may take as long as 24 hours to return to the correct size. This can be
accelerated by pushing the piston/seal assembly through a honed or polished tube with an ID equal to the
nominal cylinder bore to plus 0.010 inches. Clean the groove in the teflon ring and install the rubber quad
ring. Verify that it has not twisted. Install the wear rings into the wear ring groove. If possible, allow the
piston/seal assembly to sit at least one hour to allow the seals to elastically restore.

Mast/Rotary Drive/Pipe Rack 6-11

Hoist/Pulldown Cables-SKF

Hoist/Pulldown Cable Adjustment

The following procedure is used to adjust the ten-
sion in the hoist/pulldown cable system. Frequency of
adjustment varies according to drilling methods and
operational requirements. Proper and equal cable ten-
sion is required to prevent misalignment of the rotary
head, as well as, limiting any undesired stress forces in
the mast assembly.

1. With a piece of drill pipe in the rotary head and

through the mast table bushing, lower the mast to
horizontal position. Check for equal sag in the
hoist and pulldown cables. Adjust if necessary.
2. Be sure machine is stabilized on the jacks and is
level. Raise the mast and check head alignment
with how pipe aligns with mast table bushing.
We can assume from steps 1 and 2 that
NOTE
the cables have equal tension on each
side.
3. Raise the rotary head to the top of the mast.
Extend the automatic tool wrench, and engage
the jaw over the bit sub flats.
4. Using the automatic feed switch, apply 1500 PSI
(103 bar) of hydraulic pressure down on the tool
wrench. Lower the mast back down to the head-
ache rack, as in the tramming position.
5. Tighten the top cable adjustment nuts (fig.6-3)
until no sag is visible in the cables. Adjust each
cable equally. Release the hydraulic pressure on
the system. The cables are now adjusted.

Fig. 6-3 SKF 11.5 Meter Mast Hoist/Pulldown Cables (ref. 428646)

6-12 Mast/Rotary Drive/Pipe Rack

 Hoist/Pulldown Cables-SKF

NOTE Over time, as the cables are adjusted, it will be noticed that the rotary head does
not travel all the way to the bottom of the mast, potentially causing non-engage-
ment of the breakout wrench on the flats of the drill stem. At this point it will be
necessary to loosen the top cable adjustment nuts and then tighten the lower
cable adjustment nuts and lock nuts. There should be approximately 4 to 5 in. of
thread length on the adjusting nut side of the cylinder. Once this is done, the
normal cable adjustment procedure is to be followed.

Hoist/Pulldown Cable Replacement

1. With one piece of drill pipe attached to top drive, raise top drive up and engage the flats of the bit
sub with the deck wrench. If using a down-the-hole hammer, remove it from the drill pipe to enable
the mast to be lowered.
2. Apply about 1500 PSI (103 bar) hoist or pulldown pressure, depending on which cables you are
replacing.
• If you are replacing the hoist cables, apply pressure downward, this will put some slack in the
hoist cables, so you can loosen the nuts.
• If you are replacing the pulldown cables, apply pressure upward, this will put some slack in
the pulldown cables, so you can loosen the nuts.
3. Lower the mast to horizontal position, resting on the mast rest.
4. Loosen the cable jam nuts and adjusting nuts until there is no tension on the cable.

NOTE Always replace cables in sets. Do not install a new cable on one side and a used
one on the other side.
5. Remove cable clevis and remove all sheaves that the cable passes through. It is a good idea to
check the sheave bearings and seals and replace any worn parts at this time. Remove cable.
6. Install new cable and existing sheaves. Install clevis on rotary head guide first, then install cable
end and adjusting nut. It may be necessary to apply more hoist/pulldown pressure to engage the
threads with the adjusting nut.
7. Tighten the adjusting nuts until cable feels tight enough to be tested.
8. Follow procedures for rotary head alignment and hoist/pulldown cable adjustment.

Mast/Rotary Drive/Pipe Rack 6-13

Hoist/Pulldown Cables-SKFX

Fig. 6-4 SKFX 12 Meter Mast Hoist/Pulldown Cables (ref. 428190)

6-14 Mast/Rotary Drive/Pipe Rack

 Hoist/Pulldown Cables-SKFX

Hoist/Pulldown Cable Adjustment (manual adjustment)

The following procedure is used to adjust the tension in the hoist/pulldown cable system. Frequency
of adjustment varies according to drilling methods and operational requirements. Proper and equal cable
tension is required to prevent misalignment of the rotary head, as well as, limiting any undesired stress
forces in the mast assembly.

To Adjust Lower (pulldown) Cables:

1. Be sure machine is stabilized on the jacks and is level. Raise the mast and check rotary drive
alignment with how pipe aligns with mast table bushing. Pipe should be centered in deck bushing.
2. With a piece of drill pipe in the rotary head and bit sub installed, lower the mast to horizontal
position. Check for equal sag in the hoist and pulldown cables. Adjust if necessary.

NOTE We can assume from steps 1 and 2 that the cables have equal tension on each
side if pipe is centered in the bushing.
3. Extend the automatic tool wrench, and engage the jaw over the bit sub flats.
4. Feed UP slightly to put some slack in the lower (pulldown cables). Do not use too much feed UP
pressure or damage can occur to the automatic tool wrench.
5. Check sag of lower cables. Adjust the looser cable to match the sag of the tighter cable. Loosen
the jam nut on the mast base and tighten the adjusting nut. Tighten jam nut.

To Adjust Top (hoist) Cables:

1. Apply 500 PSI (35 bar) of hydraulic pressure down on the tool wrench to put some slack in the
upper (hoist) cables. Activate Auto Feed switch to maintain pressure. Check cable sag and adjust
both exactly the same using the adjusting nuts on the crown block.
2. Disengage Auto Feed and hoist slightly. Check sag of lower (pulldown) cables. Adjust if both are
not the same.
3. Apply 1000 PSI (69 bar) down on the tool wrench. Activate Auto Feed switch to maintain pres-
sure. Check cable sag again, to be sure both are equal. Adjust if necessary. Cables are now
adjusted.
Over time, as the cables are adjusted, it will be noticed that the rotary head does
NOTE
not travel all the way to the bottom of the mast, potentially causing non-engage-
ment of the breakout wrench on the flats of the drill stem. At this point it will be
necessary to loosen the top cable adjustment nuts and then tighten the lower
cable adjustment nuts and lock nuts. You should have approximately 4 to 5 in. of
thread length on the adjusting nut side of the cylinder. Once this is done, the
normal cable adjustment procedure is to be followed.

Mast/Rotary Drive/Pipe Rack 6-15

Hoist/Pulldown Cables-SKFX

1
27 27 1 27 27
15 27
12
61
CROWN

12

27 27 1 27 1 27 27
12
Fig. 6-5 SKFX Cable Tensioning Assembly (ref. 428791 rev. 05)
1. Tensioning Cylinder
12. Sheave Carrier
15. Tensioner Manifold
27. Bar Stop
61. Sheave Carrier

GC CE GA GB

P1
PLUGGED CSAB
PBDB
1
CXDA

3 2 1 1 2
CR
SET @
600
2 PSI

P2
3
RDFA

CXHA SET @
3000
2 1 2 PSI
T

1
C2R

C2E

CROWN

CROWN
PULLDOWN HOIST
TENSIONING CYLINDERS TENSIONING CYLINDERS

PULLDOWN
CYL.

Fig. 6-6 SKFX Auto Tensioning System (ref. 428791 rev. 05)

6-16 Mast/Rotary Drive/Pipe Rack

 Hoist/Pulldown Cables-SKFX

Auto Tensioning (optional) - Operating Principle

The auto tensioning system consists of hydraulic cylinders anchored to the feed cylinder and at-
tached to a slider block with guide grooves that cable sheaves move up and down in (fig. 6-5). A separate
cylinder is used for each sheave. Cable stretch is taken up at a 2 : 1 ratio, i.e. for every unit of cylinder
movement, two units of cable stretch are taken up.
Hydraulic valves are used to limit cable tension maximum and minimum values. The system oper-
ates in balanced tension, so that, if one cable wears or stretches more than another there will still be
equal tension on all cables.
The hydraulic valve logic uses a shuttle valve to allow for multiple pressure sources. The valve logic
also incorporates a pressure reducing valve to lower pressure from an external source of higher pres-
sure. This pressure is adjustable through a predetermined range this is appropriate for the system, and
it's setting determines the minimum cable tension value. The area of the hydraulic cylinder pistons is also
predetermined in conjunction with the system pressure to produce the appropriate forces in the system.
The valve logic also uses a check valve, with an orifice, in series with the pressure reducing valve to
prevent reverse flow, effectively locking the cylinder in position and locking the minimum value of tension
in the feed cables. This also provides "power off" load locking, and the orifice controls the cylinder speed.
Down stream of the check valve, is a relief valve which prevents oil from flowing directly to tank and
determines the maximum system pressure. A second relief valve, installed at the retract ports of the
pulldown side cylinder determines the maximum value of tension in the feed cables. The second relief
also provides a means of adjustment of the maximum tension and will relieve at a predetermined value,
should an overload occur from system impulse loads, or excessive take-up of the unloaded set of cables
during momentary deflections in the mast structure.
During a hoisting load cycle (removal of drill pipe and bit, after completion of drilling) the mast will
deflect under this loading. The set of pulldown cables may be unloaded, or at a reduced tension load
during this operation, and the tensioning system will take up slack as the mast deflects. Once the hoisting
load is removed and the mast attempts to return to its original undeflected position, the feed cable could
be over tensioned. The second relief, which is exposed to externally induced changes in cylinder pres-
sure, will open and limit additional tension to the appropriate maximum level.
A check valve with 30 psi cracking pressure, is downstream of the relief to prevent oil in the valve
and cylinder from draining to tank due to gravity head, but allows flow to tank above 30 psi. The system
relief valve should be preset to 3000 psi on the bench, by use of a hand pump or other suitable pressure
source and a gauge installed in port "GB" of the tensioner manifold. The overload relief is also preset to
3000 psi.
Two check valves are used at the hoisting side of the tensioning cylinder retract ports, allowing free
flow into the cylinders, and locking oil in the cylinders, such that oil can not be exchanged between the
two hoist side cylinders. An additional check valve is used at the pulldown side of the tensioning cylinder
retract ports, allowing free flow into the cylinders, and locking oil in the cylinders, such that oil cannot be
exchanged between the pulldown side cylinders and the hoist side cylinders.

Mast/Rotary Drive/Pipe Rack 6-17

Hoist/Pulldown Cables-SKFX

ROPE TENSIONER
HOIST/PULLDOWN CYLINDER CYLINDERS
415915 A B A B

433469 433469
PULLDOWN
RETRACT

GC C1E GA GB
P1
PBDB-LAN
2 3
2 1 1 2
1
P2 C1R
CSAB-XXN CXDA-XCN

3 600 PSI
ROPE TENSIONER
MANIFOLD

0416113 RDFA-LAN

CXHA-XCN
2 1 2 1 C2R
415915 T
SET TO
ROPE TENSIONER MAX
CYLINDERS
C2E
X

Fig. 6-7 Hydraulic Schematic of Auto Tensioning System (ref. 440857 rev. 04)

TOP VIEW REDUCING VALVE

CSAB
PBDB

GB
SET @ 600 PSI

RDFA

SAE - 4 PORT
3 PLACES

RELIEF VALVE
SET @ 1000 PSI

SAE - 20 PORT CHECK VALVE

SAE - 10 PLUG

SAE - 12 PORT
T
2 PLACES P2 CR
CXDA GC
C2E C2R CE
CXHA P1

GA

LEFT SIDE FRONT RIGHT SIDE REAR VIEW

SAE - 16 PORT
4 PLACES

Fig. 6-8 Tensioner manifold Port Identification (ref. 428791 rev. 05)

6-18 Mast/Rotary Drive/Pipe Rack

 Hoist/Pulldown Cables-SKFX

Auto Tensioning - Cable Installation and Adjustment

1. With one piece of drill pipe attached to top drive, raise top drive up and engage the flats of the bit
sub with the deck wrench. If using a down-the-hole hammer, remove it from the drill pipe to enable
the mast to be lowered.
2. Apply about 1500 PSI (103 bar) hoist or pulldown pressure, depending on which cables you are
replacing.
• If you are replacing the hoist cables, apply pressure downward, this will put some slack in the
hoist cables, so you can loosen the nuts.
• If you are replacing the pulldown cables, apply pressure upward, this will put some slack in
the pulldown cables, so you can loosen the nuts.
3. Lower the mast to horizontal position, resting on the mast rest.
4. Loosen the cable jam nuts and adjusting nuts until there is no tension on the cable.
Always replace cables in sets. Do not install a new cable on one side and a used
NOTE
one on the other side.
5. Remove cable clevis and remove all sheaves that the cable passes through. It is a good idea to
check the sheave bearings and seals and replace any worn parts at this time. Remove cable.
6. Fully extend the tensioning cylinders.
7. Install new cables and existing sheaves. Install clevis on rotary head guide first, then install cable
end and adjusting nut. It may be necessary to apply more feed pressure to engage the threads
with the adjusting nut.
8. The cables are now installed loose and sagging. Adjust the nuts so the hoist cables are sagging
about 1-1/2 in. at the mid-point. Do the same for the pulldown cables.
9. Install a 6000 PSI (414 bar) gauge in port "GA" of tensioner manifold. Pressurize the "P" port of the
tensioner manifold. Set the pressure reducing valve between 600 - 1250 PSI (41 - 86 bar). Set
the pressure on the relief valve to 3000 PSI (207 bar). Read pressure on the gauge in port "GA".
10. There is now equal pressure in the four tensioning cylinders, and equal tension of the four cables.
The rotary drive is also aligned with equal tension on all four cables. No further adjustment of the
rotary drive alignment can be made or is required.

Mast/Rotary Drive/Pipe Rack 6-19

Hoist/Pulldown Cables-SKFX

Hoist/Pulldown Cable Replacement

1. With one piece of drill pipe attached to top drive, raise top drive up and engage the flats of the bit
sub with the deck wrench. If using a down-the-hole hammer, remove it from the drill pipe to enable
the mast to be lowered.
2. Apply about 1500 PSI (103 bar) hoist or pulldown pressure, depending on which cables you are
replacing.
• If you are replacing the hoist cables, apply pressure downward, this will put some slack in the
hoist cables, so you can loosen the nuts.
• If you are replacing the pulldown cables, apply pressure upward, this will put some slack in
the pulldown cables, so you can loosen the nuts.
3. Lower the mast to horizontal position, resting on the mast rest.
4. Loosen the cable jam nuts and adjusting nuts until there is no tension on the cable.

NOTE Always replace cables in sets. Do not install a new cable on one side and a used
one on the other side.
5. Remove cable clevis and remove all sheaves that the cable passes through. It is a good idea to
check the sheave bearings and seals and replace any worn parts at this time. Remove cable.
6. Install new cable and existing sheaves. Install clevis on rotary head guide first, then install cable
end and adjusting nut. It may be necessary to apply more hoist/pulldown pressure to engage the
threads with the adjusting nut.
7. Tighten the adjusting nuts until cable feels tight enough to be tested.
8. Follow procedures for rotary head alignment and hoist/pulldown cable adjustment.

6-20 Mast/Rotary Drive/Pipe Rack

 Rotary Head Guide Alignment

REAR (CAB END) OF MACHINE

SHIM INSIDE FIRST ROTARY GUIDE

CHECK OIL LEVEL AND

DRAIN OIL WITH THIS
ARROW POINTING UPWARDS!

SHIM REAR THIRD

SHIM FRONT SECOND

TOP VIEW OF MAST

Fig. 6-9 SKF Rotary Drive Assembly on Mast (414465)

Alignment Procedure
DANGER:
LOOK UP before raising or lowering mast. Operating near or
coming in contact with electrical power lines will result in serious
personal injury or death.
DO NOT come within 10 ft. (3 m) of electrical power lines.
BE SURE all personnel are clear of machine.

1. Spot and level the machine and raise the mast as in preparation for normal drilling operations.
2. Drill one pipe into the ground. At the completion of this pass, raise the rotary head just enough to
suspend the drill pipe in the hole, approximately 2 ft.
3. Check alignment of the pipe in the drill bushing. It should be hanging in the center without touching
the sides of the bushing. If it is touching, loosen the capscrews attaching the wear pads (16) to
the rotary guide assembly (fig. 6-9 & 6-10).
4. Begin by shimming the inside wear pad first, then shim the front wear pad (towards the radiator
end of the machine) and finally, shim the rear wear pad (cab end). Add or subtract the necessary
amount of shims between the pads and guides until the drill stem hangs freely within the drill
bushing. Re-tighten the guide wear pad screws.

Mast/Rotary Drive/Pipe Rack 6-21

Rotary Drive Assembly

22

12 NOTES:

21 1. HEAT AND BEND ITEM 5 TO FOLLOW

12 21 CONTOUR OF JOINT AS SHOWN.
CHECK OIL LEVEL AND
DRAIN OIL WITH THIS
ARROW POINTING UPWARDS!

2. USE SHIMS (ITEM 17) BETWEEN

(ITEMS 3 & 16 )-( ITEMS 4 & 16)
SHIM AS NEEDED SO ROTARY HEAD
TRAVELS SMOOTHLY.
SEE 16 17 SEE
NOTE: 2 16 17 NOTE: 2

12 21 12 21 5
4

1
NOTE:
WELD ITEM #5 TO
ROTARY SHAFT AND TOP
3 NOTE: TORQUE ITEM #12 SUB AFTER JOINT IS
4 TIGHTENED.
TO 55 ft-lbs. DRY
(DO NOT LUBRICATE)
ITEM #12 TO BE LOCTITED.
3/8
TYP.
3/8

12 21
VIEW A-A

12 21
TORQUE ITEM #11
11 11 15 TO 380 FT/LBS. DRY
1.0
15
TO 280 FT/LBS. LUBE

12 21 A 12 21

1
A
12 21
12 21
5

SUB ADAPTER

Fig. 6-10 Rotary Drive Assembly (427147)

1. Rotary Gearbox 11. Capscrew (12) 17. Shim (12)
3. Guide, R.H. 12. Capscrew (24) 21. Lock Washer (20)
4. Guide, L.H. 15. Lock Washer (12) 22. Hydraulic Motor
5. Chock Bar (2) 16. Wear Pad (12)

6-22 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Assembly

Rotary Drive - Removal from Mast

WARNING:
BE SURE to relieve pressure on hydraulic or pneumatic
systems before loosening connections or parts.

1. Remove drill pipe from rotary drive and lower rotary drive to bottom of mast.
2. Remove sub-adapter or shock sub from rotary drive shaft. You will have to grind the weld from the
two chock bars (5) before removing.
3. Remove air connection (and air swivel if equipped) from rotary drive gearbox.
4. Tag and remove hydraulic hoses from rotation motor. Cap or plug all open fittings. Remove
rotation motor. Weight of motor is about 140 lbs. (63 kg).
5. Support rotary gearbox with suitable lifting device in two places. Weight of gearbox is about
1560 lbs. (708 kg.). Remove the six capscrews (11) per side that hold gearbox to mast guides.
Carefully slide gearbox forward to clear upper and lower stop blocks and be certain gearbox is
properly balanced, then lift clear of mast.

Rotary Drive - Installation

1. Hoist rotary drive into position with suitable lifting device. Align unit between upper and lower stop
blocks and slide into mast. Align the six bolt holes in the rotary drive with the holes in the right and
left mast guides.
2. Install the six capscrews (11) and hardened washers (15) on each side and torque to 297 ft. lbs.
(404 Nm).
3. Install air swivel (if equipped) and air hose to rotary drive gearbox. Install rotation motor (22)
along with all hoses and any other connections that were removed.
4. Start machine and check that rotary drive functions properly and there are no leaks. Install sub
adapter or shock sub and tighten joint. Weld new chock bars (5) in place according to fig. 6-10.

Mast/Rotary Drive/Pipe Rack 6-23

Rotary Drive Gearbox
43

18 22

19 23
3/4-10 UNC THREAD, 1.2 DEEP
20 (4) HOLES EQUALLY SPACED
ON A 9.000 DIA BC
SAE (4) BOLT "D" PAD

OIL LEVEL PLUG (ON OPPOSITE SIDE) 35

NOTE: OIL LEVEL MUST BE SET WITH THE
B SHAFTS HORIZONTAL & THE OUTPUT SHAFT
A IN THE 6 O'CLOCK POSITION

ARR

CH IN OIL
DRA
ECK
OW
POI

OIL WITH
NTIN

LEV
G UPW

EL
THI S!
AND
ARD
S
31

36 MAGNETIC DRAIN PLUG

BREATHER 32 48
84 TOOTH GEAR
CUSTOMER TO USE
FOR MAGNETIC PICKUP

61
17 21
OIL LEVEL NAMEPLATE 52
(ON OPPOSITE SIDE)
61

SHIM FOR .585/.580

SEAL HEIGHT
54 55 56

53

SECTION B-B .585.580 REF

58 60 22

DETAIL C 57
59 SHIM FOR .003/.005 END PLAY 49

11 50 SET PRELOAD TO .002/.004 PER THE FOLLOWING INSTRUCTIONS: 24 25

TIGHTEN LOCKNUT ENOUGH TO ACHIEVE .000 END PLAY 46
ROTATE LOCKNUT 1/64 TO 1/32 TURN. (5.625°/11.25°)
TIGHTEN SET SCREWS IN LOCKNUTS TO 50 FT-LB MIN. 08 34
TIGHTEN SCREWS EVENLY & OPPOSITE TO ONE ANOTHER.
GRADUALLY INCREASING THE TORQUE. DO NOT TIGHTEN
SCREWS PRIOR TO ASSEMBLING LOCKNUT TO SHAFT
39 29 16
14

26 27

40

07

09 15

27 28

42 02 24 25 06 05 38 29 04
DETAIL C
SCALE: .75 12 17 21

33
10 30 RTV
SECTION A-A

03
NOTE: INSTALL LOCTITE #515 OR EQUIVALENT
5-1/2 API REGULAR THREAD AT ALL MACHINED SPLITLINES UNLESS A
GASKET IS FURNISHED. SEAL ALL NON-MACHINED
INTERFACES WITH SILICONE SEALANT.

Fig. 6-11 Single Motor Rotary Drive Gearbox with built-in Air Swivel (ref. 427134)
NOTES:
1. Set preload to 0.002 to 0.004 by placing an 8 X 8 wood block under rotary head and load pulldown to 1200 PSI
o
(83 bar). Turn locknut (11) until it contacts bearing cone (26), then turn locknut another 15 . Tighten capscrews
(50) in locknut to 100 ft.lb. (136 Nm) min. Tighten screws evenly and opposite to one another, gradually increasing
the torque. Do Not tighten screws prior to assembling locknut to shaft.
2. Install silicone rubber sealant at all split lines unless shim or gasket is used.

6-24 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox

Rotary Drive Gearbox (427134) - Item Listing

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION

002 1.00 KEY 031 2.00 PIN, DOWEL

003 1.00 SHAFT, OUTPUT 032 1.00 BUSHING
004 1.00 SHAFT, 24T 033 1.00 PLUG, MAGNETIC
005 1.00 GEAR, 84T 034 1.00 PLUG, HEX, COUNTERSUNK
006 1.00 SHAFT, 24T 035 1.00 PLUG
007 1.00 GEAR, 110T 036 1.00 PLUG, MAGNETIC
008 1.00 END COVER 038 1.00 RING, SNAP
009 1.00 SPACER 039 1.00 RING, SNAP
010 1.00 SPACER 040 1.00 RING, SNAP
011 2.00 LOCKNUT 042 1.00 SEAL, SPECIAL
012 1.00 PLATE, SEAL 043 1.00 NAMEPLATE
014 1.00 HOUSING, SEAL 044 1.00 WINDOW, OIL LEVEL
015 1.00 CASE 046 1.00 PLUG, SHIPPING
016 1.00 COVER 047 2.00 CAPSCREW
017 10.00 CAPSCREW, HEXHEAD 048 1.00 FITTING
018 12.00 CAPSCREW, HEXHEAD 049 1.00 SHIM SET
019 8.00 CAPSCREW, HEXHEAD 050 8.00 CAPSCREW, SOCKETHEAD
020 3.00 CAPSCREW, SOCKETHEAD 051 2.00 PLUG, SOCKET HEAD
021 10.00 LOCK WASHER 052 1.00 NAMEPLATE, CHECK OIL
022 18.00 LOCK WASHER 053 1.00 HOUSING, SEAL
023 8.00 LOCK WASHER 054 3.00 SHIM, .005 in.
024 2.00 BEARING CONE 055 3.00 SHIM, .007 in.
025 2.00 BEARING CUP 056 3.00 SHIM, .020 in.
026 1.00 BEARING, CONE 057 2.00 SEAL, FACE
027 2.00 BEARING, CUP 058 1.00 SPACER, SEAL
028 1.00 BEARING, CONE 059 2.00 SEAL
029 2.00 BEARING, BALL 060 6.00 CAPSCREW, HEXHEAD
030 1.00 PIN, ROLL 061 2.00 FITTING, GREASE

51 FILLER PLUG

THIS WINDOW IS FOR REFERENCE ONLY 44

OIL SHOULD COMPLETELY FILL WINDOW
WHEN SHAFTS ARE VERTICAL

Fig. 6-11a Single Motor Rotary Drive Gear-

box with built-in Air Swivel (ref. 427134)

47 5/8-18 UNF - 2A THREAD

FOR MAGNETIC PICKUP

Mast/Rotary Drive/Pipe Rack 6-25

Rotary Drive Gearbox

Seal Installation
In order to get maximum service life out of heavy duty face seals, they must be seated in their
housings symmetrically, resulting in a stable running position. If the seal halves are not installed accu-
rately, misalignment or cocking of the seal set can occur during the assembly procedure, resulting in non-
uniform face loading and wobbling of the seals in their housings. This is the leading cause of leakage and
premature failure. To avoid this, always follow these instructions.

1. Clean all sealing components, seal rings (metal rings), load rings (bellevilles) and the housings with
denatured alcohol. Check to make sure that there is no nicks or burrs in the housing area that
could damage the load ring during installation.
2. After components have dried, the load rings should be placed back on the seal rings in their
proper position. Make sure that the load rings are seated completely and tightly on the seal ring.

WARNING:
Do not place the seal rings face down on any hard or
abrasive surface to accomplish this.

3. Quickly swab out the housing with a clean lint free cloth generously soaked with denatured alco-
hol. This is to temporarily lubricate the installation bore. then, with the same cloth, quickly swab
the outside (load ring area) of the seal half to temporarily lubricate the load ring.
4. With both hands, quickly center the load ring in the housing and firmly and evenly press the seal
into the housing bore. It is important for the load ring as well as the housing bore to be
wet with alcohol during this process.
5. Visually inspect the positioning of the load ring and seal ring relative to each other, as well as
relative to the housing. Make sure that everything is seated symmetrically.

WARNING:
Misaligned seals and improperly seated load rings can
cause leakage or premature failure.

6. The seal may be adjusted by gently pushing the load ring into position with your fingers from the
outside.

WARNING:
Never use sharp instruments such as screwdrivers. They
can cause permanent damage to the load ring and/or
seal ring, which may lead to rapid failure.

Also, the seal ring may need to be adjusted in the load ring. This can also be done with your
fingers. For twists or obvious bulges in the load ring or if the seal ring is "riding up" on the load ring
can not be adjusted, remove the seal half and repeat the procedure, beginning with the cleaning
process.

6-26 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox

7. After successful installation in housings, wait a few minutes for the alcohol to completely evapo-
rate, before assembling. The alcohol is necessary as a lubricant during the installation process,
but for assembly the area must be clean and dry in order for the load ring to properly "crush" into
its final position.

WARNING:
Never install seals with oil, grease or any solvent that can
leave a residue.

Assembly Instructions
1. After both seal halves have been installed in the case and seal plate housings and just prior to
assembly, thoroughly clean the faces with denatured alcohol. Apply a thin film of oil (the same oil
that will be used in the drive unit) to the faces of the seal rings with a clean lint free cloth. Be
careful not to get oil on the load rings.
2. Pick up the seal plate (with the half seal installed) with both hands and turn it over using your
fingers to hold the seal ring in place, while it is inverted. Line the plate up over the shaft and slide
on until the case seal face come in contact with your fingers. Slowly slide your fingers out at the
gap and let the faces come together.
3. Place both hands on the seal plate and apply even pressure to the top of it to make sure that the
seal is completely seated in the housings. Turn the plate slightly in both directions while applying
pressure. At this time it is not important to line up the bolt holes.
4. Visually inspect the gap between the plate and the case to see that it is the same size all of the
way around the circumference. If it is not, repeat step 3. If further adjustments are necessary,
remove the seal plate and the seal halves from their housings and repeat the installation proce-
dure again starting with step 1 (cleaning process).
5. Line up the bolt holes, and slowly and evenly draw the plate down to the case using the specified
torque.

Run-In Period
The run-in period is the amount of running time necessary for the faces to mate to each other to
form a perfect seal. One hour in each direction is normally sufficient. It is common for seals to
"weep" a little during this period. Continuous dripping and/or running oil is a signal that something
is wrong.

Maintenance
For trouble free function of the seal, adequate lubrication of the sealing faces is necessary at all
times. A small amount of oil may be visible on the outer diameter of the seal when it is working.
This is not a leak, but only the seal faces being properly lubricated. If a seal is removed or the
faces are separated after it has been run-in, it should be replaced with a new set.

Mast/Rotary Drive/Pipe Rack 6-27

Rotary Drive Gearbox

Rotary Drive Gearbox - Repair

1. Repair of the gearbox is limited to the replacement of damaged or worn parts.
2. Inspect gear teeth for galling or heat discoloration and replace as necessary.
3. Inspect gear teeth for uneven wear patterns.
4. Inspect bearings and replace as necessary.
5. Replace seals and gaskets
If repairs are necessary, refer to the folowing Cotta TM2132-4 Repair Manual.

NOTE Refer to parts manual for specific gearbox and part numbers.

Main Shaft Bearing Preload

After repairs are made to rotary drive gearbox, the main shaft bearing preload of 0.002 in. to
0.004 in. must be set as follows:
1. With rotary gearbox installed on the mast, place an 8 X 8 wood block on top of the deck wrench
and lower rotary gearbox so it is against the block.
2. Apply 1200 PSI (83 bar) pulldown pressure.
3. Tighten locknut (11) by hand until it contacts the upper bearing cone (26), then turn (tighten)
o
locknut another 15 .
4. Tighten the setscrews (50) in the locknuts (11) evenly and opposite one another, gradually
increasing torque to specifications on drawing.

6-28 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-29

Rotary Drive Gearbox Repair

6-30 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-31

Rotary Drive Gearbox Repair

6-32 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-33

Rotary Drive Gearbox Repair

6-34 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-35

Rotary Drive Gearbox Repair

6-36 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-37

Rotary Drive Gearbox Repair

6-38 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-39

Rotary Drive Gearbox Repair

6-40 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-41

Rotary Drive Gearbox Repair

6-42 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-43

Rotary Drive Gearbox Repair

6-44 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-45

Rotary Drive Gearbox Repair

6-46 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-47

Rotary Drive Gearbox Repair

6-48 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-49

Rotary Drive Gearbox Repair

6-50 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-51

Rotary Drive Gearbox Repair

6-52 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-53

Rotary Drive Gearbox Repair

6-54 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-55

Rotary Drive Gearbox Repair

6-56 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-57

Rotary Drive Gearbox Repair

6-58 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-59

Rotary Drive Gearbox Repair

6-60 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-61

Rotary Drive Gearbox Repair

6-62 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-63

Rotary Drive Gearbox Repair

6-64 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-65

Rotary Drive Gearbox Repair

6-66 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Gearbox Repair

Mast/Rotary Drive/Pipe Rack 6-67

Rotary Drive Hydraulic Motor

Rotary Drive Motor - Repair

NOTE It is not recommended that major repairs be made to hydraulic pumps and mo-
tors, as it will void the warranty. Usually, when a pump or motor is in need of
major repair, it is more cost effective to replace it with a new or rebuilt unit.

Refer to the following AA6VM Service Manual for complete information on adjustments and shaft
seal repair.
The motor used for this application is the 160 size.
Control type is HA1.

6-68 Mast/Rotary Drive/Pipe Rack

 Rotary Drive Hydraulic Motor

Mast/Rotary Drive/Pipe Rack 6-69

6-70 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-71
6-72 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-73
6-74 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-75
6-76 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-77
Notes

6-78 Mast/Rotary Drive/Pipe Rack

Mast/Rotary Drive/Pipe Rack 6-79
6-80 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-81
6-82 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-83
6-84 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-85
6-86 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-87
6-88 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-89
6-90 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-91
6-92 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-93
Winch Assembly

Precautions on the Use of Winches

WARNING:
Winch brakes may slip or not function if operated in cold
weather before proper warm-up.

Before operating any winch, be absolutely sure that the drill hydraulic system is properly warmed up to
100oF (38oC). After proper hydraulic system warm-up "exercise" the winch without load for several up and
down cycles to allow warm hydraulic fluid to circulate in the winch.

Wire Rope
Regular wire rope inspection, maintenance and replacement is necessary on all drill rigs. Environmen-
tal drills may have five or more different winches; each with a different wire rope size, length, operating
condition and load factor. Wear can occur rapidly on one winch and be negligible on another on the same
drill rig.

The point at which to discard a wire rope is after receiving maximum service but without sacrificing
safety. This is achieved by visual inspection of the outside condition of the wire rope. Deterioration of wire
rope occurs both internally and externally from abuse, wear and corrosion. Research by wire rope manufac-
turers has shown that internal failures are followed by external failures visible to an inspector. On this basis,
careful examination of the outside of the wire rope is a satisfactory means of determining the condition of
the rope.

Since safety is dependent on the proper operation of the wire ropes in all operations, a visual inspec-
tion of the wire rope should be performed daily by appointed personnel by running the block to its lowest
usable point, and slowly running the block up as all parts of the cable are observed for signs of wear and
damage:

A. Kinks or severe twists

B. Broken wires and nicks
C. Deformed, worn or flattened wires
D. Corroded or pitted surfaces
E. Shortened or lengthened rope lays

6-94 Mast/Rotary Drive/Pipe Rack

 Winch Assembly

Wire Rope (continued)

In addition, the following more detailed inspection should be performed monthly or at more frequent
intervals dependent upon operating conditions and usage:

WARNING:
When running out the wire rope, exercise care that the drum
stops at the end of the rope run-out and does not begin rewind-
ing in the reverse direction. Stop run-out before you reach the
dead lays on the drum.

1. Run out wire rope completely and note conditions such as the number of broken wires in one lay,
the reduction in rope diameter, corrosion, shortening of the lay and lubrication.
2. Run a soft cloth (preferably cotton) over the entire length of wire rope and examine rope lays
which pick up threads of cloth. Determine the extent of damage due to broken wires or nicks.
3. Examine sheaves and drums for abnormal wear, breakage or deterioration. Replace any sheave
or drum contributing to rope wear.
4. Examine the wire rope closely at the equalizer sheave location. Where wear is noted, the rope
can be shortened from the dead end to change the point of wear. (However, two dead wraps must
be maintained on the drum and required lift or operating range not reduced.)
5. Examine socketed fittings; if one broken wire is noted adjacent to the socket, resocket the wire
rope.
The length and type of service and the severity of operation must be taken into consideration before
determining the disposition of a wire rope which shows signs of damage. Where failure might endanger life
or equipment, the rope must be condemned and replaced if any of the following conditions are discov-
ered:

1. Six wires broken in one rope lay.

2. Three wires broken in one strand in one rope lay
3. Wear of 1/3 the original diameter of outside individual wires.
4. Rope severely kinked, crushed, cut, or unstranded, or any other damage resulting in distortion of
rope structure.
5. Considerable corrosion in the valleys between strands.
6. Reduction from nominal rope diameter of more than 1/64 in. (0.3mm) for diameters up to and
including 5/16 in. (3.1 mm); 1/32 in. (0.7mm) for diameters of 3/8 in. through 1/2 in. (9.5-12.7
mm); 3/64 in. (1.2 mm) for diameters of 9/16 in. through 3/4 in. (14.2-19.1 mm); 1/16 in.
(1.6mm) for diameters of 7/8 in. through 1-1/8 in. (22.2-28.6mm); and 3/32 in. (2.4mm) for
diameters of 1-1/4 in. through 1-1/2 in. (31.8-38.1mm).
When any of the above conditions exist, the wire rope must be condemned and replaced.

Mast/Rotary Drive/Pipe Rack 6-95

Winch Assembly

Wire Rope (continued)

Lubrication is also important in the life of wire ropes, and can be accomplished with little trouble and
expense. Regular, frequent applications of lubricant are preferred to infrequent heavy applications. Brush,
spray, or dip the wire rope with cable lubricant M-2C-10 as required, depending on service conditions. The
lubricant must be applied properly to coat the entire cable, not just the portion in most frequent use. Wire
rope subjected to high operating temperatures or corrosive atmosphere should be lubricated semi-monthly.

Keep all wire ropes, including those infrequently used or those in storage, free of contaminants and
well protected with lubricant. Dirty cables should be cleaned and flushed with M-99C30 penetrating oil;
after one week, the entire surface should be brushed to remove all excess grease, accumulated dirt,
metal rust, or other harmful contaminants.

NOTE NEVER subject a wire rope to shock loads or loads exceeding the safe load rat-
ing.

Wire Rope Clips

Wire rope clips are widely used for attaching wire rope to thimbles, hoists and for joining two ropes.
Clips are available in two basic designs; the U-bolt and fist grip. The efficiency of both types is the same.
When using U-bolt clips, extreme care must be exercised to make certain that they are attached cor-
rectly, i.e., the U-bolt must be applied so that the "U" section is in contact with the dead end of the rope.
Also, the tightening and re-tightening of the nuts must be accomplished as required.

How to Apply Wire Rope Clips

U-Bolt Clips
1. Turn back the specified amount of rope from the thimble. Apply the first clip one base width from
the dead end wire rope (U-bolt over dead end-live end rests in clip saddle). Tighten nuts evenly to
recommended torque.
2. Apply the next clip as near the loop as possible. Turn on nuts firmly, but do not tighten.
3. Space additional clips, if required, equally between the first two. Turn on nuts, take up rope slack,
tighten all nuts evenly on all clips to recommended torque.
4. Apply the initial load and re-tighten nuts to the recommended torque. New rope in particular and
used rope will stretch and shrink in diameter when loads are applied. Inspect periodically and re-
tighten.

WARNING:
Failure to make proper terminations or to periodically re-tighten
clips to the recommended torque will reduce the wire lines load
rating, thus creating a hazardous condition.

6-96 Mast/Rotary Drive/Pipe Rack

 Winch Assembly

How to Apply Wire Rope Clips (continued)

A termination made in accordance with the above instructions, and using the number of clips shown
has an approximate 80% efficiency rating. This rating is based upon the catalog breaking strength of wire
rope. If a pulley is used in place of a thimble for turning back the rope, add one additional clip.

The number of clips shown is based upon using right regular or long lay wire rope, 6 x 19 class, or 6
x 37 class, fiber core or IWRC, IPS, or XIPS. If Seale construction or similar large outer wire type construc-
tion in the 6 x 19 class is to be used for sized 1 in. (25.4 mm) and larger, add one additional clip. The
number of clips shown also applies to right regular lay wire rope, 8 x 19 class, fiber core, IPS, sizes
1 1/2 in. (38.1mm) and smaller; and right regular lay wire rope, 18 x 7 class, fiber core, IPS or XIPS, sizes
1 3/4 in. (44.5mm) and smaller.

For other classes of wire rope not mentioned above, it may be necessary to add additional clips to
the number shown. If a greater number of clips is used than shown in the table, the amount of rope turn-
back should be increased proportionately.

Mast/Rotary Drive/Pipe Rack 6-97

Winch Assembly

6-98 Mast/Rotary Drive/Pipe Rack

 Winch Assembly

How to Apply Wire Rope Clips (continued)

Fist Grip Clips
1. Turn back the specified amount of rope from the thimble. Apply the fist clip one base width from the
dead end of the wire rope. Tighten nuts evenly to recommended torque.
2. Apply the next clip as near the loop as possible. Turn on nuts firmly, but do not tighten.
3. Space additional clips if required equally between the first two. Turn on nuts, take up rope slack,
and tighten all nuts evenly on all clips to recommended torque.

WARNING:
Apply the initial load and re-tighten nuts to the recommended
torque. New rope, in particular, and used rope will stretch
and shrink in diameter when loads are applied. Inspect
periodically and re-tighten.

A termination made in accordance with the above instructions, and using the number of clips shown,
has an approximate 80% efficiency rating. This rating is based upon the catalog breaking strength of wire
rope. If a pulley is used in place of a thimble for turning back the rope, add one additional clip.

The number of clips shown is based upon using right regular or long lay wire rope, 6 x 19 class, or 6
x 37 class, fiber core or IWRC, IPS, or XIPS. If Seale construction or similar large outer wire type construc-
tion in the 6 x 19 class is to be used for sized 1 in. (25.4 mm) and larger, add one additional clip. The
number of clips shown also applies to right regular lay wire rope, 8 x 19 class, fiber core, IPS, sizes
1 1/2 in. (38.1mm) and smaller; and right regular lay wire rope, 18 x 7 class, fiber core, IPS or XIPS, sizes
1 1/2 in. (38.1mm) and smaller.

For other classes of wire rope not mentioned above, it may be necessary to add additional clips to
the number shown. If a greater number of clips is used than shown in the table, the amount of rope turn-
back should be increased proportionately. The above is based on use of Fist Grip Clips on new wire rope.

WARNING:
Failure to make proper terminations or to periodically re-tighten
clips to the recommended torque will reduce the wire lines load
rating, thus creating a hazardous condition.

Mast/Rotary Drive/Pipe Rack 6-99

Winch Assembly

Wedge Sockets
One of the more popular end attachments for wire rope is the wedge socket. For field, or on-the-job
attachment, it is easily installed and quickly dismantled.

1. Inspect the wedge and socket; all rough edges or burrs, that might damage the rope, should be
removed.
2. If the rope is welded, the welded end should be cut off. This will allow the distortions of the ropes
strands, caused by the sharp bend around the wedge, to adjust themselves at the end of the line.
If the weld is not cut off, the distortions will be forced up the working line. This may result in the
development of high strands of wavy rope.
3. Place the socket in an upright position (fig. 6-13) and bring the rope around in a large, easy to
handle loop. Care must be taken to make certain that the live-loaded side of the rope is in line
with the ears.
4. The dead end of the rope should extend from the socket for a distance approximately nine times
the rope diameter. The wedge is now placed in the socket, and a wire rope clip is placed around
the dead end by clamping a short, extra piece or rope to the tail. (DO NOT clamp to the live part.)
The U-bolt should bear against the tail; the saddle of the clip should bear against the short extra
piece.
5. Secure the ears of the socket to a sturdy support and carefully take a strain on the live side of
the rope. Full the wedge and rope into position with tension sufficiently tight to hold them in place.
6. After final pin connections are made, increase the loads gradually until the wedge is properly
seated. Avoid sudden shock loads.
The foregoing is the recommended procedure. If variations are made to suit special conditions, they
should be carefully evaluated beforehand.

6-100 Mast/Rotary Drive/Pipe Rack

 Winch Assembly

Grooved Drums
With grooved drums, the winding conditions should be closely supervised to assure adherence to
the following recommended procedures.

1. The end of the rope must be secure to the drum by such means as will give the end attachment
at least as much strength as is specified by the equipment manufacturer.
2. Adequate tension must be maintained on the rope while it is being wound so that the winding
proceeds under continuous tension.
3. The rope must follow the groove.
4. There should be at least three dead turns remaining on the drum when the rope is unwound during
normal operation. Two dead turns are a mandatory requirement in many codes and standards.
If the sire rope is carelessly wound, and, as a result, jumps the grooves, it will be crushed and cut
where it crosses from one groove to the other. Another, almost unavoidable problem is created at the
drum flange; as the rope climbs to a second layer there is further crushing and the wires receive exces-
sive abrasion. Riser and filler strips may help remedy this condition.

Plain (Smooth) Drums

Installation of a wire rope on a smooth face drum requires a great deal of care. The starting position
should be at the drum end so that each turn of the rope will wind tightly against the preceding turn. Here
too, close supervision should be maintained during installation. This will help make certain that:

1. the rope is properly attached to the drum;

2. appropriate tension on the rope is maintained as it is wound on the drum;
3. each turn is guided as close to the preceding turn as possible, so that there are no gaps between
turns; and
4. there are at least two dead turns on the drum when the rope is fully unwound during normal
operating cycles.
Loose and uneven winding on a smooth drum can, and usually does, create excessive wear, crush-
ing and distortion of the rope. The results of such abuse are lower operating performance, and a reduc-
tion in the rope's effective strength. Also, for an operation that is sensitive in terms of moving and spotting
a load, the operator will encounter control difficulties as the rope will pile up, pull into the pile and fall from
the pile to the drum surface. The ensuing shock can break or otherwise damage the rope.

Mast/Rotary Drive/Pipe Rack 6-101

Winch Assembly

Fig. 6-12 Wire Rope Cross-Over

Fig. 6-13 Diagram showing how to determine wire rope "lay"

6-102 Mast/Rotary Drive/Pipe Rack

 Winch Assembly

Plain (Smooth) Drums (continued)

The proper direction of winding the first layer on a smooth drum can be determined by standing
behind the drum and looking along the path the rope travels, and then following one of the procedures
illustrated. The diagrams (Figs 6-12 and 6-13) show the correct relationship that should be maintained
between the direction of lay rope (right or left), the direction of rotation of the drum (overwind or underwind),
winding from left to right, or right to left.

Drums - Multiple Layers

Many installations are designed with requirements for winding more than one layer of wire rope on a
drum, winding multiple layers presents some further problems.

The first layer should wind in a smooth, tight helix which, if the drum is grooved, is all ready estab-
lished. The grooves allow the operator to work off the face of the drum, and permit the minimum number
of dead turns.

A smooth drum presents an additional problem, initially, as the wire rope must be wound in such a
manner that the first layer will be smooth and uniform, and will provide a firm foundation for the layers of
rope that will be wound over it. The first layer of rope on the smooth drum should be wound with tension
sufficient to assure a close helix, each turn being wound as close as possible to the preceding turn, and
most, if not all, of the entire layer being used as dead turns. The first layer then acts as a helical groove
which will guide the successive layers. Unlike wire ropes operating on groove drums, the first layer should
not be unwound from a smooth-faced drum with multiple layers.

After the rope has wound completely across the face of the drum (either smooth or grooved), it is
forced up to a second layer at the flange. The rope then winds back across the drum in the opposite
direction, lying in the depression between the turns of the rope on the first layer. Advancing across the
drum on the second layer, the rope, following the "grooves" formed by the second layer, the rope, follow-
ing the "grooves" formed by the rope on the first layer, actually winds back one turn in each revolution of
the drum. The rope must then cross two rope "grooves" in order to advance across the drum for each
turn. The point at which this occurs is known as the cross-over. Cross-over is unavoidable on the second,
and all succeeding layers.

At these cross-over points, the rope is subjected to severe abrasion and crushing as it is pushed
over the two rope "grooves" and rides across the crown of the first rope layer. The scrubbing of the rope,
as this is happening, can easily be heard. There is, however, a special drum grooving available that will
greatly minimize the damage that can occur at cross-over points. Severe abrasion can also be reduced
by applying the rule for the correct rope lay (right or left-lay) to the second layer rather than to the first
layer. It is for this reason that the first layer of a smooth drum should be wound tight and used as dead
turns.

Winch Assembly Service

Refer to the following Braden manual covering model HU8A for service of the winch assembly.

Mast/Rotary Drive/Pipe Rack 6-103

Notes

6-104 Mast/Rotary Drive/Pipe Rack

Mast/Rotary Drive/Pipe Rack 6-105
6-106 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-107
6-108 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-109
6-110 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-111
6-112 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-113
6-114 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-115
6-116 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-117
6-118 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-119
6-120 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-121
Notes

6-122 Mast/Rotary Drive/Pipe Rack

 HOBO Wrench

Service procedures for the Hydraulically Operated Break Out (HOBO) Wrench are limited to replac-
ing or repairing cylinders, and replacing the tong dies and holders. Refer to parts manual for specific
repair part numbers, detailed drawings and cylinder repair kits.
• Refer to Section 7 of this manual for repair procedures on Texas Hydraulics cylinders.
• Refer to Section 7 of this manual for pressure relief valve settings, and for sequence valve adjust-
ment of HOBO wrench.

2 3
ROTATE
PIPE RACK ROT. CYLINDER
PROP CONT
1
PIPE RACK SW
PROP CONT
PIPE RACK
LOCK
PIPE
POSITIONER TOP CASE DRAIN MANIFOLD
SEQUENCE VALVE (LEFT SIDE)
MAST
LOCK
WINCH

HOBO CLAMP/
ROTATION
BRK OUT OR
HOBO SW
AUTO
TOOL
2 3

MAST VALVE 1

CLAMP CYLINDER

BOTTOM
SEQUENCE VALVE

SWING CYLINDER

ROTATE CYLINDER
SWING CYLINDER

Fig. 6-14 HOBO Wrench Assembly

CLAMP CYLINDER

Mast/Rotary Drive/Pipe Rack 6-123

Carousel Pipe Rack

If Pipe Rack Does Not Rotate

If pipe rack does not rotate or if it does not rotate smoothly, the problem is most likely due to a
broken or stretched chain. The rotation motor or broken woodruff key could also be at fault.
1. Check condition of chain and be sure it is tensioned properly.
2. Check to be sure sprocket is turning when carousel is in rotate position. Be sure the index cylinder
is in the UNLOCK position.
3. If sprocket does not turn and motor is getting proper flow of hydraulic oil, then remove motor and
check condition of woodruff key on motor shaft. Check to see if motor rotates when disconnected
from sprocket. Repair or replace motor as necessary. See step 2 of "Chain Drive - Adjust/Re-
place" to remove motor. See motor repair instructions at the end of this section. Refer to parts
manual for repair part numbers.

Chain Drive - Adjust/Replace

1. If chain is loose, tighten chain adjustment bolt (fig. 6-18) to get proper tension on chain. You have
to go by experience here, not too tight and not too loose. If you can not get chain tight enough
with the adjustment bolt, then chain will have to be removed and a link removed.
2. To remove chain, back out adjusting bolt all the way to relieve tension on chain. Loosen motor
mounting plate capscrews and slide motor mounting plate forward toward large sprocket all the
way. Remove chain. It would be a good idea to remove motor and mounting plate completely and
check condition of motor shaft woodruff key. This also makes it easier to remove and install chain.
3. Install new or repaired chain around large sprocket and then around small sprocket. Install motor
mounting plate with motor. Slide motor back as far as you can with a bar and tighten the four
capscrews. Check chain tension and tighten chain adjusting bolt as required, then tighten locknut.

Fig. 6-18 Pipe Rack Carousel Chain Drive

1. Adjusting Bolt 4. Capscrews (4)
2. Lock Nut 5. Hydraulic Motor
3. Motor Mounting Plate 6. Carousel Index Lock Cylinder

6-124 Mast/Rotary Drive/Pipe Rack

 Carousel Pipe Rack

Pipe Rack Bearings - Replace

This page is used to show the main components of
the pipe rack assembly. The following pages show details
of the various components for disassembly and assembly
purposes. All reference numbers on the photo's corre-
spond to the parts book drawings. Use the parts book for
your specific machine for ordering parts and for detail views
of the components shown here.
The photo's here show a 30 ft. (9 m) pipe rack. The
only difference between this other versions is that the top
tube (3) will be a different length.

1. Make sure machine is on solid level ground. Remove

all pipe from carousel pipe rack and lower mast to
horizontal position, resting on mast rest.
2. Support carousel top tube (3) and carousel pipe sup-
port (2) with a suitable lifting device. If you are only
replacing the top carousel bearing, you can sepa-
rate the top tube (3) from the carousel pipe support
(2), see fig. 6-20.
3. Refer to following pages for individual bearing replace-
ment procedures.

Fig. 6-19 Carousel Pipe Rack

1. Carousel Pivot Support
2. Carousel Pipe Support
3. Carousel Top Tube
7. End Cap, Upper Carousel Pipe Support
46. Mid-Point Support bracket
76. Mid-Point Support bracket with bushing

Mast/Rotary Drive/Pipe Rack 6-125

Carousel Pipe Rack

Carousel Top Tube Bearing - Replace

1. With mast in horizontal position and all pipe removed as described previously, support top tube
(3) and carousel pipe support (2) with a suitable lifting device.
2. Mark position of top tube at the joint. Separate the top tube from the carousel pipe support by
removing the six capscrews (71) at the joint (fig. 6-20).
3. Remove the safety wire (22), four capscrews (32) and flat washers (43) that hold the end cap (8)
to the mounting plate. Remove top tube with end cap.
4. Drive the bearing (14) out of the end cap (8). There is a lip on end cap at top where it bolts to the
mounting plate, so the bearing must be driven out the bottom.
5. Install new bearing into end cap. Clean upper portion of top tube and apply grease to tube and
bearing before installation.
6. Hoist top tube into position with end cap and bearing installed. Line up mark made before disas-
sembly and install all capscrews, but do not tighten.
7. Tighten all capscrews and torque to standard specifications. Install new safety wire (22) on the
end cap capscrews (32).

Fig. 6-20 Top Tube & Carousel Support

2. Carousel Support
3. Top Tube
40. Nut (6)
42. Hardened Washer (6)
71. Capscrew (6)

6-126 Mast/Rotary Drive/Pipe Rack

 Carousel Pipe Rack

Fig. 6-21 Upper Carousel Support Bearing

3. Top Tube
8. End Cap
14. Journal Bearing
22. Safety Wire
31. Grease Fitting
32. Capscrew (4)
43. Flat Washer (4)

Mast/Rotary Drive/Pipe Rack 6-127

Carousel Pipe Rack

Fig. 6-22 Lower Carousel Support Bearing Installation

1. Carousel Pivot Support 16. Sprocket, 42T
4. Hydraulic Motor 34. Capscrew (6)
9. Thrust Washer 44. Flat Washer (6)
11. Journal Bearing

6-128 Mast/Rotary Drive/Pipe Rack

 Carousel Pipe Rack

Carousel Lower Bearing - Replace

1. With mast in horizontal position and all pipe removed as described previously, support top tube
(3) and carousel pipe support (2) with a suitable lifting device.
2. Remove the top tube (3) as described in "Carousel Top Tube Bearing - Replace".
3. Remove the chain from the drive sprocket (16) as described in "Chain Drive - Adjust/Replace" and
remove the sprocket by removing the six capcrews (34).
4. Slide the carousel support pipe (2) out of the journal bearing (11).
5. Remove thrust washer (9) and replace with a new one.
6. Drive out old journal bearing (11) and install new bearing. Clean lower portion of carousel support
pipe (2), install thrust washer (9) and coat pipe and bearing with grease before installing.
7. Installation is basically the reverse of removal.

Fig. 6-23 Lower Carousel Support Bearing

(chain adjustment bolt not shown)
11. Journal Bearing
16. Sprocket, 42T

Fig. 6-24 Carousel Pipe Support

9. Thrust Washer

Mast/Rotary Drive/Pipe Rack 6-129

Carousel Pipe Rack

Fig. 6-25 Upper Pivot Support Bearing

7. Upper End Cap
13. Journal Bearing
31. Grease Fitting
22. Safety Wire
32. Capscrew (4)
43. Flat Washer

6-130 Mast/Rotary Drive/Pipe Rack

 Carousel Pipe Rack

Carousel Pivot Support Upper Bearing - Replace

1. Remove all pipe from pipe rack and lower mast to horizontal position, resting on mast rest.
2. Remove the capscrews at the mid-point support bracket (item 46, fig. 6-19). Separate the two
halves of the support bracket. Later machines also have an upper mid-point support bracket with
bushing (Item 76, fig. 6-19). Remove the cap on this also.
3. Remove the upper swing cylinder clevis pin.
4. If machine is equipped with auto lube system, remove grease line from upper end cap (7). Re-
move the four capscrews (32) and washers (43).
5. Lift up the pivot pipe until the cap (7) clears the mounting plate. Remove end cap from pivot pipe
and let pipe back down to rest on supports.
6. Drive out old bearing (13) from top end of cap. End cap has a lip on the top side, so bearing must
be driven out the bottom. Install new bearing in cap.
7. Clean upper portion of pivot pipe. Coat pipe end and bearing with grease. Lift up pipe and install
bearing and end cap on pipe. Lower pivot pipe back into position and align the four bolt holes. Be
sure swing cylinder clevis is aligned with pipe rack support pipe. Install the four capscrews (32)
and washers (43). Tighten bolts to standard torque specifications. Install grease line (if equipped).
8. Install the two halves of the mid-point and upper support brackets with capscrews and torque to
standard specifications. Install swing cylinder clevis pin and retainer.

Fig. 6-26 Upper Pivot Support Bearing

1. Pivot Support Pipe
7. End Cap
32. Capscrew (4)
43. Flat Washer

Mast/Rotary Drive/Pipe Rack 6-131

Carousel Pipe Rack

Fig. 6-27 Pivot Support Pipe Lower Bushing

1. Pivot Support Pipe 33. Capscrew (4)
6. Lower End Cup 42. Flat Washer (4)
10. Thrust Washer 66. Slotted Nut (4)
12. Journal Bearing 67. Cotter Pin (4)

6-132 Mast/Rotary Drive/Pipe Rack

 Carousel Pipe Rack

Carousel Pivot Support Lower Bearing - Replace

1. Remove all pipe from pipe rack and lower mast to horizontal position, resting on mast rest.
2. Support pivot pipe with a suitable lifting device at both ends.
3. Unbolt upper end cap, mid-point, and upper support brackets as described in "Carousel Pivot
Support Upper Bearing - Replace".
4. Disconnect the pipe rack swing cylinder and H.O.B.O. wrench swing cylinder from the pivot pipe
brackets (fig. 6-28). Retract cylinder rods. Disconnect the grease line to the lower bearing.
5. Remove the four capscrews (33) from the lower end cup (6). Raise the pivot pipe and carousel
pipe rack assembly up until the lower end cup clears the mast base. Remove the lower end cup.
6. Drive out bearing (12) from bottom end of cup. There is a lip on the bottom end of the cup, so
bearing must come out the top end. Install new bearing.
7. Remove old thrust washer (10) and install a new one. Clean lower end of pivot pipe and apply a
coat of grease to end of pipe and bearing.
8. Install bearing and lower end cup on pivot pipe. Be sure thrust washer (10) is in place. Lower pivot
pipe back down and install the four capscrews (33), flat washers (42) and slotted nuts (66).
Torque capscrews to standard torque values and install the cotter pins (67) in the capscrews
(33).
9. Install the mid-point support bracket caps as described in "Carousel Pivot Support Upper Bearing -
Replace". Install the four capscrews (34) and washers (42) in the upper cap (7).
10. Extend the pipe rack swing cylinder and H.O.B.O. wrench swing cylinder rods to line up with the
clevises on the pivot pipe. and install pins and retainers. Install grease line to lower and upper
bearings.

Fig. 6-28 Pipe Rack and HOBO Wrench Cylinders

Mast/Rotary Drive/Pipe Rack 6-133

Carousel Pipe Rack

Mid-Point Carousel Pivot Support

Bearing - Removal & Replacement
1. Remove the two capscrews (2) and lock washers (3) and lift off the cap (1).
2. Remove upper half of bearing (7) and replace with a new one.
3. Lift up on carousel pivot pipe so as to take load off lower bearing half. Remove lower bearing half
and grease and install new bearing. Let carousel pivot pipe back down.
4. Apply grease to upper bearing half and install bearing and cap. Install capscrews (2) and new lock
washers (3). Torque capscrews to standard torque value. Apply grease to grease fittings until it
comes out sides of bearing.

Fig. 6-29 Mid-Point Carousel Pivot Support Fig. 6-30 Mid-Point Carousel Pivot Support
1. Cap 4. Bearing Retainer (split) 6. Elastic Stop Nut (6)
2. Capscrew (2) 5. Capscrew (6) 7. Journal Bearing (split)
3. Lock Washer (2)

Carousel Rotate Motor

Refer to the following Char-Lynn Repair Information No. 7-124 on 2000 Series motors for rebuild
information. Refer to parts manual for your specific machine for repair parts numbers.

6-134 Mast/Rotary Drive/Pipe Rack

Mast/Rotary Drive/Pipe Rack 6-135
6-136 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-137
6-138 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-139
6-140 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-141
6-142 Mast/Rotary Drive/Pipe Rack
Mast/Rotary Drive/Pipe Rack 6-143
6-144 Mast/Rotary Drive/Pipe Rack
 Section 7

NOTE All part numbers on drawings and in text in this section are for reference only.
Always order parts from the parts manual for your specific machine serial number.

Hydraulic Systems
(with electronic pump controls)
CAUTION:
DO NOT weld on any part of the machine without first
disconnecting the negative battery cable or place the
battery disconnect switch in the open position. On ma-
chines equipped with electronic engine, disconnect the
connections to the Electronic Control Module (ECM) on
the engine before welding.

Fig. 7-0 Electronic Control Module - Caterpillar C-15 Fig. 7-0a Electronic Control Module - Caterpillar 3412E
Electronic Engine Electronic Engine
1. Electronic Control Module (ECM) 1. Electronic Control Module (ECM)
2. Plug-Ins - Disconnect from ECM BEFORE welding. 2. Plug-Ins - Disconnect from ECM BEFORE welding.

Hydraulic Systems 7-1

Hydraulic Tank

Hydraulic Tank
WARNING:
Relieve pressure on hydraulic and pneumatic sys-
tems before loosening connections or parts.

4
3

5
6

Fig. 7-1 Hydraulic Tank

1. Service Valve - open to relieve pressure after system is shut down.
2. Main Return Filter
3. Case Return Filter
4. Breather
5. Tank Level Sight Gauge
6. Hydraulic Oil Fill Pump
Open service valve (item 1, fig. 7-1) on top of hydraulic tank after machine is shutdown to relieve any
residual pressure in the system. Open valve for about 30 seconds and then close.

Fig. 7-1a Hydraulic Pressure Test Station (optional) - Mounted on side of hydraulic tank.
1. 6000 PSI Gauge
2. 600 PSI Gauge
3. Isolator Valves - Turn knob to isolate the circuit you are testing (see fig's. 7-1b and 7-1c for detail).

7-2 Hydraulic Systems

 Pressure Setting Sequence

Pressure Setting Sequence

The following sequence is recommended for checking and setting pressures. Be sure to relieve all
pressure in system prior to installing gauges. If machine is equipped with a hydraulic pressure test station
(see fig's.7-1a,b & c) it will not be necessary to install gauges. The pressure setting procedures and
locations are described fully in this section.

FUNCTION PRESSURE PAGE

HYDRAULIC SYSTEM
1. Charge Pressure 450 PSI (31 bar) 7-13
2. RH / LH Tram
Pressure Override (P.O.R.) 5000 PSI (345 bar) 7-13
Crossover (High Pressure) 5500 PSI (380 bar) 7-15

3. Auxiliary Pump
Standby 500 PSI (35 bar) 7-17
Main Pressure 3000 PSI (207 bar) 7-17
Auxiliary Pressure Relief Valve 2500 PSI (172 bar) 7-17
Pulldown Relief Valve 2500 PSI (172 bar) 7-23
4. Cooler Fan Speed *2000 - 3000 PSI 7-30
(138 - 207 bar)
5. Dust Collector/Water Injection 2000 PSI (138 bar) 5-21 (Section 5)
6. Jack Relief 2800 PSI (193 bar) 7-34
* Depends of fan size and cooler package. Consult factory.

Fig. 7-1b Hydraulic Pressure Test Station Detail

See fig. 7-1c on following page for isolator valve hose connections.

Hydraulic Systems 7-3

Hydraulic Pressure Test Circuit

Fig. 7-1c Hydraulic Pressure Test Circuit (ref. 418601)

7-4 Hydraulic Systems

 Hydraulic Pump Identification

Hydraulic Pump Identification - SKF

Fig. 7-2 SKF Pump Arrangement (ref.426038)

1. Charge Relief Valve (for Left Track/Rotation and Right Track pumps)
2. 426037 Left Track & Rotation AA4VG125EP (Closed Loop)
3. 429036 Right Track AA4VG125EP Thru Drive (Closed Loop)
4. 410600 Feed & Auxiliary Functions A11VLO130 (Open Loop)
5. 414414 Fan & Dust Collector P365

Hydraulic Systems 7-5

Right Track, Left Track/Rotation Pumps

Fig. 7-3 AA4VG125 Left Track & Rotation Pump

1. Charge Pressure Adjustment 4. High Pressure Adjustment (for. & rev.)
2. Relief Valve Test Port (Install gauge for 5. Pressure Cutoff (POR) Adjustment
Charge Pressure here) 6. Mechanical Zero Adjustment (at bottom)
3. Relief Valve 7. Hydraulic Centering Adjustment

7-6 Hydraulic Systems

 Right Track, Left Track/Rotation Pumps

Fig. 7-4 AA4VG125cc Hydraulic Pump Port Identification

Right Track, Left Track/Rotation

Hydraulic Systems 7-7

Right Track, Left Track/Rotation Pumps

EP (24VDC) Control
EP stands for Electrical Proportional control. Pump flow is infinitely varied from 0 to 100 percent,
proportional to an electrical current in the range of 200 - 600 mA at 24VDC, supplied to solenoid A or B
(see table 7-1). Electrical energy is converted to a force acting on the control spool. The spool then
directs control oil in and out of the stroking piston to stroke the pump as required. A feedback lever,
connected to the stroking piston, maintains the pump flow for any given current within the control range.
The plugs to the solenoid valves are equipped with a green LED light (fig. 7-6). If the light is on, it indicates
it is receiving power.

Fig. 7-5 EP Control 24VDC

Solenoids are receiving power if green LED is on.

Table 7-1 Current vs. Flow

Control Current (24 VDC): I = 200 - 600 mA
Begin of control: l = 200 mA (Vg0)
End of control: l = 600 mA (Vg max)

7-8 Hydraulic Systems

 Right Track, Left Track/Rotation Pumps

Before Making Pump Adjustments

Before the main pumps can be centered or the pressure relief and pressure cut off settings can be
adjusted, the following must be performed:
1. Disconnect the tram brake release hose at the tee above the track equalizer bar (fig. 7-6a). This will
set the brakes on and enable you to perform all main pump adjustments, and load the pump without
the rig moving.
2. Disconnect the rotation torque control line (if used) from the left track/rotation pump (port X3, fig. 7-
7c) and plug the port.

Fig. 7-6a Brake Release Line at Tee Fitting.

Located just above axle pivot beam.

Fig. 7-6C AA4VG125EP Left Track & Rotation Pump

X3 Port for Rotary Torque Control (if used)
5. Pressure Cutoff (POR) Adjustment
6. Mechanical Zero Adjustment
7. Hydraulic Zero Adjustment

Fig. 7-6b Right Track Motor and Final Drive

Hydraulic Systems 7-9

Right Track, Left Track/Rotation Pumps

Mechanical Zero Position

WARNING:
Relieve pressure on hydraulic and pneumatic sys-
tems before loosening connections or parts.
BE SURE machine is on level ground and block
tracks before removing brake lines.

The control piston has strong centering springs to ensure that once the pump is adjusted for the
neutral position, it will always return to neutral. If an adjustment is necessary, follow the steps below.

1. Connect both control chambers (X1 and X2 ports) with a hydraulic hose (1/4 I.D. minimum). Ports
are 9/16-18 UNF.
2. Install a 0-6000 PSI (0-414 bar) hydraulic pressure gauge into ports MA and MB.
3. Adjust zero position so that at blocked drive both gauges indicate the same pressure.

NOTE To deadhead the left track/rotation pump and the right track pump; disconnect
and plug the brake release line to the track final drives at the T connection above
the axle pivot beam (fig. 7-6a). With machine in PROPEL MODE activate the right
or left track levers. The final drive brakes should hold the machine from move-
ment.
4. Loosen the jam nut with a 24mm wrench. Use a 6mm allen wrench to turn the adjustment screw
until 1000 PSI (69 bar) is on gauge in MA or MB. Mark this position. Turn the screw the opposite
direction until the same reading is on the other port. Mark this position. Turn the screw back,
splitting the distance between the previous two positions. This should be the neutral position.
Pressure on the gauges should be the same.
NOTE Leave gauges installed in MA and MB ports for checking hydraulic zero position.
5. Tighten the jam nut. Shut down the machine and relieve standing pressure by opening service
valve on hydraulic tank (fig. 7-1). Remove jumper hose between X1 and X2 ports and install plugs.

Fig. 7-7 Mechanical zero position - type HD pump control.

7-10 Hydraulic Systems
 Right Track, Left Track/Rotation Pumps

Hydraulic Centering
When the control module is replaced, it is gener-
ally necessary to center the new module. Follow the
steps listed below:
1. Install a 0-6000 PSI (0-414 bar) hydraulic
pressure gauge into ports MA & MB.
2. Install a 0-600 PSI (0-41 bar) hydraulic pressure
gauge into ports X1 and X2.
3. Disconnect and plug the X3 port (fig. 7-6c) for
the rotation torque control (if used).
4. Loosen the lock nut on top of the control module
with a 4mm allen wrench. Use a 4mm allen
wrench to turn the adjusting screw. The adjust-
ment screw is an eccentric, therefore turning
o
the screw more than 90 in either direction will
have no further effect, and could cause damage
to the eccentric pin.
Fig. 7-7a Hydraulic zero position - with EP pump control.
5. With Y1 and Y2 ports vented to atmosphere, the
neutral position is correctly adjusted when:
A. Approximately equal pressures are at X1
and X2 ports.
B. The hydraulic motor does not turn when the
brake is released.
C. Charge pressure registers equal at MA & MB
ports when the pump is deadheaded.

Fig. 7-7b Hydraulic Centering Adjusting Screw - with EP

pump control.

Hydraulic Systems 7-11

Right Track, Left Track/Rotation Pumps

Fig. 7-7c AA4VG125 Left Track & Rotation Pump

1. Charge Pressure Adjustment 5. Pressure Cutoff (POR) Adjustment
2. Relief Valve Test Port (Install gauge for 6. Mechanical Zero Adjustment (at bottom)
Charge Pressure here) 7. Hydraulic Centering Adjustment
3. Relief Valve

Fig. 7-7d P.O.R. Adjustment on AA4VG125 Pump (Left Track/Rotation & Right Track Pumps)
Use 4mm allen wrench and 13mm box end wrench.

7-12 Hydraulic Systems

 Right Track, Left Track/Rotation Pumps

WARNING:
Relieve pressure on hydraulic and pneumatic sys-
tems before loosening connections or parts.
BE SURE machine is on level ground and block
tracks before removing brake lines.

1. Set Charge Pressure - 450 PSI (31 bar)

1. Shutdown machine and relieve standing pressure.
2. Install a 600 PSI (41 bar) gauge in the relief valve test port (item 2, fig. 7-7c) or if machine is
equipped with a hydraulic pressure test station, turn knob to CHARGE position.
3. Start machine and allow time to warm up. Correct charge pressure is 450 PSI (31 bar). If adjust-
ment is required, loosen locknut and turn relief valve adjustment screw to obtain correct pres-
sure. Tighten locknut.

2. Set Pressure Override (P.O.R.) - 5000 PSI (345 bar)

Function of Pressure Override
The pressure override valve varies the swashplate angle, as required to limit the maximum pressure
at port A or B. The override valve prevents continuous dumping of excessive flow at load pressure through
the cross port relief valves. This eliminates unnecessary heating of the oil and protects the pump and
motor from heavy-handed operators or if the drive stalls, causing the pump to deadhead.
The pressure override is adjusted 500 PSI (35 bar) less than the high pressure crossover relief
valves.
Adjustment Procedure
1. Shutdown machine and relieve standing pressure.
2. Install a 6000 PSI (414 bar) gauge in ports MA and MB or if machine is equipped with a hydraulic
pressure test station, turn knob to R.H. LOOP or L.H. LOOP position. Remove and plug the track
brake release line at the tee connection (fig. 7-6a).
3. Be sure the pump control is in neutral. Loosen P.O.R. valve locknut with a 13mm wrench and back
out the P.O.R. adjusting screw all the way with a 4mm allen wrench.
4. Start machine and allow time to warm up.
5. With machine in PROPEL mode, slowly move the right or left tram lever (depending upon which
pump you are setting) to full forward or reverse position, noting the pressure reading on the
gauge. Turn screw in (clockwise) until you get a reading of 5000 PSI (345 bar).
NOTE One turn of the screw equals 1200 PSI (83 bar).
6. Now move the tram lever in the opposite direction and note the pressure reading on the gauge. It
should be the same on both sides of center. When pressure setting is correct, tighten the locknut.
7. Leave gauges installed for setting of the high pressure crossover relief valves (following page).

Hydraulic Systems 7-13

Right Track, Left Track/Rotation Pumps

Fig. 7-8 AA4VG125 Left Track & Rotation Pump

1. Charge Pressure Adjustment 4. High Pressure Adjustment (for. & rev.)
2. Relief Valve Test Port (Install gauge for Other H.P. Adjustment is opposite side.
Charge Pressure here) 6. Mechanical Zero Adjustment (at bottom)
3. Relief Valve 7. Hydraulic Centering Adjustment

Fig. 7-8a High Pressure Adjustment on AA4VG125 Pump (Left Track/Rotation & Right Track Pumps)
Note adjustment screw on opposite end. Both need to be adjusted.
Use 5mm allen wrench and 17mm box end wrench.

7-14 Hydraulic Systems

 Right Track, Left Track/Rotation Pumps

WARNING:
Relieve pressure on hydraulic and pneumatic sys-
tems before loosening connections or parts.
BE SURE machine is on level ground and block
tracks before removing brake lines.

3. Set Crossover Relief (High Pressure) - 5500 PSI (380 bar)

1. Shutdown machine and relieve standing pressure.
2. Install a 6000 PSI (414 bar) gauge in ports MA and MB or if machine is equipped with a hydraulic
pressure test station, turn knob to R.H. LOOP or L.H. LOOP position. Remove and plug the track
brake release line at the tee connection (fig. 7-8b).
3. Back out both high pressure relief valves all the way (counterclockwise) until spring tension is
completely relieved. Turn both high pressure relief valves in one full turn (clockwise).
4. Start machine and allow time to warm up.
5. Turn P.O.R. adjusting screw in (clockwise) until firm resistance is encountered. Do not force the
adjustment beyond this point.

NOTE Perform steps 6 and 7 as quickly as possible to prevent overheating of pump.

Flow should not be allowed to spill over the high pressure relief valves for longer
than 10 seconds.
6. Stroke the pump to approximately 20 percent of full flow in one direction. Do this by having a
helper move the tram lever for the track pump you are adjusting forward slightly. Adjust the high
pressure relief valve 500 PSI (35 bar) higher than the P.O.R. setting.
7. Repeat step 6 moving the tram lever in reverse direction and adjusting opposite high pressure
relief valve.
8. Tighten locknuts. Reset P.O.R. to proper pressure as mentioned previously. Repeat all steps for
other pump.

Fig. 7-8b Brake Release Line at Tee Fitting.

Located just above axle pivot beam.

Hydraulic Systems 7-15

Feed and Auxiliary Pump Circuit

Fig. 7-9 Auxiliary Pump Circuit - SKF Machines

Fig. 7-9a 410600 Feed & Auxiliary Functions Pump Fig. 7-9b 410600 Feed & Auxiliary Functions Pump
A11VLO130 A11VLO130
Reach through area shown to adjust compensator.
Use 4mm or 5/32" allen wrench to adjust.

7-16 Hydraulic Systems

 Feed and Auxiliary Pump Circuit

WARNING:
Relieve pressure on hydraulic and pneumatic systems
before loosening connections or parts.

NOTE All part numbers on drawings and in text in this section are for reference only.
Always order parts from the parts manual for your specific machine serial num-
ber.

4. Feed & Auxiliary Functions Pump

Pump operates Hoist/Pulldown and Auxiliary functions circuit. The auxiliary functions include:
Mast Elevate, Mast Lock, Jacks, Main Air Valve, Dust Curtains, Pipe Positioner, Pipe Rack and Tool Wrench
functions. Maximum flow is 72 GPM (273 L/min), theoretical.

Function of Load Sensing Control (DRS)

This pump uses a load sensing control which operates as a function of the load pressure to regulate
the pump displacement in order to match the requirement of the consumer unit. The pump flow is influ-
enced by the external orifice fitted at the pump "M" port, but it is not affected by load pressure through-
out the range below the set pressure. The valve compares pressure before and after the orifice and
maintains the pressure drop (differential pressure) across the orifice and therefore the pump flow is
constant. If differential pressure increases, the pump is swivelled back towards minimum stroke; if
differential pressure decreases, the pump is swivelled out towards maximum stroke until a balance is
restored within the valve.

Adjustment Procedure
1. Shutdown machine and relieve standing pressure. Install a 6000 PSI (414 bar) gauge in the "G"
port of the pump, or if machine is equipped with a hydraulic pressure test station, turn the knob
to AUXILIARY.
2. Start machine and allow time for system to warm. Switch the AUXILIARY PUMP SWITCH on the
switch panel to PUMP LOADED position. The standby and main pressure adjustment screws are
located under the left track/rotation pump. They are not readily accessible. To access the
adjustment screws, reach through space between the left track/rotation pump and right track
pump as shown in fig. 7-9b.
The locknut takes a 13mm box end wrench.
The adjustment screw takes a 4mm allen wrench.
Standby Pressure:
Loosen the lower locknut and adjust standby pressure to 500 PSI (35 bar). Tighten locknut.
Main Pressure:
Loosen upper locknut and adjust main pressure to 3000 PSI (207 bar). Tighten locknut.
Auxiliary Pressure Relief Valve:
Set auxiliary pressure relief valve 410602 (item 6, fig. 7-11) to 2500 PSI (172 bar).

Hydraulic Systems 7-17

Feed and Auxiliary Pump Circuit

Fig. 7-10 "A: Frame - Rear View (cab end)

Hoist/Pulldown Control Valve 410665

Auxiliary Circuit
• Pump is in a non-load sensed mode.
• Auxiliary Mode Selector (ON-OFF) 410280 (item 9, fig. 7-11) is shifted such that pump stand-by
pressure (approx. 500 PSI [35 bar]) from port "M" is directed back into the "X" port thru the shuttle.
This creates a condition that disables the load sense and allows the pump to hold auxiliary pressure
set by relief valve 410602 (item 6, fig. 7-11). This pressure is set at 2500 PSI (172 bar).
Pulldown Circuit
• Pump is in a load sensed mode.
• Pump receives load sensed signal from Pulldown Control Valve (410665) as the spools are shifted.
This signal enters the pump thru the shuttle at the "X" port. The pressure shifts the load sensed spool
and vents the compensated pressure which allows the pump to stroke until the desired load sensed
pressure is obtained.
Jack/Mast Elevate Control Valve
• Jacks and Mast Elevate will function only in non-load sensed mode. Non-load sensed maximum
pressure is set by the Auxiliary Jack Relief 410602 (item 5, fig. 7-11).

7-18 Hydraulic Systems

 Hydraulic Feed Circuit

Fig. 7-11 Upper "A" Frame - Front View (engine end)

1. Main Air/Dust Curtain/ Option Valve 410088 6. Auxiliary Relief Valve 410602
2. Feed Control Valve 410666 7. Max. Pulldown Relief Valve 411774
3. Auxiliary Pump Pressure Manifold 1412986 8. Pulldown Counterbalance Valve 414867
4. Dust Collector/Water Injection Valve 410089 9. Auxiliary Pump ON-OFF Valve 410280
5. Jack Relief Valve 410602

Counterbalance and Relief Valve Adjustments

NOTE Adjustment of the counterbalance valves is directly opposite of relief valves in this
system. Clockwise adjustment of relief valves increases pressure, whereas clock-
wise adjustment of the counterbalance valves decreases pressure. This must be
remembered when performing any adjustments to the system.

Hydraulic Systems 7-19

Hydraulic Feed System

Fig. 7-12 Hydraulic Feed System (ref. 414880 rev. A)

7-20 Hydraulic Systems

 Hydraulic Feed System

Fig. 7-12a Hydraulic Feed System (ref. 414880 rev. A)

Hydraulic Systems 7-21

7-22
Hydraulic Feed Circuit

Fig. 7-13 Hydraulic Feed Circuit - (ref. 426438)

Hydraulic Systems
 Hydraulic Feed Circuit
NOTE All part numbers on drawings and in text in this section are for reference only.
Always order parts from the parts manual for your specific machine serial num-
ber.

Hoist/Pulldown Control Valve 410665 (fig. 7-10)

• Control valve operates in a Load Sensed mode as described previously.

• Both “P” ports are connected to the pressure manifold that sees stand-by pressure (approx. 500
PSI [35 bar]).
• Load sense port is connected to the shuttle at “X” port on Auxiliary Pump.
• Directional pilots are connected together such that the signal from the Hoist/Pulldown controllers
shift both spools simultaneously.
• “C” ports are connected to Max. Pulldown Relief Valve 411774 (item 7, fig. 7-15) This relief is set
at 2500 PSI (172 bar). Max. pulldown relief is a vented relief that is controlled by the remote
pulldown relief valve 57319 located in the cab (item 1, fig. 7-14).
• Remote pulldown relief 57319 (item 1, fig. 7-14) is infinitely variable from 0-2500 PSI (0-172
bar).

Fig. 7-14 Operator's Control Console - Left Side Fig. 7-15 Mast "A" Frame - Engine Side
1. Remote Pulldown Relief 57319 7. Max. Pulldown Relief Valve 411774
2. Holdback Valve 342638 8. Pulldown Counterbalance Valve "C" 414867

Set Max. Pulldown Relief Valve - 2500 PSI (172 bar)

Read pressure from gauge installed in "G" port of feed and auxiliary pump, or if machine is
equipped with a hydraulic pressure test station; turn knob to AUXILIARY.
1. Allow system to warm up and place auxiliary pump switch on switch panel to PUMP LOADED
position.
2. If no pipe is attached to rotary head, lower rotary head until feed cylinder is bottomed out and
leave pulldown lever in LOWER position. If pipe is attached, lower pipe to ground or bottom of hole
and leave pulldown lever in LOWER position. Activate pulldown system (auto feed) by pushing
switch on switch panel DOWN to engage pulldown system.
3. Loosen locknut using a 9/16 box end wrench and adjust set screw with 9/32 allen wrench until
pressure reads 2500 PSI (172 bar). Tighten locknut. Place pulldown system (auto feed) switch in
UP position to disengage pulldown system. Return pulldown lever to neutral position.

Hydraulic Systems 7-23

7-24
Hydraulic Feed Circuit

Fig. 7-13 Hydraulic Feed Circuit - (ref. 426438)

Hydraulic Systems
 Hydraulic Feed Circuit

Feed Control Valve (410666)

• Pulldown manifold contains Rotary Head counterbalance valve, Regeneration for fast down, and
Hold-Back for hammer drilling.
• (Valve “A”) Rotary Head Counterbalance Valve (409206, item 2, fig. 7-16)
Normal operation the valve opens from a pilot signal from the pulldown pressure. This signal is
dampened by the (0.016 in.) orifice. This orifice allows a pressure increase in the pulldown in
order for the counterbalance valve to meter down. Please note that the tension on the counter-
balance valve effects the amount of pulldown pressure required.
• (Valve “B”) Hold-Back (342638, item 2, fig. 7-14)
Hold-Back is active when this valve is energized. De-energized is normal drilling. With valve
energized, the pilot signal, which opens counterbalance (Valve “A”) is reduced which required a
larger pulldown pressure for valve to open. This becomes truly a power down circuit for pulldown
force control for Hammer drilling.
This circuit, if not required, can be eliminated by installing a cavity plug and removing the relief
(342638) from the cab.

Fig. 7-14 Operator's Control Console - Left Side
1. Remote Pulldown Relief 57319
2. Holdback Valve 342638
Hydraulic Systems
Fig. 7-16 Feed Control Valve 410666
1. Regeneration Valve "D" (normally open)
1a. Regeneration Valve "E" (normally closed)
2. Counterbalance Valve "A" (409206)
3. Plug
4. Orifice .016"
5. Plug
6. Hoist Control Valve "F"
7. Excess Flow Bypass Valve "G"
7-25
Hydraulic Feed Circuit

The procedure for utilizing Hold-Back:

a) Engage Pulldown.
b) Set remote Pulldown relief (item 1, fig. 7-13) such that rotary head movement occurs.
c) Engage Hold-Back using holdback switch on switch panel. Back out Hold-Back relief in cab (item
2, fig. 7-13) until the feed stops or increase until the head starts down. This is the setting that the
counterbalance valve is truly holding back against the pulldown force.
d) When more pulldown force is required, increase remote Pulldown relief and decrease Hold-Back
relief until head control is again obtained.

NOTE The Pulldown and Hold-Back reliefs must be balanced together for Hold-Back to
perform properly.

Fig. 7-14 Operator's Control Console - Left Side

1. Remote Pulldown Relief 57319
2. Hold-Back Valve 342638

Fig. 7-16 Feed Control Valve 410666

1. Regeneration Valve "D" (normally open)
1a. Regeneration Valve "E" (normally closed)
2. Counterbalance Valve "A" (409206)
3. Plug
4. Orifice .016"
5. Plug
6. Hoist Control Valve "F"
7. Excess Flow Bypass Valve "G"

Fig. 7-15 Mast "A" Frame - Engine Side

7. Max. Pulldown Relief Valve 411774
8. Pulldown Counterbalance Valve "C" 414867

7-26 Hydraulic Systems

 Hydraulic Feed Circuit

• (Valve “C”) Counterbalance Valve 414867 (item 8, fig. 7-15)

This counter balance valve (Valve “C”) is for low head speeds. At low head speeds this valve
(Valve “C”) opens rather than larger counterbalance (Valve “A”) item 2, fig. 7-16. This provides a
smooth operation at slow speeds.
Procedure for adjustment: Valve “C”
a) Adjust with rotary head free (no drill pipe attached). After adjustment check with at least one drill
stem in the head or max. number of drill stems used for drilling.
b) Valve “B” Holdback must be turned off using hold-back switch on switch panel.
c) Energize pulldown, using pulldown switch on switch panel and back out remote pulldown relief
57319 (item 1, fig. 7-14). The rotary head should stop. If head does stop, decrease counterbal-
ance spring tension until movement occurs then re-adjust to stop head (remember, COUNTER-
CLOCKWISE adjustment INCREASES pressure on counterbalance valves).
d) If the head does not stop, adjust the counterbalance valve until it does.
e) Increase pulldown pressure with the pulldown relief valve until head moves. If head movement is
stable, valve “C” is adjusted, if not adjust Valve “A”.

Procedure for adjustment: Valve “A”

a) Block pilot signal to counterbalance valve (Valve “C”) or increase valve setting (back out)
b) Now use above procedure for valve “A” rather than “C”.
c) Now reset Valve “C”.
• (Valve “D”) Regeneration (item 1, fig. 7-16)
Pilot Shifted for normal feed and electrically shifted for Regeneration.
• Pilot shifted
When the valve is pilot shifted and in the normal feed mode the return oil from the pulldown
cylinder is allowed back to the control valve.
• Electrically shifted
When valve is electrically shifted and in the regeneration mode the return oil from the
pulldown cylinder is blocked.
• (Valve ”E”) Regeneration (item 1a, fig. 7-16)
Blocked in normal feed and electrically shifted for Regeneration.
• Pilot Shifted
This valve also is shifted simultaneously with valve “D” for regeneration and normal drilling.
When pilot signal is blocked this valve blocks the regen path from the rod side to the cylinder
side of the pulldown cylinder, thus normal drilling.
• Electrically Shifted
When pilot pressure is vented, the valve shifts and allows regeneration.

Hydraulic Systems 7-27

7-28
Hydraulic Feed Circuit

Fig. 7-13 Hydraulic Feed Circuit - (ref. 426438)

Hydraulic Systems
 Hydraulic Feed Circuit

• (Valve “F”) Hoist Control (item 6, fig. 7-16)

Piloted open when Hoisting, Spring return in Pulldown.
As hoist pressure builds this valve shifts which allows this same hoist pressure to shift Valves “D”
and “E”.
Procedure for adjusting Valve "F":
a) Shift to hoisting a load. Build only pressure, do not allow load to move.
b) If pressure is stable valve is adjusted. If not, back out spring tension to where stability occurs.
Low hoist pressure needs to be able to shift and keep valve shifted against spring setting.
• (Valve “G”) Excess flow by-pass
Hoisting causes excessive return flows with dual and larger bore pulldown cylinders in many cases.
This valve will shift as back-pressure builds in the hoist side and will open another passage for return oil.

Procedure for adjusting Valve "G" Excess Flow Bypass Valve (item 7, fig. 7-16)
Normally this valve does not require adjustment. It is factory set at 400 PSI (28 bar). If, however the
valve has been tampered with and you need to get back to the original setting. Use the following proce-
dure:
1. Shutdown machine and relieve standing pressure.
2. The screw adjustment range is 5 turns, 200 - 800 PSI (14 - 55 bar). All the way in is 800 PSI (55
bar). Loosen locknut and turn screw in (clockwise) all the way, then back out 5 turns.
3. Turn screw in a little less than 1 3/4 turns. Each full turn equals 120 PSI (8 bar). This should be
about 400 PSI (28 bar). Tighten locknut.

Fig. 7-16 Feed Control Valve 410666

1. Regeneration Valve "D" (normally open)
1a. Regeneration Valve "E" (normally closed)
2. Counterbalance Valve "A" (409206)
3. Plug
4. Orifice .016"
5. Plug
6. Hoist Control Valve "F"
7. Excess Flow Bypass Valve "G"

Hydraulic Systems 7-29

Cooler Fan Circuit

Cooler fan pressure and flow is supplied by a open loop gear pump.
The fan RPM’s are set by relief valve mounted directly to the pump (fig. 7-17).

Pressure (psi) RPM’s

2000 1260
2200 1320
2400 1390
2500 1410
2600 1440
2800 1500
3000 **1550 **Max. Fan Speed

Setting Cooler Fan Speed

Fan was factory set at 2800 PSI (193 bar). If you are operating in a hotter or colder environment,
you may need to adjust fan speed accordingly. You do not want to waste horsepower by operating the fan
at a higher speed than necessary. DO NOT EXCEED 1550 RPM FAN SPEED!
1. Shutdown machine and relieve standing pressure.
2. Install a 6000 PSI (414 bar) gauge in gauge port on back side of relief valve, opposite of relief
valve adjustment screw (fig. 7-17). Or, if machine is equipped with a hydraulic pressure test
station, turn the knob to FAN PUMP.
3. Start machine and allow system to warm up. Loosen locknut and adjust screw (item 2, fig. 7-17)
to desired pressure for fan RPM. Check fan speed with a strobe tachometer. When fan speed is
correct, tighten locknut. Shutdown machine, relieve standing pressure, remove gauge and install
plug in gauge port.

Fig. 7-17 Fan Speed Adjustment

1. Fan/Dust Collector/Water Injection Pump
2. Relief Valve Adjustment
3. Gauge Port (opposite relief valve adjustment)
7-30 Hydraulic Systems
 Cooler Fan Circuit

Return flow from cooler motor is routed thru the cooler. The thermostat valve routes flow around the
o o
cooler. The oil will be directed to the cooler when oil reaches 140 F (60 C).
There is a check with a 45 PSI (3 bar) spring which will by-pass any time pressure rises.

Fig. 7-18 Schematic - Cooler

Hydraulic Systems 7-31

Jack and Mast Elevate Circuit

• Control valve (410091) is a load sensed valve used in a non-load sensed mode. The valve is
located under the cab (see fig. 7-20).
• This valve operates the jacks and the mast elevate cylinders.
• The valve is operated from hydraulic operated pilot controls in the cab.
• Pressure for the jacks and mast are supplied by the pressure manifold.
• This valve operates only in a non-load sensed mode with auxiliary pressure on.
• Each jack has a built-in dual counterbalance valve for both raising and retracting.
• The front jacks are supplied by one valve section. This allows the jacks to work in unison.

NOTE When leveling the machine the front jacks need to be operated last so that the
pressure in both cylinders are equalized and no torsional stress is induced into the
mainframe. This will allow all 4 jacks to share the weight.

• The mast elevating cylinders have counterbalance valves in the base (piston) end of each cylinder
to control the weight of the mast. The rod ends both are controlled by one counterbalance valve
which acts as a "snubber" in case mast goes over center.

Fig. 7-19 Jack Control and Mast Elevating Circuit - SKF Machines

7-32 Hydraulic Systems

 Jack and Mast Elevate Circuit

Fig. 7-20 Mast Elevate & Jack Control Valve 410091 (mounted under operator's cab)

Hydraulic Systems 7-33

Leveling Jack Cylinders

Jack Relief Valve Adjustment

1. Have a helper engage any jack lever to fully retract jack and keep lever in the full retract position.
2. Loosen lock ring on jack relief valve (item 5, fig. 7-21a) and adjust knob until you get a reading of
2800 PSI (193 bar) on the auxiliary pump pressure gauge in the cab. Tighten lock ring and return
jack lever to neutral position.

Fig. 7-21 Upper "A" Frame - Front View (engine end)

1. Main Air/Dust Curtain/ Option Valve 410088 6. Auxiliary Relief Valve 410602
2. Feed Control Valve 410666 7. Max. Pulldown Relief Valve 411774
3. Auxiliary Pump Pressure Manifold 1412986 8. Pulldown Counterbalance Valve 414867
4. Dust Collector/Water Injection Valve 410089 9. Auxiliary Pump ON-OFF Valve 410280
5. Jack Relief Valve 410602

Fig. 7-21a Jack Relief Valve Adjustment Fig. 7-22 Outer Jack Casing

7-34 Hydraulic Systems

 Leveling Jack Cylinders

Jack Counterbalance Valves

The function of the counterbalance valves on the leveling jacks (fig. 7-22) is to ensure that the drill
stays in the intended position for drilling when the jacks are extended. To determine if the counterbalance
valves are functioning correctly, the following procedure should be used.

1. Raise the machine off of the ground and level.

2. Shutdown the engine.
3. Measure distance from some point on machine to ground. Check again after a couple hours or
overnight if possible. If measurement is less, then valve needs to be adjusted or replaced.
Jack Counterbalance Valve Adjustment
While the valves are preset at the factory at 3250 PSI (224 bar) they may be adjusted if drifting is
encountered. The counterbalance valves can be reached through the cutout in the jack casing (fig. 7-22).
One is for RETRACT and the other for EXTEND. Be sure you are adjusting the right one.
1. Loosen the jam nut and back out the adjusting screw 1/4 turn (remember, COUNTERCLOCKWISE
adjustment INCREASES pressure on counterbalance valves). Tighten jam nut and retest. If no
difference is noted after one full turn of the adjusting screw, then valve must be replaced. DO NOT
exceed one full turn. If counterbalance valve is backed out too far, it will relieve pressure. When
valve is adjusted correctly, tighten jam nut.
2. If drifting is still encountered, the valve must be replaced.

NOTE If in the above test, the unit does not start lowering, but does so during normal
operations, then the jack cylinder most likely is bypassing or leaking internally,
and further diagnostics and repair or replacement will be necessary.

Fig. 7-23 Leveling Jack Plumbing (ref. 412145) - SKF Machines

Hydraulic Systems 7-35

Mast Elevating Cylinders

Mast Elevating Cylinders Counterbalance Valves

The hydraulic circuit of the mast elevating cylinders is protected by three counterbalance valves.
There is one valve at the piston end of each cylinder, as well as one that is tee'd into the rod end of both
cylinders.

The single valve on the rod ends is for controlling the mast when it breaks overcenter during setup.
This is basically acting as a snubber valve to prevent the mast from running away when gravity over-
comes the pivot support balance.

The two valves on the piston ends are for controlling the descent of the mast when lowering back to
tram position.

Fig. 7-24 Mast Elevate Cylinder Counterbalance Valve

7-36 Hydraulic Systems

 Mast Elevating Cylinders

Fig. 7-25 Mast Elevating Circuit (ref. 412135) - SKF Machines

Counterbalance Valve Adjustment

To determine if the valves are functioning correctly, use the following procedure:
1. Lower the mast within a few inches of the mast rest and shutdown the machine. Measure the dis-
tance between the mast and the mast rest. Wait for a couple hours or overnight if possible, and
check measurement. If measurement is the same, then counterbalance valves are holding, if not
they will need to be adjusted or replaced.
2. To adjust the valve, raise the mast back up and lock in position. Loosen the jam nut and back out the
adjusting screw 1/4 turn (remember, COUNTERCLOCKWISE adjustment INCREASES pressure on
counterbalance valves). Tighten jam nut and retest. If no difference is noted after one full turn of the
adjusting screw, then valve must be replaced. DO NOT exceed one full turn. If counterbalance valve
is backed out too far, it will relieve pressure. When valve is adjusted correctly, tighten jam nut.
Another indication of a malfunctioning counterbalance valve is the mast assembly bouncing during
the lowering of the assembly. If this is experienced, then the same adjustment procedure as above
applies, except that the adjusting screw would be turned clockwise in 1/4 turn increments. Again, if no
difference is noted by the end of one full turn, then the valve should be replaced.

Hydraulic Systems 7-37

Drill/Tram Control Circuit

Fig. 7-26 Schematic - Right Track - SKF Machines

Fig. 7-27 Drill/Tram Pumps and Filters

1. Right Track Pump 409972
2. Left Track/Rotation Pump 410661
3. Charge Relief Valve
4. Loop Filters (4) - optional
5. Charge Filter (2)

7-38 Hydraulic Systems

 Drill/Tram Control Circuit

NOTE All part numbers on drawings and in text in this section are for reference only.
Always order parts from the parts manual for your specific machine serial num-
ber.

Closed Loop Pump Circuit:

• Tram/Rotation Pump circuit consists of two independent closed loop systems that operate the
rotary drive head motor and the two track assemblies.
• One pump operates only the RH track motor.
• The other pump has a dual function. This pump operates both the LH track and the rotary drive head
motor for drilling. This is achieved by a directional control valve 410574 (fig. 7-28) directing the
flow to the desired motor. The DRILL/PROPEL switch on the switch panel in the operator's cab
controls the directional valve. When the switch is OPEN (de-energized) the valve directs flow to the
PROPEL circuit. When the switch is CLOSED (energized) the valve spool shifts to direct flow to the
ROTATION circuit.

Fig. 7-28 Control Console in Operator's Cab

4. Dill/Propel Select Valve 410574

• There are external charge filters for each pump.

• There is one external charge relief for both pumps.
• Both charge pumps are combined together thru the “G” ports. This is done so that the pumps can
assist each other with extra charge flow if needed.
• Left Track and Rotation Pump (410661)
This pump operates in two modes, Drill and Tram.
• Drill Mode
In drill mode pump operates rotary drive head.
• Tram Mode
In tram mode pump operates LH track.
• Right Track Pump (409972)
This pump only operates RH track in tram mode.

Hydraulic Systems 7-39

Drill/Tram Control Circuit

Fig. 7-29 Schematic - Left Track/Rotation - SKF Machines

Fig. 7-30a Diverter Valve Assembly 411903

(Located on frame cross-member adjacent to
pump drive on dust collector side).
1. Selector Valve 330291 (1410572)

7-40 Hydraulic Systems

 Drill/Tram Control Circuit

Rotate/Tram Motor Circuit:

• This portion of the Tram/Rotation Motor Circuit shows the Rotary and Track motors.
• Selector valve 330291 (item 1, fig. 7-30a) diverts the flow from the LH pump to either the rotary
motor or the LH Tram motor. The selector is shifted by a pilot source from the Drill/Propel selector
valve 410574 described previously. The pilot source shifts to the Drill mode and is vented in the
Tram mode.
• The RH tram motor is supplied by only the RH pump.
• The track brakes are spring applied and pressure released. When in the Tram mode pressure to
release brakes is supplied from the pilot pressure from the tram controllers.

Fig. 7-30 Schematic - Rotate/Tram - SKF Machines

Hydraulic Systems 7-41

Joystick Adjustments (electric)

Fig. 7-31 Electric Joysticks

1. Hoist/Pulldown Control (426108) 3. Left Track Control (426108)
2. Rotation Control (426109) 4. Right Track Control (426108)

Fig. 7-32 Right Hand Cab Section Cutaway

Items located under operator control panel, mounted to left cab wall.

7-42 Hydraulic Systems

 Joystick Adjustments (electric)

GENERAL DESCRIPTION, ADJUSTMENT PROCEDURES & TROUBLESHOOTING

Printed Circuit Board (P.C. Board) Terminal Board Connections (All terminals may not be
present on your P.C. Board)
(+) Positive voltage 12VDC or 24VDC depending on the controller ordered.
(-) Negative side of the supply voltage.
(X) Auxiliary output: Supply voltage is present whenever the controller is turned on. Output
current should not exceed 3 amps.
(A) Output terminal to proportional coil when the control handle is moved in the "A" direction.
(B) Output terminal to proportional coil when the controller handle is moved in the "B" direction.
(C) Common return when high current P.C. Boards are used. The coil's ground or (-) connection
must be return to the P.C. Board "C" terminal, not to ground.
(R) Range terminal: See Dual Range Option.
Most P.C. Boards have LEDs (Light Emitting Diodes) which can be used for troubleshooting, or
simply as an indication of output at a specific terminal. LEDs are located near the (A) and (B)
terminals.
Standard Coil Connections:
Dual Coil: Two coils or solenoids, with each coil having at least 2 connections. One is connected
to the P.C. Board (A) terminal, the other is connected to the negative (-) side of the supply voltage.
The other coil is connected to the (B) terminal and the negative (-) side of the supply voltage. Two
or more P.C. Boards can be paralleled to operate the same coil.

Fig. 7-33 Adjustment Detail and Dual Coil Connections

Adjustment Procedures:
Adjustments are made by turning a trimpot adjustment screw. It may be necessary to turn the
adjustment screw several turns (5 or more) to observe a change in output.
Clockwise (CW) adjustment of the trimpot increases the output.
Counterclockwise (CCW) adjustment of the trimpot decreases the output.
Adjustment affects output current and voltage to the coil. The minimum and maximum output
current is preset at the factory. However, for optimum performance, they must be adjusted while
the equipment is operating.
Hydraulic Systems 7-43
Joystick Adjustments (electric)

Although the following adjustments affect the current/voltage or percentage of duty cycle, the
best way to adjust the function is to observe the response or speed of the function. The following
adjustments affect function response, or speed. There may be some interaction between adjust-
ments. It may be necessary to repeat the adjustment in order to achieve the desired response.
Threshold Adjustment: Adjusts the initial current flow, function response, or speed when the handle
is first moved from the off position. Deflect the handle slowly to the position where the controller
first turns on. Adjust the threshold trimpot screw for start-up or creep speed. If the speed is too
fast, turn the trimpot screw CCW; if the speed is too slow, turn the trimpot screw CW. This
adjustment should be done first.
Maxout Adjustment: Adjusts the full stroke current, maximum function response, or speed when the
handle is deflected to its full travel. Fully deflect the handle, and adjust the maxout trimpot for
maximum desired function response or speed. To obtain proportional resolution, it is important
that the function starts to slow down as soon as the handle is moved back from the fully de-
flected position.
The ideal adjustment occurs when the function just begins to move when the handle is deflected,
and the output increases until it reaches its maximum desired response or speed at the end of
handle travel.
Integrated Ramp System (IRS): Allows the input signal to come on and go off in a controlled
manner. CW rotation of the trimpot increases ramp time and slows the response time. CCW
rotation decreases ramp time and increases the response time. To increase ramp time, turn the
adjusting screw CW a few turns, then move the controller handle abruptly. Continue to adjust until
a smooth response is observed. Most controllers have on/off contacts which remove power
from the PC board when the handle is returned to the "off" position. When the handle is abruptly
returned to neutral, the output will not ramp down, and the function will stop.
Ramp Thru Off: The P.C. board should be adjusted as outlined in the IRS adjustment procedure. If
the handle is abruptly returned to neutral (OFF), the output will ramp down to off.
Dual Range: When supply voltage is applied to the (R) terminal, the board is in "Hi Range". When
voltage is not applied to the (R) terminal, the board is in "Lo Range".
Hi Range Adjustment: With supply voltage applied to the (R) terminal, fully deflect the handle.
Adjust the "Hi Range" trimpot for desired "Hi Range" response or speed. Refer to "Maxout"
adjustment procedures. Whenever the dual range switch or contact is closed, the output should
be adjusted for the maximum function response or speed.
Lo Range Adjustment: With no voltage on the (R) terminal, fully deflect the handle. Adjust the "Lo
Range" trimpot for the desired "Lo Range" response or speed. Again refer to "Maxout" adjust-
ment procedures. Whenever the dual range switch or contact is open, you are in "Lo Range".

7-44 Hydraulic Systems

 Joystick Adjustments (electric)

When changing from "Hi Range" to "Lo Range", a change in function speed should be observed.
Dual Max:
Allows for separate "Maxout" adjustments in each direction of the handle movement. "A
Maxout" adjusts the maximum output when the handle is moved in the "A" direction, and "B
Maxout" adjusts the maximum output in the "B" direction.
Refer to Maxout Adjustment for adjustment procedures.
Problem:
1. The function will not operate when the handle is moved, The LEDs do not light.
A. Check that voltage is present at the positive (+) input terminal.
B. Check that ground is connected to the negative (-) terminal.
C. If there is an in-line fuse, check to see if it is good.
D. Check the controller on/off switch and the connectors. Voltage should be present at
the (X) terminal when the controller is turned on.
E. Check that valve wiring is not shorted to ground. The LEDs will not light.
F. Check that valve wiring is not open. The LEDs will light, but the intensity will not vary.
G. Check trimpot settings. Fully CCW turns output off, CW turns output fully on.
2. The function jumps or lurches when turned on.
A. Perform "Threshold" adjustment procedures.
3. The functions reaches maximum speed before the handle is fully deflected.
A. Perform "Maxout" adjustment procedures.
4. The function speed remains constant regardless of the degree of handle deflection.
A. Perform "Maxout" adjustment procedures.

IRS Option:
1. Function speed reacts too slowly or too quickly in relation to handle deflection.
A. Check "IRS" (Ramp) trimpot adjustment. CW increases ramp time, CCW
decreases ramp time.
Dual Range Option:
1. Controller will not switch between "HI" and "LO" range.
A. Check to see that source voltage is present at the "R" terminal when in "HI" range,
and absent when in "LO" range.
B. Check trimpot adjustments.

Hydraulic Systems 7-45

Auxiliary Functions Circuit

• The Auxiliary Circuit is the tooling functions.

• The control valve flow and pressure is supplied by the pressure manifold which is supplied by the
auxiliary pump.
• This auxiliary circuit is operational only in the Auxiliary mode. The functions will work slowly be-
cause of the stand-by pressure (500 PSI [35 bar]), however 2500 PSI (172 bar) is the normal
relief (410602) setting. Refer to Auxiliary Pump Circuit in this section for pressure setting instruc-
tions.
• The auxiliary functions control valve 410093 is located on the mast (fig. 7-35).

Fig. 7-34 Schematic - Auxiliary Mast Valve

7-46 Hydraulic Systems

 Auxiliary Functions Circuit

Fig. 7-35 Mast (Dust Collector Side)

1. Auxiliary Functions Valve Bank 410093
2. Sequence Valves for H.O.B.O. Wrench

Hydraulic Systems 7-47

Hydraulic Operated Breakout Wrench (HOBO)

Fig. 7-35 Mast (Dust Collector Side)

1. Auxiliary Functions Valve Bank 410093
2. Sequence Valves for H.O.B.O. Wrench

7-48 Hydraulic Systems

Hydraulic Operated Breakout Wrench (HOBO)

Setting of Sequence Valves

Two people are required for this procedure.
1. Position breakout wrench in open position.
2. Breakout wrench sequence valves are located on dust collector side of mast below auxiliary
valve bank (fig. 7-35).
3. Loosen and remove cap nut from adjustment screws. Loosen locknut (fig. 7-36).
4. Screw both adjustments fully in, but not overly firm.
5. Have helper operate breakout wrench to undo pipe. Pipe clamp cylinder will operate to full stroke,
but rotate cylinder will not move.
6. Have helper hold valve in "ON" position, adjust screw of the "A" (top) valve slowly outward until
rotate cylinder actuates, adjust screw slightly more so that the cylinder operates freely. "A" valve
is now correctly set. Tighten locknut.
7. Now have helper operate breakout to retract, clamp cylinder will release pipe but rotate cylinder
will not move.
8. With helper holding lever to retract, adjust screw on "B" (lower) valve slowly outward until actua-
tion occurs. Adjust slightly more to achieve free movement.
9. Tighten locknut and install both protection caps.
10. Breakout sequencing now correctly set.

Fig. 7-36 Sequence Valves for Breakout Wrench - SKF Machines

Hydraulic Systems 7-49

Dust Curtain/Main Air Circuit

• The Dust Curtain/Main Air are also tooling functions.

• The control valve flow and pressure is supplied by the pressure manifold which is supplied by the
Auxiliary pump.
• This auxiliary circuit is operational only in the Auxiliary mode. The functions will work slowly
because of the stand-by pressure (500 PSI [35 bar]), however 2500 PSI (172 bar) is the normal
relief (410602) setting. Refer to Auxiliary Pump Circuit in this section for pressure setting instruc-
tions.
• This control valve 410088 is located in the mast pivot area (item 1, fig. 7-38).

Fig. 7-37 Dust Curtain / Main Air Control Circuit - SKF Machines

7-50 Hydraulic Systems

 Dust Curtain/Main Air Circuit

Fig. 7-38 Upper "A" Frame - Front View (engine end)

1. Main Air/Dust Curtain/ Option Valve 410088 6. Auxiliary Relief Valve 410602
2. Feed Control Valve 410666 7. Max. Pulldown Relief Valve 411774
3. Auxiliary Pump Pressure Manifold 1412986 8. Pulldown Counterbalance Valve 414867
4. Dust Collector/Water Injection Valve 410089 9. Auxiliary Pump ON-OFF Valve 410280
5. Jack Relief Valve 410602

Hydraulic Systems 7-51

SKF Rotary Drive & Pulldown Tables

NOTE All values are theoretical.

Lbs. Ft. Lbs.

Pulldown PSI Head Force Rotary PSI Rotary Torque
2600 50,000 5000 9550
2500 48,100 4800 9150
2400 46,150 4600 8700
2300 44,250 4400 8300
2200 42,300 4200 7900
2100 40,400 4000 7500
2000 38,500 3800 7100
1900 36,550 3600 6650
1800 34,600 3400 6250
1700 32,700 3200 5800
1600 30,800 3000 5400
1500 28,850 2800 5000
1400 26,900 2600 4550
1300 25,000 2400 4150
1200 23,100 2200 3750
1100 21,150 2000 3300
1000 19,250 1800 2900
900 17,300 1600 2500
800 15,400 1400 2100
700 13,450 1200 1650
600 11,550 1000 1250
500 9,600 800 850

DIRECTION CYLINDER NOTE: CYLINDER SPEED

FT/MIN ½ OF HEAD
DOWN 36 NORMAL FEED (NO REGEN)
DOWN 71 FAST FEED (FULL REGEN)
UP 74 NORMAL HOIST

7-52 Hydraulic Systems

 Counterbalance Valve Adjustment

Counterbalance Valve Adjustments

CAUTION:
Overadjustment of a counterbalance valve, i.e. turning the
adjusting screw in too far, could result in uncontrolled
descent of the mast assembly.

NOTE Adjustment of the counterbalance valves is directly opposite of relief valves in this
system, in that clockwise adjustment of relief valves increases pressure, whereas
clockwise adjustment of the counterbalance valves decreases pressure. This must
be remembered when performing any adjustments to the system.

Fig. 7-39 Relief Valve vs. Counterbalance Valve Adjustment

Hydraulic Systems 7-53

Loop Filters (optional)

Fig. 7-40 Loop Filter Assembly (ref. 402263)

1. Bleed Plug 7. O Ring, Filter Element 25. O-Ring
2. O-Ring 7A. O Ring, Core Tube 26. Differential Pressure Device
3. Bowl 8. Backup Ring 27. O-Ring
4. Safety Grip 9. O-Ring 28. O-Ring
5. Label, Element Change 10. Retaining Ring 29. Dust Cover
6. Filter Element 11. Reverse Flow Valve 32. Head
6A. Core Tube 24. Bleed Plug

7-54 Hydraulic Systems

 Loop Filters (optional)

Routine Maintenance
The loop filters do not normally require special attention except for periodic monitoring of the dirty
element warning device. See lubrication section for filter change intervals. Refer to figure 7-40 for item
numbers.

1. If external leakage is noted, replace o-ring at leak. For bowl seal leaks, replace o-ring (9) and
backup ring (8), locating backup ring as shown in illustration (away from fluid, toward bowl (3) and
the atmosphere). If leakage persists, check sealing surfaces for scratches or cracks; replace any
defective parts.
2. Differential pressure indicators (26) act as a dirty element warning device and actuate when
differential pressure across the element becomes excessive because of plugging by contaminant
or because of high fluid viscosity under cold start conditions. If visual indicator actuates (red
button extends 3/16 in. or 4.8 mm), reset by pushing button back after system reaches normal
operating temperature at normal flow. If button stays in, element is still usable; if button will not
stay in, change element (6).

Changing Filter Elements

WARNING:
Relieve pressure on hydraulic and pneumatic systems before
loosening connections or parts.
Failure to depressurize system before proceeding could result
in explosive loss of fluid, damage to equipment or possible
personal injury.

1. Turn off and depressurize system. Open bleed plug (1 or 24) at top of filter one and one-half turns.
Remove plug (24 or 1) at bottom of filter and drain fluid into suitable container. Reinstall drain plug
and tighten both plugs.
2. Remove bowl (3). Remove element (6) along with core (6A) and carefully inspect the surface for
significant visible contamination. Normally, no dirt should show but visible dirt can be an early
warning of system component breakdown and can indicate potential failure. Discard both the
element and its o-ring, but do not discard the core (6A). The filter element is not cleanable.
Any attempt to clean the filter element can cause degradation of the filter medium and allow
contaminated fluid to pass through the filter.

NOTE Older model filters do not use the separate coreless filter and core assembly. The
coreless filter and core assembly can be fitted to the older models as a direct
replacement for the filter with core.
Core part number V011138.
Filter Element part number V011136.
The coreless filter elements provide longer service life and the core can be re-
used at each filter change.

Hydraulic Systems 7-55

Loop Filters (optional)

Fig. 7-41 Optional Charge Loop Filters

1. Charge Loop Filters (4)

7-56 Hydraulic Systems

 Loop Filters (optional)

Changing Filter Elements (continued)

Refer to fig. 7-40
3. Inspect filter housing and its bypass / reverse flow valve for possible damage or malfunction.
Determine whether replacement of any components is necessary. Remove any accumulated dirt
from filter, being careful to prevent contaminant from entering the outlet and washing down-
stream. Refer to element change instructions.

CAUTION:
Failure to replace damaged components, and operation without
a properly functioning hydraulic filter can cause components
downstream of the filter to fail or degrade in their performance.

Check that bowl seals; o-ring (9) and backup ring (8)) in head are not damaged. Use replacement
filter element part number called for on assembly nameplate. Lubricate threads and sealing
surfaces on bowl (3) and the o-ring (7) in element with clean system fluid.
4. Push open end of filter element onto the core (6A). Lubricate the core o-ring (7A) and push the
core and filter into the filter head (32). Screw bowl to head until bottomed. O-ring sealing is not
improved by overtightening; do not exceed 15 ft. lbs. (20 Nm) torque. Bleed system. Reset visual
warning device by pushing in the red button; electrical switch is reset automatically.
5. Pressurize system fully and check for external leaks; if leaks occur, check o-rings and sealing
surfaces. After system reaches normal operating temperature, check that electrical switch has
not actuated or that visual warning button remains down.

Hydraulic Systems 7-57

Charge Filters

Fig. 7-42 Charge Filter Assembly (ref. 58495)

1. Visual Service Indicator
2. Plug
3. O-Ring
4. O-Ring
5. Filter Element
6. Filter Bowl
7. Filter Head

7-58 Hydraulic Systems

 Charge Filters

Routine Maintenance
The charge filters do not normally require special attention except for periodic monitoring of the
dirty element warning device. See lubrication section for filter change intervals. Refer to figure 7-42 for
item numbers.

1. If external leakage is noted, replace o-ring at leak. For bowl seal leaks, replace o-ring (4). If
leakage persists, check sealing surfaces for scratches or cracks; replace any defective parts.
2. Differential pressure devices actuate when the element needs changing or because of high fluid
viscosity under cold start conditions. If visual indicator actuates (red button extends 3/16 in. or
4.8 mm), reset by pushing button back after system reaches normal operating temperature at
normal flow. If button stays in, element is still usable; if button will not stay in, change element (6).

Changing Filter Elements

WARNING:
Relieve pressure on hydraulic and pneumatic systems before
loosening connections or parts.
Failure to depressurize system before proceeding could result
in explosive loss of fluid, damage to equipment or possible
personal injury.

1. Turn off and depressurize system. Open bleed plug (if fitted) 1 1/2 turns.
2. Unscrew and remove filter bole (6) from head assembly (7), counterclockwise when viewed from
below. It may be necessary to use a lever on the "Rotolock Ring" of the filter bowl (6) to loosen
the bowl initially.
3. Remove filter element (5) along with core, and carefully inspect the surface for visible contamina-
tion. Normally no dirt should show, but visible dirt or particles can be an early warning of system
component breakdown and can indicate potential failure. Discard both the filter element and its o-
ring, but do not discard the core. The filter element is not cleanable. Any attempt to clean
the filter element can cause degradation of the filter medium and allow contaminated fluid to pass
through the filter element.

CAUTION:
DO NOT attempt to clean or reuse element.

NOTE Older model filters do not use the separate coreless filter and core assembly. The
coreless filter and core assembly can be fitted to the older models as a direct
replacement for the filter with core.
Core part number V011137.
Filter Element part number V011135.
The coreless filter elements provide longer service life and the core can be re-
used at each filter change.

Hydraulic Systems 7-59

Charge Filters

Fig. 7-43 Charge Filter Assembly - adjacent to pumps

1. Charge Filters (2)
2. Loop Filters (4) - optional

Fig. 7-43a Charge Filter

1. Filter Indicator/Reset Button

7-60 Hydraulic Systems

 Charge Filters

Changing Filter Elements (continued)

4. DO NOT run the system without a filter element (5) installed. Check that the o-ring (4) on the head
assembly (7) is not damaged. Use replacement filter element part number called for on the
element change label, or refer to the parts manual.
5. Lubricate element o-ring (4) with clean system fluid and push open end of filter element (5) onto
the core. Lubricate o-ring on core and push core and filter into filter head (7). Clean out filter bowl
(6) interior and lightly lubricate threads of filter bowl with clean system fluid. Screw filter bowl onto
head assembly until it bottoms. O-ring sealing is not improved by overtightening.

CAUTION:
DO NOT use pipe wrench, hammer, or any other tool to tighten
bowl.

6. Bleed the system and check for leaks. To bleed filter, open bleed plug, if fitted, 1 1/2 turns. Jog
system and fill filter until all air bleeds through plug, then tighten plug. Pressurize system fully and
check for leaks; if leaks occur, check o-rings and sealing surfaces.
7. After element change, ensure differential pressure device is reset by pushing in the button; electri-
cal switches reset automatically. When system reaches normal operating temperature, check
that the electrical switch has not actuated and/or the visual warning button has remained de-
pressed. If visual indicator rises due to a cold start condition, reset again as outlined in "Routine
Maintenance."

Hydraulic Systems 7-61

Main Return and Case Drain Filters

Fig. 7-44 Main Return and Case Drain Filter

1. Head
2. Cover Assembly
3. Shell
4. Upper Cover O-Ring
5. Lower Cover O-Ring
6. Head to Reservoir O-Ring
7. Filter Element
8. Element O-Ring
9. Indicator
10. Indicator O-Ring
11. Indicator O-Ring
12. Anti-Backflow Assembly
13. Weldable Adapter Flange

7-62 Hydraulic Systems

 Main Return and Case Drain Filters

Routine Maintenance
Main Return and Case Drain filters do not normally require special attention except for periodic
monitoring of the differential pressure warning device. Schedule replacement of filter element every 500
hours, and have ample supply of spare elements available.

1. If external leaking is noted, replace o-ring at leak. For cover seal (4) and reservoir to head seal (6)
leaks, replace o-rings. If leakage persists, check sealing surfaces for scratches or cracks; re-
place any defective parts.
2. Differential pressure devices actuate when the element needs changing or because of high fluid
viscosity in "cold start" conditions. If visual indicator is fitted and actuates during "cold start",
reset by depressing the rubber button when the normal operating temperature is reached. If
indicator actuates after resetting, replace element.

Changing Filter Elements

WARNING:
Relieve pressure on hydraulic and pneumatic systems before
loosening connections or parts.
Failure to depressurize system before proceeding could result
in explosive loss of fluid, damage to equipment or possible
personal injury.

1. Turn off and depressurize the system. Open bleed plug (if fitted) 1 1/2 turns.
2. Unscrew and remove filter cover assembly (2) from head assembly (1), counterclockwise when
viewed from above. It may be necessary to use a correct sized wrench on the hexagon on the
filter cover assembly (2) to loosen the cover initially.
3. Remove filter element (7) and carefully inspect the surface for visible contamination. Normally no
dirt should show, but visible dirt or particles can be an early warning of system component break-
down and can indicate potential failure. Discard both the filter element and its o-ring. The filter
element is not cleanable. Any attempt to clean the filter element can cause degradation of the
filter medium and allow contaminated fluid to pass through the filter element.

CAUTION:
DO NOT attempt to clean or reuse element.

Hydraulic Systems 7-63

Main Return and Case Drain Filters

Fig. 7-45 Main Return and Case Drain Filter Assembly

1. Main Return Filter
2. Case Drain Filter
3. Air Filter
4. Service Valve (open to relieve pressure after machine is shut down)

Fig.7-45a Main Return and Case Drain Filters

7-64 Hydraulic Systems

 Main Return and Case Drain Filters

Changing Filter Elements (continued)

4. DO NOT run the system without a filter element (7) installed. Check that the o-ring (4 and 5) on the
head assembly (1) is not damaged. Use replacement filter element part number called for on the
element change label.
5. Lubricate element o-ring (8) with clean system fluid and push open end of filter element (7)
straight onto the nipple in the head assembly (1). Lightly lubricate threads of filter cover assembly
with clean system fluid. Screw cover assembly onto head assembly until it bottoms. O-ring sealing
is not improved by overtightening.

CAUTION:
DO NOT use pipe wrench, hammer, or any other tool to tighten
outer shell.

6. Bleed the system and check for leaks. To bleed filter, open bleed plug, if fitted, 1 1/2 turns. Jog
system and fill filter until all air bleeds through plug, then tighten plug. Pressurize system fully and
check for leaks; if leaks occur, check o-rings and sealing surfaces.
7. After element change, ensure differential pressure device is reset by pushing in the button; electri-
cal switches reset automatically. When system reaches normal operating temperature, check
that the electrical switch has not actuated and/or the visual warning button has remained de-
pressed. If visual indicator rises due to a cold start condition, reset again as outlined in "Routine
Maintenance".

Hydraulic Systems 7-65

Hydraulic Cylinder Repair

WARNING:
RELIEVE all pressure before attempting service or mainte-
nance procedures to this machine.
RELIEVE pressure in both hydraulic and pneumatic systems
before loosening any connections or parts.

The following maintenance manual provides information on repair of Texas Hydraulics cylinders.

Refer to your parts manual to identify and order replacement parts for the cylinder.

There are specific procedures for different types of heads and pistons. Compare the drawing in the
parts manual to the type of head and piston shown in the Texas Hydraulics Maintenance Manual. Follow
the procedure for the specific type of head and piston you are working on.

7-66 Hydraulic Systems

 Hydraulic Cylinder Repair

Hydraulic Systems 7-67

Hydraulic Cylinder Repair

7-68 Hydraulic Systems

 Hydraulic Cylinder Repair

Hydraulic Systems 7-69

Hydraulic Cylinder Repair

7-70 Hydraulic Systems

 Hydraulic Cylinder Repair

Hydraulic Systems 7-71

Hydraulic Cylinder Repair

7-72 Hydraulic Systems

 Hydraulic Cylinder Repair

Hydraulic Systems 7-73

Hydraulic Cylinder Repair

7-74 Hydraulic Systems

 Hydraulic Cylinder Repair

Hydraulic Systems 7-75

Hydraulic Cylinder Repair

7-76 Hydraulic Systems

 Hydraulic Cylinder Repair

Hydraulic Systems 7-77

Hydraulic Cylinder Repair

7-78 Hydraulic Systems

 Hydraulic Cylinder Repair

Hydraulic Systems 7-79

Hydraulic Cylinder Repair

7-80 Hydraulic Systems

 SKF Hydraulic Schematic
3K PSI
MAX. PULLDOWN PSI PULLDOWN PSI ADJUSTMENT

B
4 411774 (IN CAB) VALVE COUNTER
EF

3K PSI BALANCE CF P
RET-2 410665 3 342638 414867 WATER
4 PUMP DUST
T LS P 1 2 81239 COLL.
NC NO 2 RET-10 P T 410089

WP
2250
1
414858 HDR1 GV1 G2 GR GC1 B
PSI

DC
C
SWITCH, PRESSURE 3
ROTATION MOTOR DUST COLLECTOR
CAIA-LHN
220 psi
9.76 IN^3 4

3K PSI
GEARBOX RAITO - 16:1 V1A

A
ATM C1A P T
1 1 2 2 1
-16

B
3 PULLDOWN
V2A RET-9
3 C2A RET-11

P
2 3 1
3
1
4 2
4
1
G1
C2
XX 410093
FEED CYL

C
R 2

a
2 7.0" BORE X C1
1 C1B 5.0" ROD
PIPE RACK ROTATION
DRN-3 3 PROP CONT

b
T

A
V1B
Ø.016
-16

B
C2
C2B
LS P

a
T
V2B C1
PIPE RACK SWING

PIPE RACK
T HBP GC2
HDR2 410666

A
DRN-1 PROP CONT

b
LOCK
R. TRAM MOTOR 342638 HOLDBACK PSI C2
V DRN-16

a
125CC (7.63 IN^3)/ (IN CAB) C1
B1 107CC (6.52 IN^3) RET-3 DRN-18 SWING PIPE RACK LOCK
DRN-2 P1 FINAL DR RATIO 99:1

b
339027
VALVE, 3 WAY RET-16
B2 HOLDBACK OFF/ON
C2
PULLDOWN PRESSURE RET-6

a
B B C1

RETURN MANIFOLD
(PISTON AREA) RET-6 RET-8 PIPE POSITONER

330291

b
LOW SPEED TRAM RET-9
RET-10
PILOT C2

LOCK
MAST
RET-3 RET-11

a
X X 410280 C1
RET-2 RET-12 MAST LOCK

b
A A

ROTATE
DRN-2 2
3
RET-1 RET-13
1 C2

CLAMP

a
A2 C1
RET-14 WINCH CONTROL
P2

DRN-2

b
L. TRAM MOTOR
RET-15
125CC (7.63 IN^3)/

2000 PSI
A1

2000 PSI
C2
107CC (6.52 IN^3) V

a
C1
FINAL DRIVE RATIO 99:1 HOBO CLAMP/ROT
DRN-18

b
BREAKOUT C2
DRN-13 (OPTIONAL)

a
Ø.0313 DRN-1 C1

DRN-2 HOBO SW

b
A
DRN-3
DRN-4 C2

a
DRN-5 C1

B
435436 AUTO TOOL
DRN-6

b
LS

AUTO
TOOL

T
LS
DRN-7 -12 -12
M
DRAIN MANIFOLD
DRN-17 P T
X
DRN-8 401065
P
DRN-16

PRESS MANIFOLD
L DRN-9 RET-13
DRN-13
410088
0 max DRN-10 DRN-13

AUX PUMP
C2

a
DRN-11

333017
C1
GUAGE OPTION
T U

b
DRN-9 DRN-12
C2

a
C1
DUST CURTAIN

b
RET-8
C2
450

a
DRN-5 DRN-7 C1
PSI MAIN AIR
50 PSI

b
AUX PMP 410280
Y1 Z1
A
OFF-LS
ON-HI
X 2
434542 (4) P T
5510
S
PSI 4500 PSI TR TR
24.4 3 1 AUX PUMP RV DRN-11
GPM 100 410602
GPM
5510
1.0
mm
PSI
P R R RET-12
DRN-8
B
2500PSI
DRN-14
437663
Z
TP
DRN-10
E E
5000 PSI 1 3 410091
Y TP
600 PSI

B
A B P T
3 TE TE
TRAM ALARM TR TR

RH REAR
4
C 2

A
JACK
5000 5000
2 1 410574
PSI PSI MZ MY
P ROTARY TORQUE TRAM/DRILL SEL
CAB PANEL ON = DRILL
OFF = TRAM R R JACK RH REAR
435434 DRN-6

LS
P

T
DRN-6

B
E E

FRONT
JACKS

A
50 PSI
1700-2400 psi TE TE
424706 424706
JACKS FRONT
Y1 RET-1
Z1

LS
5510

P
PSI

T
4.12 2.94 2 1 2 1
CIR CIR
100

B
LH REAR
JACK
GPM
5510
409974

A
1.0 PSI
mm P 3 3 438794 (2)
4000 PSI
JACK LH REAR
TR TR

LS
TP
Z

T
ELEVATE
MAST
Y TP
R R

B
A
5000 5000
PSI PSI MZ MY
MAST ELEVATE
E E
410208

435434

LS
DRN-12 TE TE

T
RET-14

3 PSI 410602
DRN-17 COOLER
10 MICRON
SUCTION A 5.1 B
DRN-15

MANIFOLD RET-15
CIR
2800PSI
B AUX PUMP RV
150 DEG F
1600 RPM CLOSE
MAX. 45 PSI
A C
OPTIONAL 2 3 PSI

FAN SYSTEM 419943

HIGH A 5.1 B
HP UNITS

(Ref. 439407 rev 8)

CIR

RET-16
HYD. TANK
1600 RPM
MAX.

Hydraulic Systems 7-81

 SKFX Hydraulic Schematic
(IN CAB) 0410208 1 2

MAST RAISE/LOWER RIGHT REAR JACK FRONT JACKS LEFT REAR JACK

1 2 1 2

1 P T 2 1 P T 2 1 P T 2 1 P T 2

0410091 B
B
WINCH
BRAKE
ROTATE
SPARE
3 3
A
WINCH ASSEMBLY
A

JACK LH REAR
W/BRAKE VALVE P T
1 2 1 2 & STATIC BRAKE
B
DR
B
0033985 0033985 BR

(IN CAB) CAROUSEL SWING

BRAKE
VALVE
A
A P T
B B
B
LS T
ROTATION PULLDOWN
(7500 PSI) (7500 PSI) WINCH CONTROL
51710 KPa 51710 KPa A

JACKS - FRONT
A A P T
B B
B
0052696 0033985 3 MAST LOCKS
1 2 A
A A P T
B B
3 B
LS T
BIT AIR AUXILIARY
(600 PSI) (7500 PSI) (2000 PSI) CLAMP CENTER GUIDE
1 2
4136 KPa 51710 KPa HYD. RELIEF VALVE
A
A A P T

JACK RH REAR
3
0410602 B B
1 2 B

PIPE POSITIONER
PULLDOWN PSI ADJUSTMENT ROTARY TORQUE PSI ADJUSTMENT
A
P T 0057319 0057319 A A P T
(2000 PSI) B B
B
3 LS T
3
HOBO SWING
P T P T 1 2 1 2 A

MAST ELEVATE
A A P T
B B
B
0402263 HOBO CLAMP/
(2000 PSI) CLAMP ROTATE
A
A A P T
3
B B
1 2 B
3 3 P LS T
DECK SPANNER
1 2 1 2 A
A A P T
(2000 PSI)

0058495
LEFT TRACK/ROTATION PUMP

TP12 TP13 TP14 TP15 TP16 TP17 TP18

7.63 CIR (135CC) @ 2100 R.P.M.

ROTATE
AUTO-PULLDOWN PULLDOWN PULLDOWN PULLDOWN PULLDOWN ROTATION ROTATION ROTATION ROTATION AUX. PRIORITY P1
1 1
3.19 CIR (52.3CC) @ 2100 R.P.M.

1
4 4 4 4
LEFT CHARGE PUMP

3 3 3
V01
1 3 1 3 1 1 3 1
1 2 4 4 4
LS1 2 2 2 2 3 0.030
2 2 1 1
2 2 3 2 3 2 3
LS2 1 2
AUX. MANIFOLD
TP10 V02 V04 V05 V06 V08 V09 V10
TP11 1412986
34474 kPa 4137 kPa 4826 kPa 34474 kPa 4137 kPa 4826 kPa
PC2 V03 (5000 psi) (600 psi) (700 psi) V07 (5000 psi) (600 psi) (700 psi) V11
Z1 Y1
0.157 1 2
PC1
S 5500 TP09
PSI TP08
LS3 V12
2 P2
P10
0067735
5500
416054 LS4 1 3
435435

PSI 1.0
START UNLOADER DRILL/TRAM AUX. PRIORITY PULLDOWN
P mm
CHARGE OFF=LOAD AUTO-PULLDOWN OFF=TRAM DRILL/TRAM INTERLOCK OFF=FAN FULL SPEED OFF=DRILL
(350 PSI) TP07 ON=UNLOAD SET-UP INTERLOCK NOT WIRED ON=DRILL NOT WIRED ON=FAN RESTRICTED ON=CAROUSEL PULLDOWN
2413 KPa 13790 kPa
(2000 psi)
B B
ROPE TENSIONER
TRAM BRAKE SOL. CYLINDERS B
OFF=BRAKE SET
TP TP06 1 MAIN AIR
Z 1 1 1 3 2 1 1 1 2
D1 ON=TRAM MODE 415915 A B A B
LS5 A
3 2 3 2 3 2 1 4 3 2 3 2 3 2
TP
Y A A P T
B B
B
V13 433469 433469
TP01 1 SKIRT LIFTERS
5000 5000 TP05 V20 V19 V18 V17 V16 V15 V14 TP19 3 2 A
MY MZ PSI PSI TP04 GC C1E GA GB A A P T
TP03 TP20 B B
P1
TP02 PBDB-LAN B
TP21 0075137
P9 2 3
TRAP DOOR
0410280 2 1 1 2 A
P8 1 A A P T
P2 C1R
P7 CXDA-XCN B
CSAB-XXN 0075137 B
P6
SPARE
P5 3 600 PSI A
0426787 ROPE TENSIONER A P T
D2 MANIFOLD
0402263 B
B
P4 P3 0416113 RDFA-LAN
SPARE
A
A P T
CXHA-XCN B
B
2 1 2 1 C2R
415915 T SPARE
7.93 CIR (130CC) @ 2100 R.P.M.

LS SET TO
AUXILIARY/FAN PUMP

A
ROPE TENSIONER MAX A P T
CYLINDERS
P
C2E
LS P A B T P A B T B X
3
0.030"
LEFT HAND
TRAM MOTOR
1 2
X
A2 A1 B2 B1 A2 A1 B2 B1 V005035
P RIGHT HAND LEFT HAND
WATER INJ. PUMP
DIVERTER VALVE DIVERTER VALVE
B
0084242 0084242 A 0087252 B
DR
COUNTERBALANCE
L VALVE

0085962 A
412082

0.015" 0415113 0081239

FUNK PUMP DRIVE GEAR BOX

0 max A
2 P P T
CROSS/PORT A2 B2 CF P
RELIEF B EF 0406042
0433920

VALVE GA1 GB1

DUST COLLECTOR

TRAM MOTOR
0043379

RIGHT HAND

V005035
WATER INJECTION
435436

T U X
HOLDBACK 1 1 (3)*
0402263 ON/OFF
(2)* (1)* HDC1800-3
1
2 3 A
B06B3PZ
DR DUST COLLECTOR
0410602

CAV06-S3
(C16-S3)*

A1 B1

HOLDBACK 2 U B X M1
RELIEF ROTATION MOTOR
TRAM ALARM
0438776
0058495
RIGHT CHARGE PUMP

SUCTION MANIFOLD
3.19 CIR (52.3CC)
@ 2100 R.P.M.

0.07"
DUST COLLECTOR/WATER INJ. PUMP

416567 3500 PSI

(1.8MM)
PULLDOWN
RETRACT

(24131 KPA)
2.55 CIR (41.8CC) @ 2100 R.P.M.

Z1 Y1 A G T

S 5500
PSI

5500
435435

PSI 1.0 416055

P mm
CHARGE
(350 PSI)
2413 KPa

TP
Z
RIGHT TRACK/PULLDOWN PUMP

0402263
TP
Y
7.63 CIR (135CC) @ 2100 R.P.M.

0056385

5000 5000
RETURN MANIFOLD DRAIN MANIFOLD CASE DRAIN MANIFOLD
PSI PSI
MY MZ
0401065 0401426 0401065

0034053 0403030

CASE DRAIN RETURN

0088596 0088595
HYDRAULIC TANK

(Ref. 440857 rev 4)

416211

7-82 Hydraulic Systems

 Hydraulic Piping - SKF Cab Controls

2-SECT. FEED VALVE

RH PUMP "FA" PORT

ROTARY FEED VALVE

TO DRAIN MANIFOLD
(SUPPERCHARGED)

(HOLDBACK PSI)

(PULLDOWN PSI)
DRAIN MANIFOLD

DRAIN MANIFOLD
CONTROL VALVE

CONTROL VALVE
TO PULLDOWN

TO PULLDOWN
TRAM BRAKE
LH DIVERTER
VALVE PILOT

HBP PORT
RELEASE
CAB WALL

12 31 6 9 16 32 3 15 5 14 4

33 AUX PUMP

P T P T

DRILL/
HOUR
ROTATE
20 RH AIR CLEANER METER 13 LH TRACK
INDICATOR SWITCH REMOTE REMOTE
RELIEF RELIEF
HOIST/PULLDOWN VALVE VALVE
PRESSURE SWITCH
HOLDBACK PULLDOWN BIT AIR
10 BACKUP ALARM 11 GAUGE
PRESSURE SWITCH
PULLDOWN PULLDOWN
LH AIR CLEANER DRILL/TRAM CONTROL CONTROL
INDICATOR SELECTOR VALVE VALVE
23 (SIDE) (FRONT) 1 PULLDOWN
VALVE
10X NOTE:
PRESSURE
1" TO 4" 3 3
2 2
(LOW
START/RUN
24 1 1 19 HIGH/LOW (HIGH

2
1* MAST
4
3
2 LR 12
25 1* JACK 2
2 FT
1* JACK
3-WAY
26 2 RR VALVE
1* P JACKT
(SUPPLIED W/
COMPRESSOR)

27
36 35 34 33

32 31 30 29 28 27 26 25 24 23 22 21
ROTARY TORQUE
OPTION
10 9 8 7 6 5 4 3 2 1
START RUN AIR PRESS.
28 20 19 18 17 16 15 14 13 12 11
SELECTOR OPTION

HOLES SHOWN ARE REPRESENTED

BY HEX BALLOONS ON SCHEMATIC CAB
MAST SIDE
30
NOTE: "*" INDICATES PORTS CLOSEST CAB WALL

29

(Ref. 426061 rev 23)

Hydraulic Systems 7-83
 SKF Rotary Torque Control
ROTATION MOTORS
SET ABOVE 5000 PSI DRN-7
LEFT HAND PUMP ROTATION TORQUE CONTROL
600 PSI 3
A
B
2 1
C P B B
2 DRN-6 P
CAB
407730
Y1 437842 B1 B2
A A
1 1

A1 A2
X

ROTATION TORQUE X PORT RELIEF DRN-1

DRN-11
MS
L
B2 A2 P
B
B1
A1 L.H. TRAM DRN-2 3 4
1
1 2
PST
2 A DR
DRILL/PROPEL
3 VALVE

DRN-3

REFERENCE SCHEMATIC 1526393.

DRAIN MANIFOLD

FOR BULKHEAD PORT PRESSURE FROM PORT 4

LOCATIONS - SEE CAB DRILL TRAM SELECTOR
DRAIN
15 35 5

410208
B2 B1

X
TO MAST FORWARD ROTATION
FROM DIVERTER
2
MAST *1

SEQ
A2 A1
LR 2
JACK *1 C A
FT 2
JACK *1
RR 2 P
JACK B
T P 1
*

NOTE:
T P PRESSURIZED "B" TO "C"

ASSEMBLY
(Ref. 440597 rev 2)

7-84 Hydraulic Systems

 SKFX Rotary Torque Control

LEFT HAND PUMP

Z1

MP

TP12 TP13 TP14 TP15 TP16 TP17 TP18

AUTO-PULLDOWN PULLDOWN PULLDOWN PULLDOWN PULLDOWN ROTATION ROTATION ROTATION ROTATION AUX. PRIORITY

1 1 1
P1
3 4 3 4 4 3 4
V01
1 3 1 3 1 1 3 1
1 2 4 2 2 4 2 2 4
LS1
2 2 1
2 2 3 2 3 2 3
LS2 1

TP10 V02 V04 V05 V06 V08 V09 V10

TP11
34474 kPa 3100 kPa 4135 kPa 34474 kPa 3100 kPa 4135 kPa
PC2 V03 (5000 psi) (450 psi) (600 psi) V07 (5000 psi) (450 psi) (600 psi) V11

DRAIN MANIFOLD PC1

TP09
TP08
LS3 V12
2
P10 P2
1 3
LS4 START UNLOADER SET-UP INTERLOCK AUTO-PULLDOWN DRILL/TRAM DRILL/TRAM INTERLOCK AUX. PRIORITY PULLDOWN
OFF=MANUAL FEED OFF=FAN FULL SPEED OFF=DRILL
OFF=LOAD OFF=JACKS/MAST OFF=TRAM OFF=DRILL/TRAM
TP07 ON=UNLOAD ON=PULLDOWN ON=FAN RESTRICTED ON=CAROUSEL
ON=INTERLOCKED ON=DRILL ON=INTERLOCKED PULLDOWN
13790 kPa
(2000 psi)

TP06 1
1 1 1 3 2 1 1 1
D1
2
LS5
3 2 3 2 3 2 1 4 3 2 3 2 3 2

V13
410208 FOR BULKHEAD PORT TP01
LOCATIONS - SEE CAB TP05
TP04
V20 V19 V18 V17 V16 V15 V14 TP19

TP03 TP20
TP02
TP21
P9

2 35 34
P8

MAST
P7

*1 P6
P5

LR 2 D2

JACK *1 P4 P3 91-A40-081

FT 2
JACK *1 PILOT CONTROL VALVE SCHEMATIC
RR 2
JACK * 1
T P
B2 B1
T P

X
FORWARD ROTATION
TO MAST
FROM DIVERTER

ASSEMBLY
SEQ

A2 A1 (Ref. 441073 rev 2)

Hydraulic Systems 7-85

 SKFX Rotary Torque Control Plumbing
PILOT CONTROL
CASE DRAIN MANIFOLD
MANIFOLD (#428764)
(#411937)

LS1 P8 P10
V08 PC2
PC2 LS3
D2
LS2 TP1 LS4
V09 P1
P6
LS5 P9 P2

P7
PC1
P5 P3
V12 P4
V13 D1
TP20

PILOT
CONTROL
MANIFOLD
FOR BULKHEAD PORT Z1
LOCATIONS - SEE CAB CASE
DRAIN
MANIFOLD
35 34
MP

LEFT HAND PUMP

T P
B2 B1

X
FORWARD ROTATION
TO MAST
FROM DIVERTER
SEQ

A2 A1

CROSS/PORT RELIEF VALVE

(#442078) (Ref. 441074 rev 1)

7-86 Hydraulic Systems

 SKF Auxiliary Pump and Feed Valve Plumbing-Linde

LS
JACK/MAST RAISE AUX. PUMP 3-BANK
VALVE MANIFOLD VALVE

P T

OUTLET INLET
FEED CONTROL PUMP-RH TRACK
CIA
C2A VALVE
MAST VALVE ASSY.

OUT
V1B

V2A

IN
V1A V2B OPEN LOOP FEED PUMP
RIGHT SIDE

PUMP FAN/DUST

Y X

T P

VALVE ASSY.
DUST COLLECTOR

PULLDOWN
DIR. CONTROL
VALVE
MAIN RETURN
MANIFOLD
(CAB SIDE)

(Ref. 439368 rev 5)

Hydraulic Systems 7-87

 SKF Auxiliary Pump and Feed Valve Plumbing-Linde
MAX SET-UP
REF. RELIEF VALVE MAX SET-UP MAX PULLDOWN
MAST PLUMBING SET-UP RELIEF VALVE RELIEF VALVE FEED CONTROL C1B CV1
R
HDR2

@ 2800 SET-UP MAX SET-UP

ROTARY DRIVE SET-UP VALVE
@ 2000 @ 2400 SOLINOID HDR1

2 GC1
4 HBP T 3 V1B V2B
1 2 3 2
1 1
2
1
GR
VIEW A-A

A HDR1
A
CASE DRAIN HDR2 MAIN RETURN
MANIFOLD RIGHT PUMP
MANIFOLD
(DUST COLL. SIDE) (CAB SIDE) CHARGE FILTER

DIVERTER
VALVE A2 B2

PILOT

PULLDOWN
DIR. CONTROL
VALVE

LS
IN

LS
REF. OUT

HOBO ASSY.
ON MAST

OPEN LOOP FEED PUMP

(LEFT SIDE)
.03125

4
3

2
1

4 5 31 16 33 14 15 3 32 1 6

MAX PULLDOWN CAB BULKHEAD

COUNTERBALANCE VALVE

JACK/MAST RAISE
VALVE

(Ref. 439368B rev 5)

LS

7-88 Hydraulic Systems

 SKF Charge Plumbing-Linde
MAIN MANIFOLD

IN OUT OUT IN

MAST SUPPORT
(CAB SIDE)

OUT OUT IN

OUT

ACTUAL VIEW

FITTINGS ROTATED FOR CLARITY

13
NOTE: HEX BALLOONS INDICATE BULKHEAD (Ref. 439240 rev B)
LOCATION ON CAB WALL

Hydraulic Systems 7-89

 SKF Suction/Return/Drain Plumbing-Linde
PUMP,-LH. TRACK & ROTATION

(DUST COLL. SIDE)

CASE DRAIN
MANIFOLD
"L" PORT

SUCTION MANIFOLD

PUMP,-OPEN LOOP
FEED & AUX. FUNCTIONS

MAIN RETURN
MANIFOLD
(CAB SIDE)

PUMP, FAN/DUST

OUT
L

IN
PUMP,-RH. TRACK

HYD. TANK

(Ref. 439379 rev 4)

7-90 Hydraulic Systems

 Section 8

Fig. 8-0 Electronic Control Module - Caterpillar C15

Electronic Engine
1. Electronic Control Module (ECM)
2. Plug-Ins - Disconnect from ECM BEFORE welding

Electrical Components
CAUTION:
DO NOT weld on any part of the machine without first
disconnecting the negative battery cable or place the
battery disconnect switch in the open position. On ma-
chines equipped with electronic engine, disconnect the
connections to the Electronic Control Module (ECM) on
the engine before welding.

Fig. 8-0a Electronic Control Module - Cummins QST30-
Left Side
1. Electronic Control Module (ECM)
2. Plug-Ins - Disconnect from ECM BEFORE welding.
Electrical Components
Fig. 8-0b Electronic Control Module - Cummins QST30-
Right Side
1. Electronic Control Module (ECM)
2. Plug-Ins - Disconnect from ECM BEFORE welding.
8-1
Jump Starting

Fig. 8-1 Connection of Battery Cables

Jump Starting
1. Always wear safety goggles when working around batteries.
2. DO NOT smoke when jump starting.
3. DO NOT jump start if the battery fluid is frozen or slushy as the battery may explode. The battery
o o
should be warmed to at least 40 F (4.4 C) before attempting a jump start.
4. Jump start only with an external power source, having an electrical system of the same voltage,
ground polarity and equipped with battery or batteries of comparable size or larger.
5. DO NOT jump start using motor generator sets, welders or other sources of DC power.
6. DO NOT jump start 24V electrical systems with two 12V batteries connected in series. The
current drain will be too high on the 12V batteries possibly causing an explosion.
7. DO NOT permit metal-to-metal contact between the machine and starting vehicle and do not
allow jumper cable terminal clips to contact either vehicle as arcing may result in fire or explo-
sion.
8. Use only jumper cables that are clean, in good condition, and are heavy enough to handle the
starting current.
9. DO NOT use battery terminal for jump starting. Arcing at battery could result in explosion. Con-
nect jumper cables as shown in figure 8-1.
10. Stand as far away as possible from batteries before actual starting.

8-2 Electrical Components

 Batteries and Circuit Breakers

Batteries
1. Acid burn, fire and explosion hazards exist when working around drill and vehicle batteries. Sulfuric
acid in batteries will cause severe burns. Batteries emit hydrogen gas, which will burn or explode if
sparks or flame are present.
2. Always add battery water before starting up, not after shutting down. Keep batteries filled and
charged. A discharged battery will freeze at much higher temperatures than a fully charged battery.
3. Wear protective clothing, gloves, an acid-resistant apron and a face shield when servicing batteries.
4. Always loosen vent caps from the weak batteries and cover with a cloth before charging.
5. DO NOT short across battery terminals. The spark can ignite gases.
6. Be sure battery fluid is at the proper level.
7. When charging batteries, always disconnect battery charger from its power source or turn it off
before connecting or disconnecting charger leads to battery terminals.
8. When removing a battery, disconnect ground (-) terminal FIRST.
9. When installing a battery, connect ground (-) terminal LAST.

Circuit Breakers
Circuit breakers are located in the operator's cab on the side of the control console. They are
disabled by pulling out on the knob and reset by pushing in on the knob. Before working on an electrical
system, disable it at the circuit breaker or remove the positive battery terminal connector. Place an OUT
OF SERVICE tag on the ignition switch and on the breaker or battery to keep machine from being acci-
dently started while someone is performing service work.

Fig. 8-2 Drill Control Console

1. Circuit Breaker Panel
2. Circuit Breakers for Air Conditioner

Electrical Components 8-3

Welding Precautions

Fig. 8-2a Electronic Control Module - Caterpillar C15

Electronic Engine
1. Electronic Control Module (ECM)
2. Plug-Ins - Disconnect from ECM BEFORE welding

Fig. 8-2b Electronic Control Module - Cummins QST30- Fig. 8-2c Electronic Control Module - Cummins QST30-
Left Side Right Side
1. Electronic Control Module (ECM) 1. Electronic Control Module (ECM)
2. Plug-Ins - Disconnect from ECM BEFORE welding. 2. Plug-Ins - Disconnect from ECM BEFORE welding.

8-4 Electrical Components

 Welding Precautions

CAUTION:
DO NOT weld on any part of the machine without first
disconnecting the negative battery cable or place the
battery disconnect switch in the open position. Discon-
nect the connections to the Electronic Control Module
(ECM) on the engine before welding.

Whenever possible, remove component to be welded from machine. If this is not possible or practi-
cal, follow the steps below to provide minimum risk of damage to electrical components.

1. Stop engine. Turn the switched power to the OFF position.

2. Disconnect negative battery cable from battery, or if equipped with a battery disconnect switch,
place switch in OPEN position.
3. Disconnect the connectors from the ECM. Move the plug-ins so they can not accidently make
contact with any of the ECM pins again.
4. Connect welder ground clamp directly to part being welded. If this is not done, any electronic
components or bearings between the ground and the weld could be severely damaged by the
current flow from the welder.
5. Protect wiring harness and wire rope from weld spatter.
6. Use standard welding practices to weld materials. All work is to be done by a certified welder.

Electrical Components 8-5

Switch Panel

FRONT VIEW

1 1 1 1
3
2

2 2 2 2
3 3 3 3

OIL INJECTION THREAD LUBE HOLDBACK HOBO CLAMP HOBO SWING

1 1 1
3
2

2 2 2
3 3 3

MAST LOCK DUST CURTAIN POSITIONER DUST / WATER

3
2

1 1 1 1
3
2

2 2 2 2
3
2

3 3 3 3

MAIN AIR PIPE RACK PIPE RACK PIPE RACK AUX. PUMP
LOCK INDEX SWING

1 1 1 1 1

2 2 2 2 2
3 3 3 3 3

DRILL/PROPEL AUTO TOOL WINCH FAST DOWN AUTO

PULLDOWN

BACK VIEW

Fig. 8-3 SKF Switch Panel (ref. 410226)

8-6 Electrical Components

 Gauge Panel

CONTROL PANEL BREAKER

TO GROUND
IN CAB 15

51A
47A

47C 47B
47H
S
I
KEY RUN/START
G
I S S
I
AMM COIL
G
G

51C 51B 2
ACC
START
47I 47J 47K
FUEL VOLT
47D

51D TACH
47G
47E 47F
ETHER

51H

I S I S I S 51G

G G G - -
+ +
51E 51F

COMP TEMP WATER OIL ENGINE HR DRILL HR

Fig. 8-4 Gauge Panel (ref. 405306)

Electrical Components 8-7

Cab Wiring Harness
CAB WIRING (SEE SCHEMATIC #426455)
ITEM PART WIRE WIRE TERMINAL
QTY DESCRIPTION AND/OR FUNCTION
NO. NO. COLOR CODE GA. NUMBER
1 44093 8' GREEN/YELLOW 16 COMPRESSOR TEMP, FROM SENDING UNIT TO MTR. 1
2 17816 8' WHITE 16 WATER TEMP, FROM SENDING UNIT TO MTR. 2
3 17821 8' BROWN 16 FUEL, FROM SENDING UNIT TO MTR. 3
4 99329 8' BLACK/ORANGE 16 OIL PRESSURE, FROM SENDING UNIT TO MTR. 4
5 17820 8' YELLOW 16 TACH, FROM TACH SENDING UNIT TO MTR. 5
6 17819 8' RED 16 TACH, FROM MTR. TO SENDING UNIT 6
7 17814 8' BLUE 16 RUN-KEY, FROM RUN SW. TO ENGINE ECM 7
8 17817 8' GREEN 16 DIAGNOSTIC LAMP, FROM DIAG. LAMP TO ECM UNIT 8
9 88009 8' WHITE/GREEN 16 ENGINE HOUR, FROM ENGINE HR SW. TO MTR. 9
10 88010 3' GREEN/WHITE 16 DRILL HOUR, FROM DRILL HR. SW. TO MTR. N/A
12 88012 3' GREEN/BLACK 16 KEY DRILL HOUR, FROM ING. RELAY TO DRILL HR SW. N/A
13 88013 8' GREEN/RED 16 BACK-UP ALARM, FROM BACK-UP ALARM SW. TO ALARM 13
14 17814 8' BLUE 16 FROM RUN SWITCH TO THROTTLE POSITION SENSOR CNTLR. N/A
15 17823 8' GREEN 10 DRILL LIGHT POWER, FROM 50 AMP FUSE TO LIGHT RELAY 15
16 17824 8' RED 10 MAIN POWER, FROM 50 AMP FUSE TO KEYSWITCH 16
17 35399 8' BLUE 12 FROM ING. RELAY THRU STRTR BTN. TO STARTER SOL. 17
18 88015 8' GREEN/GRAY 16 FRONT LIGHTS, FROM LIGHT RELAY TO FRONT LIGHTS 18
19 99313 8' RED/WHITE 16 MAST UNLOCK, SW. TO SOL."B" 19
20 99353 8' GRAY/WHITE 16 MAST LOCK, SW. TO SOL. "A" 20
21 99351 8' GRAY/BLUE 16 MAIN AIR CLOSE, SW. TO SOL. "A" 21
22 99333 8' BLUE/YELLOW 16 MAIN AIR OPEN, SW. TO SOL. "B" 22
23 99341 8' PINK/BROWN 16 DUST COLLECTOR, SW. TO SOL. "B" 23
24 99362 8' BROWN/WHITE 16 WATER INJECTION, SW. TO SOL "A" 24

25 99348 8' PINK/BLACK 16 PIPE RACK OUT, SW. TO SOL. "A" 25

26 99330 8' BLACK/PINK 16 PIPE RACK IN, SW. TO SOL. "B" 26
27 88016 8' YELLOW/WHITE 16 PIPE RACK INDEX CW, SW. TO SOL. "A" 27
28 88017 8' YELLOW/BLACK 16 PIPE RACK INDEX CCW, SW. TO SOL. "B" 28
29 88018 8' YELLOW/BROWN 16 PIPE POSITIONER IN, SW. TO SOL. "A" 29
30 88019 8' YELLOW/RED 16 PIPE POSITIONER OUT, SW. TO SOL. "B" 30
31 88020 8' YELLOW/GREEN 16 AUTO TOOL IN, SW. TO SOL. "A" 31
32 88021 8' YELLOW/ORANGE 16 AUTO TOOL OUT, SW. TO SOL "B" 32
33 17814 8' BLUE 16 CAB TOP LIGHTS 33
35 88023 8' WHITE/YELLOW 16 DUST CURTAIN DOWN, SW. TO SOL. "B" 35
36 88024 8' WHITE/RED 16 DUST CURTAIN UP, SW. TO SOL. "A" 36
37 88025 8' WHITE/BLACK 16 PROPEL SELECT, SW. TO SOL. N/A
39 99320 8' ORANGE/BLACK 16 HOBO RELEASE, SW. TO SOL. "A" 39
40 99321 8' ORANGE/WHITE 16 HOBO CLAMP, SW. TO SOL. "B" 40
41 99331 8' BLUE/WHITE 16 HOBO SWING OUT, SW. TO SOL. "A" 41
42 99327 8' BLACK/WHITE 16 HOBO SWING IN, SW. TO SOL. "B" 42
43 99328 8' BLACK/YELLOW 16 PIPE RACK LOCK, SW. TO SOL. "A" 43
44 99352 8' GRAY/RED 16 PIPE RACK UNLOCK, SW. TO SOL. "B" 44
47 44089 16' GRAY 16 FEED TO SWITCHES ON DRILL FUNCTIN PANEL N/A
51 17818 32' BLACK 16 GND N/A

57 17824 2' RED 16 FROM KEYSWITCH TO ENGINE INGITION RELAY N/A

58 17824 2' RED 10 PWR AROUND KEYSWITCH TO IGNITION RELAY N/A

59 44089 8' GRAY 16 PWR FROM CNTRL PANEL 15 AMP FUSE TO ENGINE GAGES N/A
60 44089 3' GRAY 16 POWER FROM TACH GAGE TO PANEL LIGHTS N/A
61 99345 8' PINK/ORANGE 16 AUX. PSI, FROM SW. TO AUX. PUMP SOL. 61

62 99344 8' PINK/YELLOW 16 HOLDBACK, FROM SW. TO HOLDBACK SOL. N/A

63 99349 8' PINK/RED 16 FAST PULLDOWN SPEED, FROM SW. TO SOL. 63
64 17823 8' GREEN 10 PWR FROM DRILL LIGHT 50 AMP FUSE TO LIGHT RELAY N/A

66 88015 8' GREEN/GRAY 16 PWR FROM LIGHT SW. TO ENERGIZE LIGHT RELAY N/A
67 88015 3' GREEN/GRAY 16 FROM LIGHT SW. TO DOME LIGHT SW. N/A

68 88015 8' GREEN/GRAY 16 FROM DOME LIGHT SW. TO PWR DOME LIGHT N/A
69 88015 8' GREEN/GRAY 16 FROM 5 AMP FUSE TO DRILL LIGHT SW. N/A
71 44091 8' VIOLET 16 THRTL POS SNSR, FROM SNSR TO P61 PLUG, PIN #10 71
72 44089 8' GRAY 16 FROM INGITION RELAY TO DRILL/PROPEL SW. N/A

Fig. 8-5 Cab Wiring Harness (ref. 426517)

8-8 Electrical Components

 Cab Wiring Harness

ITEM PART WIRE WIRE TERMINAL

QTY DESCRIPTION AND/OR FUNCTION
NO. NO. COLOR CODE GA. NUMBER
73 88012 8' GREEN/BLACK 16 PWR FROM IGNITION RELAY TO REALY #2, TERMINAL #11 N/A
74 88026 8' WHITE/BROWN 16 DRILL, FROM SW. TO RELAY #2, TERMINAL #10 N/A
75 17816 8' WHITE 16 PROPEL, FROM SW. TO RELAY #3, TERMINAL #10 N/A
76 416888-019 8' YELLOW 9 18 FROM RELAY #2, TERM. #9 TO PWR. ROTATE JOYSTICK N/A
77 416888-037 8' WHITE 7 18 FROM RELAY #2, TERM. #8 TO PWR. L.H. JOYSTICK N/A
78 416888-036 2' WHITE 6 18 FROM PWR ON L.H. JOYSITCK TO PWR ON R.H. JOYSTICK N/A
79 44089 8' GRAY 16 FROM ING. RELAY TO 15 AMP CONTROL PANEL FUSE N/A
80 88015 2' GREEN/GRAY 16 JUMPER FROM 50 AMP FUSE TO PWR 15 AMP FUSE N/A
81 416888-118 8' BROWN 8 18 FROM RELAY #3, TERM #11 TO R.H. PUMP SOL. "A" 81
82 416888-114 8' BROWN 4 18 FROM RELAY #3, TERM. #1 TO R.H. PUMP SOL. "B" 82
83 416888-019 8' YELLOW 9 18 FROM RELAY #3, TERM #9 TO R.H. JOYSTICK TERM. A N/A
84 416888-098 8' GREEN 8 18 FROM RELAY #3, TERM. #8 TO ROTATE JOYSTICK TERM. A N/A
85 416888-094 8' GREEN 4 18 FROM RELAY #3, TERM. #4 TO ROTATE JOYSTICK TERM. B N/A
86 416888-013 8' YELLOW 3 18 FROM RELAY #3, TERM. #3 TO R.H. JOYSTICK TERM. B N/A
87 416888-028 8' BLUE 8 18 FROM L.H. JOYSTICK TERM. A TO L.H. PUMP SOL. "A" 87

88 416888-024 8' BLUE 4 18 FROM L.H. JOYSTICK TERM. B TO L.H. PUMP SOL. "B" 88
89 416888-066 8' GRAY 6 18 FROM RELAY #4, TERM. #6 TO ROTATE JOYSTICK PWR N/A

95 416888-072 8' PINK 2 18 FROM PULLDOWN JOYSTICK TERM. B TO UP PULLDOWN VLV 95

96 416888-076 8' PINK 6 18 FROM PULLDOWN JOYSTICK TERM. A TO DWN PULLDOWN VLV 96
97 416888-040 8' PURPLE 18 FROM HOIST JOYSTICK TO AUTO SW. N/A
98 416888-040 8' PURPLE 18 FROM AUTO SW. TO CARD TERM. (+) N/A
99 416888-070 8' PINK 0 18 FROM AUTO CARD "A" TO HOIST/PLDWN JOYSTCIK TERM. A N/A
100 44089 8' GRAY 16 FROM RUN START SW. TO IGNITION RELAY N/A
101
102

103
104

105
106
107
108
109
110 45259 300 N/A N/A TERMINAL, SPADE, 3/16" STUD, 16/14 N/A
111 45258 4 N/A N/A TERMINAL, SPADE, 3/16" STUD, 10/12 N/A
112 45255 13 N/A N/A TERMINAL, 5/16" RING, 16/14 N/A
113 45251 1 N/A N/A TERMINAL, 5/16" RING, 12/10 N/A
114 45261 10 N/A N/A TERMINAL, BUTT, 16/14 N/A
115 45260 1 N/A N/A TERMINAL, BUTT, 10/12 N/A
116 350477 2 N/A N/A CONNECTOR, CROUSE HIN N/A
117 98241 1 N/A N/A CONNECTOR, DIN N/A

Fig. 8-5 Cab Wiring Harness (cont.)

Electrical Components 8-9

Cab/Engine Wiring
CAB/ENGINE WIRING (SEE SCHEMATIC #426455)

ITEM PART WIRE WIRE TERMINAL

QTY DESCRIPTION AND/OR FUNCTION
NO. NO. COLOR CODE GA. NUMBER
1 44093 35' GREEN/YELLOW 16 COMPRESSOR TEMP, FROM SENDING UNIT TO MTR. 1
2 17816 35' WHITE 16 WATER TEMP, FROM SENDING UNIT TO MTR. 2
3 17821 35' BROWN 16 FUEL, FROM SENDING UNIT TO MTR. 3
4 99329 35' BLACK/ORANGE 16 OIL PRESSURE, FROM SENDING UNIT TO MTR. 4
5 17820 35' YELLOW 16 TACH, FROM TACH SENDING UNIT TO MTR. 5
6 17819 35' RED 16 TACH, FROM MTR. TO SENDING UNIT 6
7 17814 35' BLUE 16 RUN-KEY, FROM RUN SW. TO ENGINE ECM 7
8 17817 35' GREEN 16 DIAGNOSTIC LAMP, FROM DIAG. LAMP TO ECM UNIT 8
9 88009 35' WHITE/GREEN 16 ENGINE HOUR, FROM ENGINE HR SW. TO MTR. 9
13 88013 40' GREEN/RED 16 BACK-UP ALARM, FROM BACK-UP ALARM SW. TO ALARM 13
15 17823 35' GREEN 10 DRILL LIGHT POWER, FROM 50 AMP FUSE TO LIGHT RELAY 15
16 17824 35' RED 10 MAIN POWER, FROM 50 AMP FUSE TO KEYSWITCH 16
17 35399 35' BLUE 12 FROM ING. RELAY THRU STRTR BTN. TO STARTER SOL. 17
18 88015 25' GREEN/GRAY 16 FRONT LIGHTS, FROM LIGHT RELAY TO FRONT LIGHTS 18
51 17818 70' BLACK 16 GND N/A

52 44093 10' GREEN/YELLOW 16 FROM 50 AMP FUSE TO ENGINE HR. MTR. 52

53 44080 3' RED 6 FROM (+) LEAD ON STARTER TO (+) LEAD ON ALTERNATOR N/A

54 346854 3' RED 14 FROM P61 PLUG, PIN #1 TO 15 AMP FUSE N/A
55 346854 3' RED 14 FROM P61 PLUG, PIN #31 TO 15 AMP FUSE N/A
56 346854 3' RED 14 FROM P61 PLUG, PIN #32 TO 15 AMP FUSE N/A

71 44090 35' ORANGE 16 THROTTLE POS. SNSR., FROM SNSR TO P61 PLUG, PIN#10 71
101 17818 10' BLACK 16 FROM P61 PLUG, PIN #27 TO COMP. TEMP. SW. N/A
102 17824 3' RED 10 FROM STARTER TO 15 AMP FUSE N/A

104 305982 3' BLACK 6 FROM (-) LEAD ON ALT. TO (-) LEAD ON STARTER N/A

105 17818 15' BLACK 16 FROM (-) LEAD ON STARTER TO (-) LEAD ON BAT #1 N/A
107 423294 3' RED 000 FROM (+) LEAD ON BAT #1 TO (-) LEAD ON BAT #2 N/A
108 423294 15' RED 000 FROM (+) LEAD ON BAT #2 TO (+) LEAD ON STARTER SOL. N/A
109 44080 8' RED 6 FROM (+) LEAD ON STARTER TO 50 AMP FUSE N/A
110 96331 3' BLACK 000 FROM GND ON STARTER TO GND ON STARTER SOL. N/A
111
112
113
114
115
116
117
118
119
120 45261 27 N/A N/A TERMINAL, BUTT, 16/14 N/A
121 45259 45 N/A N/A TERMINAL, 3/16" SPADE, 16/14 N/A
122 45254 9 N/A N/A TERMINAL, 3/8" RING, 16/14 N/A
123 45249 2 N/A N/A TERMINAL, 1/2" RING, 10/12 N/A
124 45258 14 N/A N/A TERMINAL, 3/16" SPADE, 10/12 N/A
125 45246 8 N/A N/A TERMINAL, 1/2" RING, #6 N/A
126 96332 2 N/A N/A BATTERY END, POSITIVE N/A
127 96333 2 N/A N/A BATTERY END, NEGATIVE N/A
128 17830 2 N/A N/A EYELETS N/A
129 57860 20' N/A N/A CONDUIT, 1" N/A
130 57854 2 N/A N/A CONNECTOR, CONDUIT, 1" N/A
131 95129 9 N/A N/A CONNECTOR, 2-WAY, MALE N/A
132 95128 9 N/A N/A CONNECTOR, 2-WAY, FEMALE N/A

Fig. 8-6 Cab/Engine Wiring (ref. 426518)

8-10 Electrical Components

 Cab/Mast Valve & Pump Wiring

A B A B

70
72
WIRING, CAB/MAST VALVE
(SEE SCHEMATIC 426455)
A B A B
GRAY/WHITE RED/WHITE GROUND/BLACK
20 19 51 ITEM PART WIRE WIRE TERMINAL
MAST LOCK MAST UNLOCK QTY DESCRIPTION AND/OR FUNCTION
NO. NO. COLOR CODE GA. NUMBER
69
19 99313 17' RED/WHITE 16 MAST UNLOCK, SW. TO SOL."B" 19
YELLOW/WHITE, PIPE RACK INDEX CW HOBO CLAMP, ORANGE/WHITE 20 99353 17' GRAY/WHITE 16 MAST LOCK, SW. TO SOL. "A" 20
27 40
WINCH DOWN OPT. HOBO SWING IN, BLACK/WHITE 25 99348 17' PINK/BLACK 16 PIPE RACK OUT, SW. TO SOL. "A" 25
42
BLUE/WHITE, HOBO SWING OUT AUTO TOOL IN, YELLOW/GREEN 26 99330 17' BLACK/PINK 16 PIPE RACK IN, SW. TO SOL. "B" 26
41 31
PINK/BLACK, PIPE RACK SWING OUT PIPE RACK UNLOCK, GRAY/RED 27 27
25 44 88016 17' YELLOW/WHITE 16 PIPE RACK INDEX CW, SW. TO SOL. "A"
28 88017 17' YELLOW/BLACK 16 PIPE RACK INDEX CCW, SW. TO SOL. "B" 28
68
29 88018 17' YELLOW/BROWN 16 PIPE POSITIONER IN, SW. TO SOL. "A" 29

BLACK/PINK, PIPE RACK SWING IN HOBO RELEASE, ORANGE/BLACK 30 88019 17' YELLOW/RED 16 PIPE POSITIONER OUT, SW. TO SOL. "B" 30
26 39
YELLOW/BROWN, PIPE POSITIONER IN PIPE RACK INDEX CCW, YELLOW/BLACK 31 88020 17' YELLOW/GREEN 16 AUTO TOOL IN, SW. TO SOL. "A" 31
29 28
BLACK/YELLOW, PIPE RACK LOCK PIPE POSITIONER OUT, YELLOW/RED 32 88021 17' YELLOW/ORANGE 16 AUTO TOOL OUT, SW. TO SOL "B" 32
43 30
YELLOW/ORANGE, AUTO TOOL OUT WINCH UP OPT. 39 99320 17' ORANGE/BLACK 16 HOBO RELEASE, SW. TO SOL. "A" 39
32
40 99321 17' ORANGE/WHITE 16 HOBO CLAMP, SW. TO SOL. "B" 40
41 99331 17' BLUE/WHITE 16 HOBO SWING OUT, SW. TO SOL. "A" 41

MAST HARNESS 42 99327 17' BLACK/WHITE 16

16
HOBO SWING IN, SW. TO SOL. "B" 42
43 99328 17' BLACK/YELLOW PIPE RACK LOCK, SW. TO SOL. "A" 43
44 99352 17' GRAY/RED 16 PIPE RACK UNLOCK, SW. TO SOL. "B" 44
51 17818 34' BLACK 16 GND N/A
52
53
54
55
A B A B
56
70
72 57
58
59
60
A B A B
61
GROUND/BLACK GRAY/WHITE RED/WHITE
51 20 19 62 45259 32 N/A N/A TERMINAL 3/16 STUD 16/14 N/A
MAST LOCK MAST UNLOCK
68 63 35659 13' N/A N/A CONDUIT-3/4" N/A
64 56780 2 N/A N/A CONNECTOR-STR-CONDUIT-3/4" N/A
HOBO CLAMP, ORANGE/WHITE YELLOW/WHITE, PIPE RACK INDEX CW
40 27 65 350477 16 N/A N/A CONNECTOR-CROUSE HIN N/A
HOBO SWING IN, BLACK/WHITE WINCH DOWN OPT.
42 66 320167 1 N/A N/A COUPLING-PIPE-3/4" N/A
AUTO TOOL IN, YELLOW/GREEN BLUE/WHITE, HOBO SWING OUT
31 41 67 39999 5 N/A N/A P CLAMP-1.06 N/A
PIPE RACK UNLOCK, GRAY/RED PINK/BLACK, PIPE RACK SWING OUT
44 25 68 95124 2 N/A N/A CONNECTOR-8 WAY-MALE N/A

69 69 95126 2 N/A N/A CONNECTOR-FEMALE-8 WAY N/A

70 95129 2 N/A N/A CONNECTOR-2 WAY-MALE N/A

HOBO RELEASE, ORANGE/BLACK BLACK/PINK, PIPE RACK SWING IN 71 95125 20 TERMINAL-MALE
39 26 N/A N/A N/A
PIPE RACK INDEX CCW, YELLOW/BLACK YELLOW/BROWN, PIPE POSITIONER IN 72 95128 2 CONNECTOR-2 WAY-FEMALE
28 29 N/A N/A N/A
PIPE POSITIONER OUT, YELLOW/RED BLACK/YELLOW, PIPE RACK LOCK 73 20 N/A N/A N/A
30 43 95127 TERMINAL-FEMALE
WINCH UP OPT. YELLOW/ORANGE, AUTO TOOL OUT
32

MAST VALVE

Fig. 8-7 Cab/Mast Valve Wiring (ref. 426520)

WIRING, PUMPS
(SEE SCHEMATIC #426455)

ITEM PART WIRE WIRE TERMINAL

QTY DESCRIPTION AND/OR FUNCTION
NO. NO. COLOR CODE GA. NUMBER
51 17818 100' BLACK 16 GND N/A
81 416888-114 25' BROWN #4 18 PWR TO R.H. TRAM/ROTATE PUMP SOL. "A" 81
82 416888-118 25' BROWN #8 18 PWR TO R.H. TRAM/ROTATE PUMP SOL. "B" 82
87 416888-044 25' PURPLE #4 18 PWR TO L.H. TRAM/ROTATE PUMP SOL. "A" 87
88 416888-048 25' PURPLE #8 18 PWR TO L.H. TRAM/ROTATE PUMP SOL. "B" 88
89
90 60666 1 N/A N/A CONNECTOR, 1/2" STR, 3/8 I.D. N/A
91 56719 1 N/A N/A CONNECTOR, STR, 1/2", SEALTITE N/A
92 54430 15' N/A N/A CONDUIT, 1/2", SEALTITE N/A
93 344929 6' N/A N/A LOOM, 1/4" SPLIT N/A
94 95129 4 N/A N/A CONNECTOR, 2-WAY MALE N/A
95 95128 4 N/A N/A CONNECTOR, 2-WAY, FEMALE N/A
96 45254 4 N/A N/A TERMINAL, RING, 3/8 STUD, 16/14 N/A
97 45259 12 N/A N/A TERMINAL, SPADE, 3/16 STUD, 16/14 N/A
98 350477 4 N/A N/A CONNECTOR, CROUSE HIN N/A
99 320354 2 N/A N/A CLAMP, TUBING, 1" N/A
100 347037 2 N/A N/A WELD STUD 3/8-16UNC X 1" LG N/A
101 45261 8 N/A N/A TERMINAL, BUTT, 16/14 N/A

Fig. 8-8 Pump Wiring (ref. 426521 rev. A)

Electrical Components 8-11

Pulldown Valve & Engine Wiring

WIRING, PULLDOWN VALVES

(SEE SCHEMATIC #426455)

ITEM PART WIRE WIRE TERMINAL

QTY DESCRIPTION AND/OR FUNCTION
NO. NO. COLOR CODE GA. NUMBER
51 17818 40' BLACK 16 GND N/A
95 416888-072 20' PINK #2 18 PWR FROM PULLDOWN JOYSTICK TO PULLDOWN VLV, DOWN 95
96 416888-076 20' PINK #6 18 PWR FROM PULLDOWN JOYSTICK TO PULLDOWN VLV. UP 96
97
98
99
100 344929 6' N/A N/A LOOM, 1/4" SPLIT N/A
101 323194 1 N/A N/A CONNECTOR, 1/2" STR, 1/4" I.D. N/A
102 95129 2 N/A N/A CONNECTOR, 2-WAY, MALE N/A
103 95128 2 N/A N/A CONNECTOR, 2-WAY, FEMALE N/A
104 45254 2 N/A N/A TERMINAL RING, 3/8 STUD, 16/14 N/A
105 45259 6 N/A N/A TERMINAL, SPADE, 3/16 STUD, 16/14 N/A
106 350477 2 N/A N/A CONNECTOR, CROUSE HIN N/A

Fig. 8-9 Pulldown Valve Wiring (ref. 426522)

WIRING, ENGINE HOUR METER

(SEE SCHEMATIC #426455)
ITEM PART WIRE WIRE TERMINAL
QTY DESCRIPTION AND/OR FUNCTION
NO. NO. COLOR CODE GA. NUMBER
9 88009 30' WHITE/GREEN 16 ENGINE HOUR 9
51 17818 30' BLACK 16 GND 51
52 99355 30' GRAY/YELLOW 16 PWR TO PRESS SWITCH 52
53
54
55
56
57
58
59
60 344929 10' N/A N/A LOOM, 1/4" SPLIT N/A
61 45259 8 N/A N/A TERMINAL, 3/16" SPADE, 16/14 N/A
62 45254 1 N/A N/A TERMINAL, 3/8" STUD, 16/14 N/A
63 347072 1 N/A N/A SWITCH, PRESSURE N/A
64 17702 1 N/A N/A BUSHING N/A

Fig. 8-10 Engine Hour Meter Wiring (ref. 426524)

8-12 Electrical Components

 Auxiliary Pump & Water/DC Valve Wiring
WIRING, AUX. PRESSURE PUMP
(SEE SCHEMATIC #426455)

ITEM PART WIRE WIRE TERMINAL

QTY DESCRIPTION AND/OR FUNCTION
NO. NO. COLOR CODE GA. NUMBER
51 17818 30' BLACK 16 GND N/A
61 99345 15' PINK/ORANGE 16 AUX. PRESS. PUMP 61
62
63
64
65
66
67
68
69
70 54430 15' N/A N/A CONDUIT, 1/2" N/A
71 56719 2 N/A N/A CONNECTOR, CONDUIT, 1/2" STR N/A
72 350477 1 N/A N/A CONNECTOR, CROUSE HINDE N/A
73 347037 1 N/A N/A WELD STUD, 3/8-16UNC X 1" LG N/A
74 46103 1 N/A N/A CLAMP, TUBING, 1" N/A
75 45259 3 N/A N/A TERMINAL, SPADE, 3/16" STUD, 16/14 N/A
76 45261 2 N/A N/A TERMINAL, BUTT, 16/14 N/A
77 95129 1 N/A N/A CONNECTOR, 2-WAY, MALE N/A
78 95128 1 N/A N/A CONNECTOR, 2-WAY, FEMALE N/A

Fig. 8-11 Auxiliary Pressure Pump Wiring (ref. 426525)

WATER & DUST COLLECTOR VALVE WIRING 410089

(SEE SCHEMATIC #426455)
ITEM PART WIRE WIRE TERMINAL
QTY DESCRIPTION AND/OR FUNCTION
NO. NO. COLOR CODE GA. NUMBER
23 99341 15' PINK/BROWN 16 DUST COLLECTOR 23
24 99361 15' BROWN/WHITE 16 WATER INJECTION 24
51 17818 30' BLACK 16 GND N/A
52
53
54
55
56
57
58
59
60 54430 15' N/A N/A CONDUIT, 1/2" N/A
61 56719 2 N/A N/A CONNECTOR, CONDUIT, 1/2" STR N/A
62 350477 2 N/A N/A CONNECTOR, CROUSE HINDE N/A
63 45254 2 N/A N/A TERMINAL, 3/8" STUD, 16/14 N/A
64 45259 6 N/A N/A TERMINAL, SPADE, 3/16" STUD N/A
65 320354 2 N/A N/A CLAMP, TUBING, 1" N/A
66 347037 1 N/A N/A WELD STUD, 3/8-16UNC X 1" LG N/A
67 95129 2 N/A N/A CONNECTOR, 2-WAY, MALE N/A
68 95128 2 N/A N/A CONNECTOR, 2-WAY, FEMALE N/A
69 344929 8' N/A N/A LOOM 1/4" SPLIT N/A
70 323194 1 N/A N/A CONNECTOR, CONDUIT, STR., 1/4" I.D. N/A

Fig. 8-12 Water and Dust Collector Valve Wiring (ref. 426526 rev. A)

Electrical Components 8-13

Fast Pulldown & Lights Wiring
WIRING, FAST PULLDOWN 410666
(SEE SCHEMATIC #426455)

ITEM PART WIRE WIRE TERMINAL

QTY DESCRIPTION AND/OR FUNCTION
NO. NO. COLOR CODE GA. NUMBER
51 17818 30' BLACK 16 GND N/A
63 99349 15' PINK/RED 16 FAST PULLDOWN 63
64
65
66
67
68
69
70 54430 15' N/A N/A CONDUIT, 1/2" N/A
71 59347 2 N/A N/A CONNECTOR, CONDUIT, 1/2" 90 DEG N/A
72 350477 2 N/A N/A CONNECTOR, CROUSE HINDE N/A
73 45254 2 N/A N/A TERMINAL, 3/8" STUD, 16/14 N/A
74 45259 4 N/A N/A TERMINAL, SPADE, 3/16" STUD N/A
75 320354 2 N/A N/A CLAMP, TUBING, 1" N/A
76 347037 1 N/A N/A WELD STUD, 3/8-16UNC X 1" LG N/A
77 95129 2 N/A N/A CONNECTOR, 2-WAY, MALE N/A
78 95128 2 N/A N/A CONNECTOR, 2-WAY, FEMALE N/A
79 344929 8' N/A N/A LOOM 1/4" SPLIT N/A
80 323194 1 N/A N/A CONNECTOR, CONDUIT, STR., 1/4" I.D. N/A

Fig. 8-13 Fast Pulldown Wiring (ref. 426527)

WIRING, CAB TOP LIGHTS

(SEE SCHEMATIC #426455)

ITEM PART WIRE WIRE TERMINAL

QTY DESCRIPTION AND/OR FUNCTION
NO. NO. COLOR CODE GA. NUMBER
33 17814 30' BLUE 16 POWER FROM LIGHT RELAY TO CAB TOP LIGHTS N/A
51 17818 20' BLACK 16 GND N/A
52
53
54
55
56
57
58
59
60 60666 1 N/A N/A CONNECTOR, 1/2" STR, 3/8 I.D. N/A
61 344929 20' N/A N/A LOOM, 1/4" SPLIT N/A
62 95129 2 N/A N/A CONNECTOR, 2-WAY MALE N/A
63 95128 2 N/A N/A CONNECTOR, 2-WAY, FEMALE N/A
64 45254 6 N/A N/A TERMINAL, RING, 3/8 STUD, 16/14 N/A
65 45259 4 N/A N/A TERMINAL, SPADE, 3/16 STUD, 16/14 N/A
66 45261 8 N/A N/A TERMINAL, BUTT, 16/14 N/A

Fig. 8-14 Cab Top Lights Wiring (ref. 426686)

8-14 Electrical Components

 Battery/Engine Disconnect

OPTIONAL STANDARD
BATTERY BOX BATTERY BOX DISCONNECT
SWITCH

BATTERY BOX
TOP VIEW

STARTER
G + S SOLENOID
+

G STARTER
BLK 000
RED 000
RED 000

105 REF
108 REF
REF143
OPTIONAL
REF MASTER
BLK 000 DISCONNECT
SWITCH
141 OPTIONAL MASTER
REF DISCONNECT SWITCH
7 6 160 BLK 000
RED 000 142
REF
107 RED 000

NOTES:
BAT#4 BAT#3 BAT#2 BAT#1 1. REF ELECTRICAL SCHEMATIC #426455.
OPTIONAL 2. XX = WIRE NUMBER ON SCHEMATIC.

BATTERIES
OPTIONAL
BATTERIES
3&4

Fig. 8-15 Battery/Engine Disconnect Installation and Wiring (ref. 426598 rev. C)

Electrical Components 8-15

Filter/Indicator Wiring
LOOP LOOP LOOP LOOP LOOP CHARGE CHARGE MAIN MAIN CASE COMPRESSOR
FILTER FILTER FILTER FILTER FILTER FILTER FILTER FILTER FILTER FILTER FILTER
#1 #2 #3 #4 #5 #1 #2 #1 #2

NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO

C C C C C C C C C C C
BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK
WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE
RED

RED

RED

RED

RED

RED

RED

RED

RED

RED

RED
BLACK-16 GA

BLACK-16 GA

BLACK-16 GA

BLACK-16 GA

BLACK-16 GA

BLACK-16 GA

BLACK-16 GA

BLACK-16 GA

BLACK-16 GA

BLACK-16 GA

BLACK-16 GA
GREEN-16 GA

GREEN-16 GA

GREEN-16 GA

GREEN-16 GA

GREEN-16 GA

GREEN-16 GA

GREEN-16 GA

GREEN-16 GA

GREEN-16 GA

GREEN-16 GA

GREEN-16 GA
WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA
LOOP#1
1
LOOP#2
LOOP #1 LOOP#3
1 2
LOOP#4
LOOP#2 LOOP#5
2 3
CHARGE#1
LOOP#3 CHARGE#2
3 4
MAIN #1
LOOP#4 MAIN #2
4 5
CASE
LOOP#5 COMP
5 6
CHARGE#1 LOOP#1
6 7
LOOP#2
CHARGE#2 LOOP#3
7 8
LOOP#4
MAIN #1 LOOP#5
8 9
CHARGE#1
MAIN #2 CHARGE#2
9 10
MAIN #1
CASE MAIN #2
10 11
CASE
COMP COMP
11 12

TERMINAL BOX
GRY/GR-16 GA

GRY/BLK-16 GA
WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

WHITE-16 GA

KEY
LOOP LOOP LOOP LOOP LOOP CHARGE CHARGE MAIN MAIN CASE COMPRESSOR
FILTER FILTER FILTER FILTER FILTER FILTER FILTER FILTER FILTER FILTER FILTER
#1 #2 #3 #4 #5 #1 #2 #1 #2
CAB CONSOLE

Fig. 8-16 Filter/Indicator Wiring (ref. 400346 rev. G)

8-16 Electrical Components

 Rotary Drive Tachometer Installation

DIGITAL TACHOMETER

MAGNETIC
LST-100

SENSOR
RPM
DYNALCO

INSTRUMENT CONSOLE

}
A
MAGNETIC PICKUP
B

}
1 + 10 TO 30 Vdc
A - POWER INPUT 1 2 3 4 5 6
N.

A B
IG

}
2 115 Vac GREY
D.

SENDOR
R

POWER INPUT
GN

DO

3
(NOT USED IN "L" VERSION)
SEN

4 BLACK

5
) JUMPER FOR X10 DISPLAY RED YELLOW

6 ) JUMPER FOR X100 DISPLAY

BACKSIDE TACHOMETER

Fig. 8-17 Rotary Drive Tachometer (Ref. 413279 rev. B)

Electrical Components 8-17

AC/Heater Wiring

REF
OPTIONS
RED 14
RELAY
RED 12
M 192 10
159
BLU 14

197 PRESSURIZER
FAN MOTOR RED 14
194 15

193
RESISTOR
RED 14
M
HIGH (ORANGE)
LOW (YELLOW)

MED (RED)

REF
CAB JUNCTION
BOX TERMINALS
RED 14 RED 14
OFF

PWR TO AC CONDENSOR 192

YLW 14 YLW 14 YLW 14
195 PWR TO BINARY SW. 195
GRN 14 GRN 14
PWR TO AC CLUTCH 196 196
ROTARY A/C THERMOSTAT
SWITCH TOGGLE SHITCH
REF
A/C HEATER UNIT ENGINE JUNCTION
BOX TERMINAL
GRN 14
AC CLUTCH 196 196

A/C COMPRESSOR
GRN 14 CLUTCH

196
NOTES:
1. REF ELECTRICAL SCHEMATIC #426455.
2. XX
= WIRE NUMBER ON SCHEMATIC.
3. XX = TERMINAL STRIP CONNECTION ON SCHEMATIC. RED 14

192

85 87 87a 85 87 87a

M
86 30 86 30

RELAY RELAY
YEL 14
195

LOW HIGH
PRESS PRESS
BINARY SWITCH

A/C CONDENSER
OPENS CLOSES
30-15 PSIG 40 PSIG MAXIMUM
LOW PRESSURE PROTECTION (FALLING PRESSURE) (RISING PRESSURE)
HIGH PRESSURE PROTECTION 270-330 PSIG 70-90 PSIG BELOW
(RISING PRESSURE) (OPENING PRESSURE)

Fig. 8-18 AC/Heater Wiring (Ref. 435130 rev. D)

8-18 Electrical Components

 24/12 VDC Converter

+POWER
FROM OPTIONS
RELAY
58 172

WIRING DIAGRAM

ENTERTAINMENT RADIO/CD
+ YEL -
163 +12VDC
24/12VDC 162 RED 16 201 ENTERTAINMENT
RED 18
ORG 14 CONVERTER 5A RADIO/CD PLAYER
418334 - +
2 1
MEMORY -
198 ORG 18 MODULE
BLK
ORG +24VDC SM2412-M
421289

162 RED 16 CB BLK 16 CB

5A
RADIO RADIO
401337

REF CAB ASSY

AIR WATER OIL HOURS HOURS

TEMP TEMP PRESSURE

RPM X 0

BATTERY
A

PWR TO 12VDC
5 AMP BREAKER
PWR FROM
OPTIONS RELAY

CONVERTER, ELECTRONIC, DC/DC-10A

17 18

NOTES:
1. REF ELECTRICAL SCHEMATIC #433752.

Fig. 8-19 24/12 VDC Converter (Ref. 426790 rev. B)

Electrical Components 8-19

Sound System

RADIO

SPEAKERS

Fig. 8-20 Sound System Installation (Ref. 418695 rev. C)

8-20 Electrical Components

 Electrical Schematic–SKF/SKFX
OPTIONAL

NOTE: See Parts Manual to establish the

BATTERY JUMP START

15

correct drawings for your machine.

58 79

PB2
12 VDC 12 VDC
186 186 RED 16 OPTIONAL
HRN
142 ATTENTION HORN
OPTIONAL ADDITIONAL BATTERIES 96908
RED 000 42259
141 143
PS2
STANDARD-2) 8D 12V BATTERIES
BATTERY 12 GRN/BLK 16 10 GRN/WHT 16
DISCONNECT 12 VDC 12 VDC HRM DRILL HOUR
SWITCH N0 METTER
108 RED 000 107 BLK 000 105 96192
168437
RED 000 PS3
425881 41758 12 GRN/BLK 16 13 GRN/RED 16
FRONT
N0 TRAM ALARM
S2T 32817
108 RED 000 105
M TOP STARTER 69499
BLK 000 MOTOR
REAR
TRAM ALARM
32817
S1T
110
S2T TOP STARTER
BLK 000 TS1 DRILL
SOLENOID 74 WHT/BLK 16 (SXL)
R2 ROTATE/DC SIDE PROPEL
72 GRY 16 10 2 JOYSTICK RELAY
340440
340997 PROPEL
S2B 37 WHT/BLK 16 (SXL)
108 RED 000 105 DCV DRILL/PROPELL ENGERGIZE TO DRILL
M BOTTOM STARTER
BLK 000 DIVERTER VALVE DE-ENERGIZED TO PROPEL
MOTOR

OPTIONAL DUAL STARTERS SKF-SKF11-410280

S1B SKF12/15 PILOT (SKF12/15 ONLY)
110 SKF12/15-428764 (V17) CONTROL MANIFOLD
S2B BOTTOM STARTER
BLK 000 SOLENOID CARTIRDGE (V17)
109
RED 6

224 WHT/BLK 16
DCV PARKING BRAKE ENGERGIZE TO RELEASE BRAKE
RELEASE VALVE DE-ENERGIZED TO DRILL
53 RED 4 B+ B- 104
ALT ALTERNATOR 433410
OPTIONAL SIGMA BLK 4
(LOCATED IN ENGINE
A/C SYSTEM BUSS
CIRCUIT BREAKER SKID JUNCTION BOX)

60A A/C SYSTEM BUSS

CATERPILLAR
SEE SHEET 5
WIRING HARNESS
ENGINE ECM
J2/P2
CIRCUIT BREAKER
P61/J61
102
75 WHT (#0) 18 FEED/CAB SIDE PROPEL
56 RED 14 R3
15A +BAT (UNSWITCHED) 32 32 10 2 JOYSTICK RELAY
55 RED 14 CATERPILLAR
57913 +BAT (UNSWITCHED) 31 31 ECM
207 340440
REMOTE SHUTDOWN SW 27 27
7
RED 6 +BAT (SWITCHED) 26 26
8 GRN 16 J1/P1
DIAGNOSTIC LAMP 24 24
203
109

71
THROTTLE POSITION SENSOR 10 10
54 RED 14
OPTIONAL +BAT (UNSWITCHED) 1 1
REMOTE CATERPILLAR ENGINE
60A

60A

ENGINE SKID ELECTRONICS GROUND STUD

CIRCUIT BREAKER
START ENGINE CONTROL MODULE
CIRCUIT BLK 16
BREAKER PROPEL INTERLOCK
CAT SUPPLIED ENGINE SERVICE TOOL CONNNECTION PIPE IN THE HOLE
204
16

R1 LIGHT (LIGHT ON INDICATES

CAT SUPPLIED TERMINATION RESISTOR NC 9 GRY (#9) 18
PIPE PRESENT)
RED 10

4 1
THROTTLE POSITION SENSOR RED
14 BLU 16 416873
+ - THROTTLE POSITION
BLK 16 SENSOR
R1 PROPEL INTERLOCK
71 PRP 16
SIGNAL 10 2 RELAY
LOAD
+
INTERSTAGE TEMP HIGH PRESSURE COMP NC 2 139 RED/GRN 16 340440
100
R DIAGNOSTIC LAMP HIGH PRESSURE COMPRESSOR ONLY V000898 1 + NO 4
7 BLU 16 250 F 265 F
COMPRESSOR OVER - 3 BLK 16 PROPEL INTERLOCK
NC NC TEMPERATURE SWITCH PIPE IN THE HOLE
ENGINE SHUTDOWN ENGINE SHUTDOWN 83327 ENGINE SHUTDOWN 65237 240 F PROXIMITY SWITCH
CAB ENGINE SKID DECK MOUNT LOW PRESSURE 410482

RED/BLK16
COMP 134 GRN (#7) 18
7 BLU 16
OPTIONAL PROPEL INTERLOCK
REMOTE START 135 BLK 16 PIPE IN THE HOLE
REMOTE ENGINE
KEY SWITCH STOP SWITHCES LIGHT (LIGHT ON INDICATES
GRN
OFF ON + JACKS UP)

140
R R R 416874
133 BRN

432407 432407 432407 TAN/RED 16 DCS DE JACK UP

136 PPL/GRN 16 PROX SWITCH
207 BLU 16 VOLTMETER
16864 S G BLK 16 418673 136
EITHER 319240 BLU PPL/WHT 16
INJECTION L OPTIONAL
PB 319151
EITHER INJECTION PROPEL INTERLOCKS
GRN/BRN 16
ETH SOLENOID VALVE +

79
(MAY ALSO BE BRN
42259 BLK
LOCATED IN CAB) DCS NDE JACK UP

GRN/BLK 16
REMOTE LOCATED AT ENGINE PROX SWITCH
REMOTE START SOLENOID START
418673 136
CIRCUIT BREAKER PB
205 206 190 WHT/BLU 16 BLU TAN/GRN 16
GRN 12 GRN 12 ENGINE HOUR
15A HRM
METER (ENGINE)
42259 96192
+
BRN
PS1 R2 R1 BLK
CS NDE JACK UP
73 NC NO
52 GRN/BLK 16 9 WHT/GRN 16
ENGINE HOUR PROX SWITCH
N0
HRM 11 8 7 6
METER (CONSOLE)
418673 136
96192 77 WHT (#7) 18
BLU
100

168437 PPL/YLW 16
DUST COLLECTOR TIMER
BLU 16

190 WHT 16 191

OPTIONAL
+
KEY SWITCH + - DUST COLLECTOR

WHT (#6) 18
GRY (#0) 18
BLK 16 BRN
OFF ON TIMER BLK
CS DE JACK UP
MAIN POWER IGNITION CONTACTOR
KS1
CIRCUIT BREAKER CIRCUIT BREAKER PROX SWITCH
16 16 RED 10 57 GRY/PNK 16
50A 15A S3 IGNITION SOLENOID 418673 136
CONTACTOR

73
57913 BLU TAN/YLW 16
47840
58

16864

57 RED 16 OPTIONAL
S4
RED 10

SIGMA A/C SOLENOID

47840 CONTACTOR
START
STARTER SOLENOID
PB1 CIRCUIT BREAKER
S3
58 17 17 BLU 12
15A S1T TOP OR SINGLE
STARTER SOLENOID 15 58 79 73 59
57913
42259 47840
79

S1B BOTTOM
GRN/BLK 16

STARTER SOLENOID
47840 INDICATES WIRE COLOR WITH (NUMBER) - PNK (#2) 18 NOTE: DO NOT USE P/N'S TO ORDER REPLACEMENT PARTS
ORDER REPLACEMENT PARTS FROM MACHINE PARTS BOOK Ref. 433752 rev. 06 (1 of 6)
15 58 79

Electrical Components 8-21

 Electrical Schematic–SKF/SKFX
15 58 79 73 59
15 58 79 47 59

2 WHT 16 ENGINE COOLANT

TEMP SENDER
59 GRY 16 S G BLK 16 319153
ENGINE COOLANT
319240 TEMP GAUGE
L
60 GRY 16
440314 319147
3 BRN 16 FUEL TANK
NO NC NC NO
LEVEL SENDER
SPRING RETURN HANDLE 59 GRY 16 S G BLK 16 84609
FUEL TANK
LOCKING CENTER POSITION
319240 LEVEL GAUGE
C C L
60 GRY 16
+ A X B - DC SIDE PROPEL 96193
4 BLK/ORG 16
JOYSTICK ENGINE OIL
PRESSURE SENDER
59 GRY 16 S G BLK 16 319152
ENGINE OIL
A 319240 PRESSURE GAUGE
87 BLU (#8) 18

WHT (#6) 18
DCV DC SIDE MAIN PUMP L
60 GRY 16
319145

59 GRY 16 S G BLK 16
VOLTMETER
88 BLU (#4) 18
DCV DC SIDE MAIN PUMP

78
L
B 60 GRY 16
440314 319151
6 RED 16
V014499
NO NC NC NO S
TACHOMETER
SPRING RETURN HANDLE 59 GRY 16 G 5 YLW 16
LOCKING CENTER POSITION I
413271
C C L
60 GRY 16
+ A X B - CAB SIDE PROPEL 96194

GRN 10
JOYSTICK
DRILL LIGHT CAB ROOF
MAIN POWER CAB ROOF LIGHT
81 A CIRCUIT BREAKER CIRCUIT BREAKER LIGHT, RIGHT REAR
R3 S5

15
83 YLW (#9) 18 NO BRN (#8) 18 64 GRN 10 33 33 BLU/GRY 16
DCV CAB SIDE MAIN PUMP 50A 15A
9 11 57913
57912 75321
CAB ROOF
86 82
R3 LIGHT, LEFT REAR
YLW (#3) 18 NO BRN (#4) 18
DCV CAB SIDE MAIN PUMP
3 1 B
81
R3 75321
GRY (#0) 18

84 GRN (#8) 18 NC V014499 CAB ROOF

8 11
LIGHT, RIGHT FRONT

R3 82
85 GRN (#4) 18 NC
75321
4 1 CAB ROOF
73

BLU (#9) 18 LIGHT, LEFT FRONT

R2
NO 76 ROTATE
+ A X B -
11 9 JOYSTICK
C C 75321
FRICTION HOLD HANDLE
89 PIPE RACK SWING
LOCKING CENTER POSITION
GRY (#6) 18 INTERLOCK RELAY
NO NC NC NO DRILL LIGHT
SEE SHT 2 FOR R4 CONTACT SET DRILL LIGHT
CIRCUIT BREAKER FRONT
440315
18 GRN/GRY 16
OPTIONAL 10A
TS OFF PIPE RACK SWING 69681 75321
R4
NO 155 ORG (#7) 18 INTERLOCK OVERRIDE SWITCH DRILL LIGHT
FRONT
6 7
407791 ON
R4
NC 75321

6 5
154 ORG (#5) 18 DRILL LIGHT
FRONT

440314
75321
PNK (#5) 18

OPTIONAL
153

NO NC NC NO

SPRING RETURN HANDLE

5 ADDITIONAL DRILL LIGHTS
LOCKING CENTER POSITION

C C DRILL LIGHT
DRILL LIGHT
FEED-HOIST/PULLDOWN CIRCUIT BREAKER FRONT DECK
+ A X B - S6
JOYSTICK 161 GRY 14
15A
57913 75321
DRILL LIGHT
96 PNK (#6) 18 FRONT DECK
SV PULLDOWN CONTROL VALVE

75321
V014499
DRILL LIGHT
REAR DECK

95 PNK (#2) 18
SV HOIST CONTROL VALVE
75321
DRILL LIGHT
V014499
REAR DECK
99 PNK (#0) 18

TS OFF 75321
DRILL LIGHT
97 PPL 16 (SXL) AUTO FEED MAST
98 PPL 16 (SXL) + - BLK 16
CONTROL AUTO FEED CONTROL
65226 ON CARD
79

75321
426233
GRY 16

ON
66 GRN/GRY 16
S6 LIGHT SOLENOID
CONTROL PANEL 1 GRN/YLW 16 COMPRESSOR

GRN/GRY 16
CONTACTOR
CIRCUIT BREAKER TEMP SENDER 47840
59 GRY 16 S G BLK 16 319153
COMPRESSOR 65226
15A OFF
57913 319240 TEMP GAUGE DRILL LIGHT
CIRCUIT BREAKER ON
L 66 GRN/GRY 16
LIGHT SOLENOID
319146 80 69 GRN/GRY 16 S5
5A CONTACTOR
57914 47840

GRN/GRY 16
65226 CAB DOME
OFF LIGHT
ON
68 GRN/GRY 16
67
88194
ABBREVIATION DEFINITIONS: DCS - DUST COLLECTOR SIDE
15 58 79 47 59 58 79 47 65226
CS - CAB SIDE OFF

DE - DRILLING END
NDE - NON DRILLING END
INDICATES WIRE COLOR WITH (NUMBER) - PNK (#2) 18 Ref. 433752 rev. 06 (2 of 6)

8-22 Electrical Components

 Electrical Schematic–SKF/SKFX
58 79 47

58 79 47

36 WHT/RED 16
A
TS UP DCV DUST CURTAIN
UP
47 GRY 16

A 35 WHT/YLW 16
YLW/GRN 16
AUTO TOOL WRENCH DOWN DCV DUST CURTAIN
TS ENGAGE DCV B
31 ENGAGE 66425
DOWN
47 GRY 16
32 410088

DISENGAGE YLW/ORG 16
DCV AUTO TOOL WRENCH
66425 DISENGAGE
B

410093 PNK/BRN 16
A
23
TS DUST COLLECTOR DCV DUST COLLECTOR
47 GRY 16

BLU/WHT 16
A
TS DCV HOBO SWING
OUT 24 BRN/WHT 16
GRY 16
41 OUT WATER INJECTION DCV WATER INJECTION
47
B
42 66424

IN BLU/ORG 16
DCV HOBO SWING 410089
66425 IN
B

404002 410093

63 PULLDOWN SPEED
TS OFF/FAST DCV
A OFF/FAST
ORG/BLK 16 47 GRY 16 PS
TS
RELEASE DCV HOBO CLAMP
39 RELEASE WHT BLK PNK/RED 16
47 GRY 16 N0
ON 63 PULLDOWN SPEED
40 66226 DCV
ON/SLOW
ORG/WHT 16 PULLDOWN SPEED
CLAMP DCV HOBO CLAMP
B CLAMP PRESSURE SWITCH 410666
66425

410093
404002 HIGH SPEED PROPEL
TS ON
61 PNK/ORG 16 AUX PUMP PRESS
A 47 GRY 16 SV
YLW/BLU 16 HIGH SPEED PROPEL
TS UP DCV WINCH
171 UP
47 GRY 16
OFF 410280
170
65226
YLW/GRN 16
DOWN DCV WINCH
B DOWN OIL INJECTION
66425 BLK 16
TIMER ACTIVE LIGHT

410093
WHT 16
RED 16

A ON
GRY/WHT 16
MAST LOCK 150 WHT/BRN 16 + OIL INJECTION
TS LOCK DCV 47 GRY 16 TIMER OIL INJECTION TIMER
20 LOCK
47 GRY 16 RED 16
19
OFF 57641
RED/WHT 16
UNLOCK DCV MAST LOCK 65226
B UNLOCK BLK 16
66425 P OIL INJECTION PUMP
55672
404002 410093
BIT OIL INJECTION
PANEL LIGHT
151 PNK/BLU 16
AUX PRIORITY
225 RED 16
SV SKF12/15 ONLY 57797
PILOT CONTROL MANIFOLD (V15)

TS ON 152 TAN 16
47 GRY 16 SV THREAD LUBE

OFF
407791 V004434
STANDARD PIPE POSITIONER
YLW/BRN 16
A
TS DCV PIPE POSITIONER
LOCK TS ON
29 EXTEND (ENGAGES PIPE) 62 PNK/YLW 16
47 GRY 16 47 GRY 16 HBV HOLDBACK VALVE
30

UNLOCK YLW/RED 16
66425 DCV PIPE POSITIONER OFF
65226 410280
B RETRACT
OPTIONAL
AUTOMATIC PIPE POSITIONER CONTROL
SEE OPTIONAL AUTOMATIC
410093
PIPE POSITIONER BELOW WITH MANUAL OVERRIDE
TS AUTO
BLK/YEL 16
A 47 GRY 16
TS DCV PIPE RACK LOCK 51 BLK 16 PIPE POSITIONER OVERRIDE
LOCK 30 TAN/PNK 16
43 LOCK R7 RETRACT TOGGLE SWITCH
47 GRY 16 85 86
RETRACT (LOCATED ON OPERATOR CONSOLE)
66425
44

UNLOCK GRY/RED 16
DCV PIPE RACK LOCK
66425 UNLOCK 403689 R6 AND R7 LOCATED IN
B
ELECTRICAL BOX MOUNTED
IN MAST
157 GRN/BLK 16
410093 R6
85 86

PNK/BLK 16
A +
TS DCV PIPE RACK SWING 157 BRN
OUT 25 OUT BLK 51 BLK 16
403689
47 GRY 16
BLU
26

IN BLK/PNK 16 418673 51 BLK 16

66425 DCV PIPE RACK SWING PIPE POSITIONER OVERRIDE
B IN RETRACT

PIPE POSITIONER
410093
RED ENGAGED INDICATOR LIGHT
R7
A NO TAN/WHT 16
YLW/WHT 16
TS DCV PIPE RACK INDEX 30 87
CW 27 CW 404002 416873
47 GRY 16
R6 R7
28 NC NC
YLW/RED 16 A
YLW/BLK 16 214
CCW PIPE RACK INDEX 30 87a 30 87a DCV PIPE POSITIONER
66425 DCV 404002
B CCW ENGAGE PIPE

R6
410093 NO 216 BLU 16 215 YLW/BRN 16
DCV PIPE POSITIONER
GRN/BLK 16 30 87 B RETRACT
404002

22 BLU/YLW 16
A 410093
TS DCV MAIN AIR VALVE
OPEN OPEN 58 79 157
47 GRY 16

CLOSE 21 GRY/BLU 16 ABBREVIATION DEFINITIONS: DCS - DUST COLLECTOR SIDE

DCV MAIN AIR VALLVE
66425 CLOSE
B CS - CAB SIDE

DE - DRILLING END
410088
NDE - NON DRILLING END Ref. 433752 rev. 06 (3 of 6)
58 79 47

Electrical Components 8-23

 Electrical Schematic–SKF/SKFX
58 79 157 58 172

TEST SWITCH
172
OPTIONAL
GRN/BLK 16 OPTIONAL
PIPE RACK SWING INTERLOCK SYSTEM
65226 FILTER BYPASS
INDICATOR LIGHTS
LIMIT SWITCH SENSES PIPE RACK POSITION AND 173 GRY/BLK 16
PREVENTS ROTARY HEAD FROM CONTACTING CAROUSEL
SHOULD CAROUSEL BE UNDER THE ROTARYHEAD,
UNLESS OVERRIDE SWITCH IS USED COMPRESSOR
PS
PIPE RACK POSITION LIMIT SWITCH FILTER
SHOWN IN "PIPE RACK IN" POSITION 172
GRN/GRY 16 N0 WHT 16 182
NC C
NC 2 416873
157
156 ORG/GRN 16 BLK 16 PIPE RACK SWING 400017
GRN 16 1
R4 INTERLOCK RELAY CASE
NO 3 10 2
SEE SHT 2 FOR R4 CONTACT SET PS
FILTER
340440 172
5 N0 WHT 16 181
GRN/GRY 16
4 NC C
6 416873

81187 400016
MAIN
PS
FILTER #1
172
GRN/GRY 16 N0 WHT 16 180
NC C
WIPER 416873
CIRCUIT BREAKER 400015
116 117 CHARGE
10A PS
GRY 16 GRY 16
FILTER #1
69681 172
GRN/GRY 16 N0 WHT 16 178
HI OFF LO NC C
118 PPL/BLU 16 416873

400017
P
120 PPL/YLW 16 CHARGE
M DECK WIPER MOTOR PS
B L FILTER #2
172
119 PPL/WHT 16 WHT 16 179
GRN/GRY 16 N0
342364
H NC C
416873
127 YLW/BLK 16
W
P DECK WASHER PUMP 400017
LOOP
PS
328990 330310 FILTER #1
172
GRN/GRY 16 N0 WHT 16 174
NC C
HI OFF LO 416873
124 BLU/WHT 16
400017
P
LOOP
126 BLU/YLW 16 PS
FILTER #2
B L
M FRONT WIPER MOTOR 172
GRN/GRY 16 N0 WHT 16 175
125 BLU/PNK 16
342364 NC C
H
416873
129 YLW/RED 16 400017
W
P FRONT WASHER PUMP LOOP
PS
FILTER #3
328990 330310 172
GRN/GRY 16 N0 WHT 16 176
NC C
416873
HI OFF LO 400017
121 PNK/BLU 16 LOOP
PS
FILTER #4
P 172
123 PNK/BLK 16 WHT 16 177
GRN/GRY 16 N0
B L
M REAR WIPER MOTOR
117 NC C
122 PNK/YLW 16 416873
GRY 16
342364
H
400017
128 YLW/GRN 16 OPTIONAL
P REAR WASHER PUMP 184 TAN/BLU 16
W ROTARYHEAD
TACHOMETER
328990 330310 B A RED/GRY 16
OPTIONAL 185
183 GRY 16 417219
LEVELING JACK UP 1
INDICATOR LIGHTS 414898
+
165 BRN
BLK BLK 16 81187
PRL/GRN DCS NDE JACK UP
16 PROX SWITCH
6
4
418673 166
5
BLU PPL/GRN 16 DCS UNPINNED 189 RED 16
DCS NDE JACK UP
3
INDICATOR LIGHT 1

GRN 2
+
418677
172

BRN
BLK BLK 16
DCS DE JACK UP 189 RED 16
PROX SWITCH
GRN/GRY 16

418673 168
BLU PPL/WHT 16 NOT PRESENT
2
DCS DE JACK UP WHEN PROPEL
INDICATOR LIGHT INTERLOCK OPTION 187 1
3
IS SELECTED GRN/BLK 16
+ GRN
418677 DCS PINNED 5
BRN
BLK BLK 16
CS NDE JACK UP 4
6
PROX SWITCH

418673 167 81187

BLU PPL/YLW 16
CS NDE JACK UP 81187
INDICATOR LIGHT OPTIONAL
6 MAST UNLOCKED
+ GRN
4 CS UNPINNED INDICATOR LIGHT
BRN 418677
BLK BLK 16 5
CS DE JACK UP 189 GRN/BLU 16
PROX SWITCH 3
1 RED
418673 169 416873
2
BLU TAN/YLW 16
CS DE JACK UP
INDICATOR LIGHT
OPTIONAL
GRN MAST LOCKED
418677 2
INDICATOR LIGHT
188 1
3 188 ORG/YEL 16
GRN 16

5 GRN
4 CS PINNED 416874
6
58 172 ABBREVIATION DEFINITIONS: DCS - DUST COLLECTOR SIDE 58 172
81187
CS - CAB SIDE

DE - DRILLING END
NDE - NON DRILLING END Ref. 433752 rev. 06 (4 of 6)

8-24 Electrical Components

 Electrical Schematic–SKF/SKFX
58 172

OPTIONAL
OPTIONAL
211 RED 16 (LOCATED IN CAB) (LOCATED IN SIGMA UNIT) SIGMA A/C
RED 16 BLK 16
DEI POWER A/C SYSTEM BREAKER AIR CONDITIONER
ORG 16 DEI PWR COND GRN 16 CIRCUIT BREAKER CIRCUIT BREAKER
CONDITIONER S4
WHT 10
A/C SYSTEM BUSS 50A 30A AIR CONDITIONER
212 ORG 16 NO AIR CONDITIONER
57912 CLUTCH
SIGMA
CIRCUIT BREAKER
LP
14 ORG 16
15A CC A/C COMPRESSOR CLUTCH
418693 N0 (LOCATED IN SIGMA UNIT)

ENTERTAINMENT RADIO/CD

+ YEL - OPTIONAL
REFERGERATOR
163 24/12VDC
+12VDC
162 RED 16 201 ENTERTAINMENT CIRCUIT BREAKER OPTIONAL
5A RED 18
ORG 14 CONVERTER RADIO/CD PLAYER RED 12 REFRIGERATOR REFRIGERATOR
57914 15A 24VDC
- 57913
418334 +
MEMORY
2 1 MODULE -
198 ORG 18
BLK 430986
ORG +24VDC SM2412-M
421289
OPTIONAL

162 RED 16 CB BLK 16 CB

5A RADIO
57914 RADIO
401337

OPTIONAL

OPTIONAL AUTOMATIC

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
LUBE SYSTEM
LINCOLN LUBRICATION
PS
TIMER BOX
N0
LUBE SYSTEM
CHARGED PRESSURE SWITCH

ORG 16
MUST CUT

145
24 VDC

8
JUMPER 146 ORG 16

7
6
5
24V

4
3
1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 2
144 GRN/BLK 16 147 YLW 16
SV PNEUMATIC SOLENOID VALVE

148 YLW 16

144 GRN/BLK 16

CAB HEATER RHEOSTAT

OPTIONAL
164 GRY/YLW 14 RED/YWL 14
5A M CAB
57914 HEATER FAN MOTOR
38595
45838

196 ORG 14 AIR CONDITIONING

CC
COMPRESSOR CLUTCH

159 RED 12 192 RED 14

10A
69681

AIR CONDITIONING
CONDENSER UNIT

85 87 87a 85 87 87a

M
86 30 86 30

RELAY RELAY

LOW HIGH OPTIONAL

PRESS PRESS
RED 14

BINARY SWITCH A/C CONDENSER

AIR PRO A/C
408321
195 BLK/WHT 14
193

197 BRN 14 PRESSURIZER

M FAN MOTOR
PRESSURIZER
FAN MOTOR

RESISTOR
AIR CONDITIONING
M HEATER UNIT
HIGH (ORANGE)
LOW (YELLOW)

MED (RED)
OFF

ABBREVIATION DEFINITIONS: DCS - DUST COLLECTOR SIDE

CS - CAB SIDE
ROTARY A/C THERMOSTAT
SWITCH TOGGLE SHITCH DE - DRILLING END
194 RED 14 A/C HEATER UNIT 425127 NDE - NON DRILLING END
15A
57913 Ref. 433752 rev. 06 (5 of 6)

Electrical Components 8-25

 Electrical Schematic–SKF/SKFX
109

6 YLW 16 CUMMINS ALTERNATOR

TACH SIGNAL TACHOMETER SIGNAL (SEE SHEET 3)

53 RED 4 B+ B- 104
ALT ALTERNATOR
BLK 4
BLU 16
421321
STOP
R CUMMINS
31 PIN CONNECTOR
DIAGNOSTIC 8
TS1 OFF
OPTIONAL SIGMA DIA
A 9
A/C SYSTEM BUSS BRN/RED 16
CIRCUIT BREAKER STOP 12
BRN/YLW 16
(LOCATED IN ENGINE DIAGNOSTIC 13
SKID JUNCTION BOX) ENG GRN 16
G ENG PROTECTION 14
ECM HARNESS
PROTECTION
DIAGNOSTIC 15
60A A/C SYSTEM BUSS OFF/ON
31 PIN CONNECTOR
442042 SEE SHEET 6 GRY/ORG 16 20
207
ON
TS 21
TAN/BRN 16 29
RED 6 ISC ON/OFF
ORG/BLU 16
ISC 1 (1800 RPM) 23

203
109
ORG/GRY 16
ISC 2 (2100 RPM) 24
ISC ON/OFF
OPTIONAL CUMMINS

442042

442042
REMOTE
ENGINE CONTROL

60A

60A
MAIN BUSS
START
CIRCUIT BREAKER
CIRCUIT MODULE CONNECTIONS
BREAKER
TS ECM HARNESS
(LOCATED IN ENGINE ISC 1(1800 RPM)
50 PIN CONNECTOR

16
SKID JUNCTION BOX)
ENGINE RIGHT BANK

TAN/ORG 16
ISC 2(2100 RPM)

CUMMINS
21 PIN CONNECTOR
ENGINE
ECM FUSE BLK 12
102
-V BATTERY B
ECM HARNESS
-V BATTERY E
20A 21 PIN CONNECTOR
+V BATTERY D
ENGINE RED 12 +V BATTERY G
ECM FUSE
102
KEY SWITCH A
20A
INTERSTAGE TEMP
HIGH PRESSURE HIGH PRESSURE COMP
COMPRESSOR ONLY V000898 COMPRESSOR OVER
7 BLU 16 250 F 265 F TEMPERATURE SWITCH
REMOTE START NC NC
KEY SWITCH
83327 65237 240 F
OFF ON
PB PB PB LOW PRESSURE
NC 7 BLU 16 NC NC COMP
OPTIONAL
REMOTE ENGINE
N0 N0 N0 STOP SWITHCES
16864 402278 402278 402278

207 BLU 16 S G BLK 16

VOLTMETER
1156000
L
REMOTE 1155171 OPTIONAL

7
REMOTE START SOLENOID START REMOTE ENGINE LOCATED AT ENGINE

RED/BLU 16
CIRCUIT BREAKER PB START SWITHCES

15A
57913
190 WHT/BLU 16
42259 HRM ENGINE HOUR
METER (ENGINE)
96192
OPTIONAL CUMMINS QST30 ENGINE ARRANGEMENT DUST COLLECTOR TIMER
CIRCUIT BREAKER PS1

52 GRN/BLK 16 9 WHT/GRN 16
15A HRM ENGINE HOUR
N0 METER (CONSOLE)
57913
OPTIONAL

100 GRY 16
96192
BATTERY JUMP START 168437
DUST COLLECTOR TIMER
OPTIONAL
8 WHT/GRN 16 191
KEY SWITCH + - DUST COLLECTOR
BLK 16
12 VDC 12 VDC OFF ON TIMER
MAIN POWER IGNITION CONTACTOR
KS1
CIRCUIT BREAKER CIRCUIT BREAKER
142
OPTIONAL ADDITIONAL BATTERIES 16 16 RED 10 57 GRY/PNK 16
141
RED 000
143 50A 15A S3 IGNITION SOLENOID
57912 57913 CONTACTOR
STANDARD-2) 8D 12V BATTERIES 47840

58
BATTERY 16864
12 VDC 12 VDC DISCONNECT OPTIONAL
57 GRY/PNK 16
SWITCH S4 SIGMA A/C SOLENOID

RED 10
108 RED 000 107 BLK 000 105 TAN/WHT 16 CONTACTOR
47840
RED 000
START
425881 STARTER SOLENOID
41758 PB1 CIRCUIT BREAKER 200 BLK
ENGINE OIL PRESSURE S3
NO 17 PS PRELUB PRELUB
15A 1
PRELUB 57913
PRESSURE SWITCH
2
PUMP 42259 A447 PNK NC

4 PSI

PRELUBE FUSE
S2T
108 RED 000 NO 105
(LOCATED IN PRELUB HARNESS) M TOP STARTER
BLK 000 MOTOR WITH PRELUBE PUMP
PRE
101 RED 6 NO 301 PUR 6
CUMMINS

337
50A S1T
NO 110 BLU
S2T TOP STARTER

WHT
BLK 000 SOLENOID 1 YEL
OPTION
2 GRN PRELUB
1 3 WHT PRE SOLENOID, 3 SEC TIME DELAY
2 4 BLK AFTER PRESSURIZING ENGINE OIL
SYSTEM TO START
S2B 5 WHT/BLK 3 SEC
109

NO 307 ORG
108 RED 000 105 TIME DELAY
M BOTTOM STARTER GRN
BLK 000 MOTOR PRELUB TIMER
RED 6

SWITCH/SOLENOID
(DUAL STARTERS STANDARD WITH CUMMINS QST30)
S1B
NO 110
S2B BOTTOM STARTER
BLK 000 SOLENOID
307 ORG 17 BLU 12
S1T PRELUBE
STARTER SOLENOID
PRELUBE HARNESS CONNECTOR
INVERTER CIRCUIT
BREAKER
LOCATED IN INVERTER BOX RED 14 S1B BOTTOM
S6 AC/DC INVERTER MICROWAVE OVEN STARTER SOLENOID
NO 110VAC
135A PURE SIN WAVE 600W OPTIONAL MICROWAVE OVEN
413223 WHT 14
426393
LOCATED WITH INVERTER
430956 426453 15 58 79

INDICATES WIRE COLOR WITH (NUMBER) - PNK (#2) 18

109

NOTE: DO NOT USE P/N'S TO ORDER REPLACEMENT PARTS

ORDER REPLACEMENT PARTS FROM MACHINE PARTS BOOK
Ref. 433752 rev. 06 (6 of 6)

8-26 Electrical Components

 Electrical Schematic–SKF (Cat)
TO RELAY #2,
TERMINAL #11 GRN/YEL 16 COMPRESSOR TEMP
1 1
SEE SHT 5 GRN/YEL 16 WHT 16
2 WHT 16 2 WATER TEMP
BRN 16 BRN 16
3 3 FUEL
BLK/ORG 16 BLK/ORG 16 4
4 OIL PRESSURE
POWER TO
GRY 16
DRILL/PROPEL SW. 60
COMP WATER GRY 16
SEE SHT 3 TEMP TEMP FUEL OIL
73 BATT.
1155163 1155164 96193 1155162 1155171 60
GRN/BLK 16

TACH
L L L L L
96194

GRY 16
S G S G S G S G S G L
72 I
1156000 16 G YEL 16 YEL 16
4 PLACES Y S 5 5 TACH GND
GR RED 16 RED 16
GRY 16 6 6 TACH SIGNAL
59 59
RUN BLUE 16 BLU 16
7 7 7 7 RUN KEY
GRY 16 CIRCUIT WITHOUT
START
218

GRY 0
-OR (REF. ONLY)-

WITH OPTIONAL

BLUE 1
REMOTE TRAM PENDANT
BLU 16 GRN 16
14 217 8 8 DIAGNOSTIC LAMP

TO
OPTION FROM
WHT/GRN 16
9 WHT/GRN 16 9 ENGINE HOUR

GRY 16 100 RED 10

58 ECM DIAGNOSTIC LAMP
OPTIONS DRILL
RED 10 HOUR
RELAY START IGNITION
47840 RELAY 58 10 GRN 16
17
96192 8 96192
GRN/WHT 16
57
GRY 16

N.O. THROTTLE -
KEY DRILL HR ENGINE HR
16 POSITION +
GRN/BLK 16 16
R ED SENSOR SIGNAL
71
57 ORG 16

BACK-UP
69499
17 GRN/BLK 16 GRN/RED 16 GRN/RED 16
12 13 13 BACK UP ALARM
GRY 16
BLU 12

RED 10

BLU 12

ORG 16
GRY 16

GRY 16 17
79
LIGHT SWITCH
GRN/GRY 16
GRN 10 15 GRN 10
15 DRILL LIGHT POWER
GRN/GRY 16

64
DRILL DRILL CONTROL START
LIGHT RELAY 66 67 LIGHT LIGHT MAIN
80 PANEL POWER
47840 MAIN
POWER
5 50 15 15 50
69
GRN/GRY 16

45 18 59 RED 10
16 16 MAIN POWER
68
GRN 10

DOME
LIGHT
GRY 16
GRN 10
GRN/GRY 16

GRN/GRY 16
BLU 12
17 17 STARTER BUTTON
88194
BLU 16

24V LIGHT
BULB
GRN/GRY 16
10
18 18 FRONT LIGHTS

BLU 16
15
45 45 CAB TOP LIGHTS

47 ORG 16
71 71 THROTTLE POSITION SENSOR
GRY 16

REF CAB
1 JUNCTION BOX
POWER TO CONTROL
PANEL SWITCHES
SEE SHT 3
Ref. 426455 rev. 06 (1 of 12)

Electrical Components 8-27

 Electrical Schematic–SKF (Cat)
REF CAB REF ENGINE
JUNCTION BOX JUNCTION BOX

CATERPILLAR
GRN/YEL 16 GRN/YEL 16 WIRING HARNESS
COMPRESSOR TEMP 1 1 1
WHT 16 WHT 16 1155175
WATER TEMP 2 2 2
BRN 16 BRN 16 COMP
FUEL 3 3 3 FUEL TEMP
BLK/ORG 16 BLK/ORG 16
OIL PRESSURE 4 4 4
1155175
1155173 WATER J2/P2
OIL PRESS TEMP COMP
TEMP
P61/J61
BLK 16 RED 14 CATERPILLAR
101 56 +BAT (UNSWITCHED) 32 32
YEL 16 YEL 16 15 ECM
TACH GND 5 5 5 N.O. 55 +BAT (UNSWITCHED) 31 31
TACH RED 14
RED 16 RED 16 SENDER
TACH SIGNAL 6 6 6 REMOTE SHUTDOWN SW 27 27
BLU 16 BLU 16 BLU 16
RUN KEY 7 7 7 +BAT (SWITCHED) 26 26 J1/P1
GRN 16 GRN 16 GRN 16
DIAGNOSTIC LAMP 8 8 8 DIAGNOSTIC LAMP 24 24
WHT/GRN 16
ENGINE HOUR 9 9 9 THROTTLE POSITION SENSOR 10 10

WHT/GRN 16
54 +BAT (UNSWITCHED) 1 1
GRN/RED 16 GRN/RED 16
BACK UP ALARM 13 13 13 RED 14
REAR ELECTRONICS GROUND STUD
GRN/RED 16

BACKUP ALARM 71
CAT SUPPLIED ENGINE SERVICE TOOL CONNNECTION

ORG 16
CAT SUPPLIED TERMINATION RESISTOR
9

13

REF ENGINE JUNCTION

BOX TERMINAL
FRONT ENGINE
BACKUP ALARM PRESS SW.

52

GRY/YEL 16
52 102

BLU 12
REF ENGINE JUNCTION

RED 10
GRN 10 GRN 10
DRILL LIGHT POWER 15 15 15 BOX TERMINAL
17

RED 6 RED 6
50 109 109
STARTER 53
G + S SOLENOID
RED 10 RED 10
MAIN POWER 16 16 16
BLK 000 110 + B+

STARTER

BLK 000
G B-

RED 000
BLU 12 BLU 12 ALTERNATOR
STARTER BUTTON 17 17 17 104
BLK 6
105
108

GRN/GRY 16 GRN/GRY 16
FRONT LIGHTS 18 18 18
107 RED 000

CAB TOP LIGHTS 45

ORG 16 ORG 16
THROTTLE POSITION 71 71 71

45
BAT#2 BAT#1
BATTERIES
BLU 16

18
GRN/GRY 16

LEFT RIGHT LEFT RIGHT

CAB TOP LIGHTS

LEFT RIGHT MOUNTED ON Ref. 426455 rev. 06 (2 of 12)

COOLER

FRONT LIGHTS

8-28 Electrical Components

 Electrical Schematic–SKF (Cat)

PWR FROM CONTROL

PANEL 15 AMP BREAKER
SEE SHT 1 REF DRILL
HOLDBACK FUNCTION PANEL
VALVE REF CAB
GRY 16

JUNCTION BOX

YEL/BLU 16
47 33
YEL/GRY 16
34 RED/WHT 16
47 47 19 MAST UNLOCK
WINCH
GRY/WHT 16
20 MAST LOCK

GRY 16
GRY 16

GRY 16
GRY 16

GRY 16
GRY/BLU 16
21 MAIN AIR CLOSE
BLU/YEL 16
22 MAIN AIR OPEN
HOBO CLAMP PNK/BRN 16
HOLDBACK RELEASE HOBO SWING 23 23 DUST COLL
HAMMER LUBE THREAD LUBE ON OUT BLU/WHT 16 24 BRN/WHT 16
24 WATER
PNK/YLW 16 ORG/BLK 16
62 39 PNK/BLK 16
WHT/BLU 16 TAN 16 ORG/WHT 16 BLK/WHT 16 25 PIPE RACK OUT
38 46 40
BLK/PNK 16 26
OFF CLAMP IN PIPE RACK IN
YEL/WHT 16
GRY 16

GRY 16

GRY 16
GRY 16

27 PIPE RACK INDEX CW

47 47 47 47 YEL/BLK 16
28 PIPE RACK INDEX CCW
MAST LOCK D/C CURTAIN PIPE POSITIONER OVERRIDE D/C-WATER
DUST COLL 29
LOCK DOWN TAN/PINK 16

GRY 16
AUTOMATIC PNK/BRN 16 30 PIPE POSITIONER OVERRIDE RETRACT
GRY/WHT 16 WHT/YEL 16
20 35
RED/WHT 16 WHT/RED 16 47 TAN/PINK 16 BRN/WHT 16 YEL/GRN 16 AUTO TOOL IN
19 36 30 SEE SHT 8 31
UNLOCK WATER INJ YEL/ORG 16
UP RETRACT 32 AUTO TOOL OUT
YEL/BLU 16
GRY 16

GRY 16

GRY 16

GRY 16
33 WINCH UP
47 47 47 47 YEL/GRY 16
34 WINCH DOWN
MAIN AIR PIPE RACK LOCK PIPE RACK INDEX PIPE RACK SWING WHT/YEL 16
AUX PSI 35 DUST CURTAIN DOWN
CLOSE LOCK CW OUT WHT/RED 16
GRY/BLU 16 ON PNK/ORG 16 DUST CURTAIN UP
BLK/YEL 16 YEL/WHT 16
27
PNK/BLK 16 36
21 43 25 WHT/BLU 16
BLU/YEL 16 GRY/RED 16 YLW/BLK 16 BLK/PNK 16 38 HAMMER LUBE
22 44 28 26
ORG/BLK 16
OPEN UNLOCK CCW IN OFF 39 HOBO RELEASE
ORG/WHT 16
40 HOBO CLAMP
GRY 16

GRY 16
47 47 BLU/WHT 16
41 41 HOBO SWING OUT
AUTO TOOL PULLDOWN SPEED AUTO FEED
DRILL/PROPEL BLK/WHT 16
42 42 HOBO SWING IN
DRILL IN OFF/FAST OFF
WHT/BRN 16 YEL/GRN 16 BLK/YEL 16
31 43 PIPE RACK LOCK
WHT/BLK 16 YEL/ORG 16 PNK/RED 16 GRY/RED 16
37 32 63 44 PIPE RACK UNLOCK
OUT ON TAN 16
GRY 16

PROPEL ON THREAD LUBE

46

PRPL

PRPL
PNK/ORG 16
61 61 AUX PUMP PRESSURE
PNK/RED 16
63 FAST PULLDOWN SPEED
WHT 16

72 97

74 98
75
PULLDOWN
FROM IGNITION RELAY SPEED
PRES. SW.
SEE SHT 1

TO RELAY #3, TERMINAL #10 TO RELAY #2, TERMINAL #10

SEE SHT 5 SEE SHT 5

FROM HOIST/PULLDOWN
JOYSTICK
SEE SHT 5

DRILL/TRAM
SELECTOR TO AUTOFEED CARD,
VALVE (+) TERMINAL
SEE SHT 5

Ref. 426455 rev. 06 (3 of 12)

Electrical Components 8-29

 Electrical Schematic–SKF (Cat)

REF CAB
JUNCTION BOX

RED/WHT 16 RED/WHT 16 RED/WHT 16

MAST UNLOCK 19 19
GRY/WHT 16 GRY/WHT 16 GRY/WHT 16
MAST LOCK 20 20
GRY/BLU 16 GRY/BLU 16
MAIN AIR CLOSE 21 21
BLU/YEL 16 BLU/YEL 16
MAIN AIR OPEN 22 22
PNK/BRN 16
DUST COLL 23 23
WATER BRN /WHT 16
24 24
PIPE RACK OUT 25 PNK/BLK 16 25 PNK/BLK 16

PIPE RACK IN 26 BLK/PNK 16 26 BLK/PNK 16

PIPE RACK INDEX CW YEL/WHT 16 27 YEL/WHT 16

27
PIPE RACK INDEX CCW YEL/BLK 16 28 YEL/BLK 16
28
PIPE POSITIONER IN YEL/BRN 16 YEL/BRN 16
29 29
PIPE POSITIONER OUT 30 YEL/RED 16 30 YEL/RED 16
YEL/GRN 16 YEL/GRN 16
AUTO TOOL IN 31 31
YEL/ORG 16 YEL/ORG 16
AUTO TOOL OUT 32 32
YEL/BLU 16
WINCH UP 33 33
WHT/GRY 16
WINCH DOWN 34 34
WHT/YEL 16 WHT/YEL 16
DUST CURTAIN DOWN 35 35
WHT/RED 16 WHT/RED 16
DUST CURTAIN UP 36 36

WHT/BLU 16
HAMMER LUBE 38 38
ORG/BLK 16 ORG/BLK 16
HOBO RELEASE 39 39
ORG/WHT 16 ORG/WHT 16
HOBO CLAMP 40 40
BLU/WHT 16 41 BLU/WHT 16
HOBO SWING OUT 41
BLK/WHT 16 BLK/WHT 16
HOBO SWING IN 42 42
BLK/YEL 16 43 BLK/YEL 16
PIPE RACK LOCK 43
GRY/RED 16 GRY/RED 16
PIPE RACK UNLOCK 44 44

TAN 16
THREAD LUBE 46 46

AUX PUMP PRESSURE PNK/ORG 16 61

61

PNK/RED 16 63
FAST PULLDOWN SPEED 63

YEL/BLU 16

YEL/BLK 16

YEL/WHT 16

BLK/WHT 16

BLU/WHT 16
PNK/BLK 16
YEL/GRY 16

GRY/WHT 16

RED/WHT 16
BLK/PNK 16

BLK/YEL 16

YEL/ORG 16

YEL/GRN 16
YEL/RED 16

ORG/BLK 16
YEL/BRN 16

GRY/RED 16
ORG/WHT 16
36 35 22 21
24 23
WHT/RED 16

BLU/YEL 16

GRY/BLU 16
WHT/YEL 16
PNK/RED 16

BRN /WHT 16

PNK/BRN 16
WHT/BLU 16
PNK/ORG 16

33 34 28 27 26 25 30 29 40 39 44 43 20 19 42 41 32 31
TAN 16

A B B A B A B A B A B A B A B A A B B A B A
A B
61 46 38
CLOSE

OUT

OUT

OUT

OUT
IN

IN

IN

IN
LOCK

LOCK
UNLOCK

UNLOCK
UP

OPEN

UP
DOWN

CWW

CLAMP
CW

RELEASE
DOWN
WATER

DUST
COLL

FAST AUX DUST DUST COLL MAIN OPTIONAL OPTIONAL PIPE RACK PIPE RACK PIPE HOBO PIPE RACK MAST HOBO AUTO
PULLDOWN PUMP THREAD HAMMER WATER CURTAIN AIR CONTROL WINCH INDEX SWING POSITIONER CLAMP LOCK LOCK SWING TOOL
PSI LUBE LUBE
410089 410088 410093
410666 410280

Ref. 426455 rev. 06 (4 of 12)

8-30 Electrical Components

 Electrical Schematic–SKF (Cat)
HOIST/PULLDOWN ROTATE L.H. R.H.
JOYSTICK JOYSTICK JOYSTICK JOYSTICK

AUTO
FEED
PRPL PRPL
AUTO
97 98
+ CARD -

BLK
A

+ B A - BLK + B A - + B A - + B A -

BLK

BLK

BLK
PNK #0
99

WHT #6
WHT #7

WHT #6
BLU #4
GRN #4

BLU #8
GRN #8
YLW #9
GRY #6

YEL #3
YEL #9
PNK #2
PNK #6
GRY #6

REF CAB JUNCTION

BOX TERMINALS

96 96

95 95 78

89

84 83

UP DN.
85 86
PULLDOWN PULLDOWN
CONTROL CONTROL
VALVE VALVE

77

76

WHT #7
GRN #8
GRN #4

YEL #9

YEL #9
YEL #3 6 6
5 7 5 7
4 8 4 8
88

3 9 3 9 87
RELAY #3 RELAY #2
N.C. N.C.
-2 +10 -2 +10

WHT 16

WHT/BRN 16
6 6
BLK

BLK
1 11 1 11
5 7 5 7
4 8 4 8
82
3 9 3 9
RELAY #4 81
REF CAB JUNCTION RELAY #1
N.C. N.C.
-2 +10 REF CAB JUNCTION BOX TERMINALS +10
-2
1 11 BOX TERMINALS 88 87
1 11
82 81
SEE SHT 7 FOR
INTERLOCK OPTIONS BLU #4 BLU #8
INVOLVING THIS RELAY BRN #4 BRN #8
SEE SHT 6 FOR
B A INTERLOCK OPTIONS
B A INVOLVING THIS RELAY

75 73 74
R.H. PUMP
L.H. TRAM/ROTATE
PUMP

WHT/BRN 16
GRN/BLK 16

POWER FROM POWER FROM

WHT 16

IGNITION RELAY DRILL/PROPEL SW.

SEE SHT 1 SEE SHT 3

POWER FROM
Ref. 426455 rev. 06 (5 of 12)
DRILL/PROPEL SW.
SEE SHT 3

Electrical Components 8-31

 Electrical Schematic–SKF (Cat)
TAN/RED 16 REF L.H. REF R.H.
133
JOYSTICK JOYSTICK
PRPL/GRN 16
136 SHOWN ON SHT 5 SHOWN ON SHT 5

BL TAN/RED 16
K 133
U BL
LEFT RIGHT PRPL/GRN 16
BRN BRN 136
FRONT FRONT BL
K
BL JACK JACK U

BL K
U BL
BRN LEFT RIGHT BRN
PRPL/GRN 16 PRPL/GRN 16 FRONT FRONT BL
136 136 K
BL JACK JACK U
TAN/RED TAN/RED + B A - + B A -
133 133

WHT 6
132 PRPL/GRN 16 PRPL/GRN 16
U BL 136 136
BL K
LEFT RIGHT TAN/RED TAN/RED
BRN BRN 133 133
REAR REAR WHT 6
BL U 78
JACK K BL JACK

JACK INTERLOCK
JACKS UP = WHT 4
GREEN LIGHT 130

PRPL/GRN 16
U BL

TAN/RED 16
136
TAN/RED 131 6 BL K
LEFT RIGHT
16 5 7 BRN BRN

WHT 4
(-) (+) 4 8 REAR REAR
135 134 BL U
BLK 16
137 JACK K BL JACK

3 9

WHT 7
133 133

136 136 136 -2 +10

PRPL/GRN 16
1 11 REF L.H. REF R.H.

TAN/RED 16
136
POWER FROM JOYSTICK JOYSTICK
REF RELAY #1, N.C. RELAY #2, TERMINAL #8 SHOWN ON SHT 5 SHOWN ON SHT 5
REF CAB JUNCTION SEE SHT 5
SHOWN ON SHT 5
BOX TERMINALS

OPTIONAL 136

JACK INTERLOCK CIRCUIT

WHEN USED INDEPENDANTLY REF CAB JUNCTION
BOX TERMINALS

REF L.H. REF R.H. 136 133

JOYSTICK JOYSTICK + B A - + B A -
SHOWN ON SHT 5 SHOWN ON SHT 5

WHT 6
JACK INTERLOCK
132
JACKS UP =
GREEN LIGHT
WHT 6
78
(-) (+)
REF CAB JUNCTION 135 134
BOX TERMINALS BLK 16 TAN/RED
WHT 4
16
130
5A
131 6
+ B A - + B A - PIPE PRESENT PROXIMITY SW. 5 7
RED/BLK 4 8
WHT 6

133
PIPE PRESENT PROXIMITY SW. 132 16
+ 1
140 140 5A 3 9
WHT 6
+ 1 78 - 3
136 -2 +10 138
- 3 1

BLK
140 PRPL/GRN 16
11
130 WHT
BLK

RED/BLK 16

WHT 4 REF RELAY #1, N.C.

4 SHOWN ON SHT 5

WHT 7
LOAD RED/GRN 16
131 6
4 2
5 7 139 139
LOAD 4 8 LOAD
2 140
LOAD POWER FROM
3 9
PROPEL INTERLOCK RELAY #2, TERMINAL #8
WHT 7

PIPE PRESENT = SEE SHT 5

BLK
BLK

RED LIGHT
PROPEL INTERLOCK -2 +10 138
BLK

PIPE PRESENT = 1 11
RED LIGHT WHT
POWER FROM OPTIONAL
RELAY #2, TERMINAL #8
REF CAB JUNCTION
REF RELAY #1, N.C.
SHOWN ON SHT 5 SEE SHT 5 DRILL STEEL & JACK INTERLOCK
BOX TERMINALS
139 139
CIRCUITS WHEN USED SIMILTANEOUSLY
RED/GRN 16

OPTIONAL
DRILL STEEL INTERLOCK CIRCUIT
WHEN USED INDEPENDANTLY Ref. 426455 rev. 06 (6 of 12)

8-32 Electrical Components

 Electrical Schematic–SKF (Cat)
GRN/BLK 16
144

WHT 16
OPTIONAL

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

WHT/BLK 16
LINCOLN LUBRICATION
TIMER BOX

GRN/BLK 16
145

MUST CUT 146

24 VDC
GRN/BRN 16

WHT 16
JUMPER

WHT/BLK 16
149
24V N.O.
1 2 3 4 5 6 7 8 9 10 11 12 13 14

1
OPTIONAL ACCESSORY RED 12 145
OPTIONAL 158

TAN 16
TAN 16

TAN/BLK 16
147 ETHER GRN/BRN 16
OPTIONAL AIR CONDITONER / HEATER 149
TAN/BLK 16 146
148 CAB HEATER
GRN/BLK 16 RHEOSTAT
RED 14 144 144
ORG 14 ORG 14 REF 147
RED 12 164 164 OPTIONS
M 192 10
159
RELAY
BLU 14

SEE 148 CAB JUNCTION

197 PRESSURIZER OPTIONAL PIPE RACK SWING INTERLOCK
FAN MOTOR RED 14 SHT 1 BOX TERMINALS
15 ROTATE HOIST/PULLDOWN 12VDC PWR RED 16 OPTIONAL ORG 14
5 162 163
JOYSTICK 24/12 VDC
JOYSTICK
194 SEE SHT 5 & 6 CONVERTER
RESISTOR SEE SHT 5 & 6
M RED 12
159
HIGH (ORANGE)
LOW (YELLOW)

GRN 16
193
MED (RED)

149 RUN KEY 7

RED 14 REF PWR FROM OPTIONAL

GRN/BRN 16
CONTROL PANEL OIL INJ LIGHT
15 AMP BRKR PIPE POSITIONER IN 29
ORG 14 157 REF
OFF

164 PIPE POSITIONER OUT 30

47

GRY 16
YLW 14

PWR TO LUBE TMR PRS. SW. 145

PNK/BLU 16
ROTARY A/C THERMOSTAT SIGNAL FROM TMR PRS. SW. 146
SWITCH TOGGLE SHITCH
PWR TO LUBE SOL. 147
A/C HEATER UNIT 195 + B A - + B A -
47 47 SIGNAL FROM TMR SOL. 148

GRY #6

PNK #5
GRN/BRN 16 ETHER 149

GRY 16

GRY 16
GRY 16

GRY 16
WHT/BRN 16
OIL INJECTION 150
PNK/BLU 16 OIL INJ LIGHT
89 OPTIONAL OPTIONAL 151 151
OIL INJ THREAD LUBE TAN 16
152

GRY #6
THREAD LUBE
OVERIDE ON ON ON
153 WHT/BRN 16 TAN 16 REF PIPE RACK SWING LIMIT SW. 156
OFF 150 152 HOLDBACK
PIPE RACK SWING & PIPE POSITIONER PWR 157
SEE SHT 3 GRN 16 GRY 14
154 OFF OFF 5 LIGHT PACKAGE 161

ORG #5

ORG #7
OFF ORG/GRN 16 ORG 14
PWR TO CAB FLOOR HEATER 164

GRY 16

GRY 16
ON

GRY 16
47 47 YEL/GRY 16
155 47 WINCH DOWN 170
YEL/BLU 16 WINCH UP 171
6 LOCK DOWN CW WHT 16
REF REF DUST REF PIPE PWR TO DC TIMER 190
5 7
4 8 MAST LOCK CURTAIN RACK INDEX BLK 16
GND FROM DC TIMER 191

GRY 16
SEE SHT 3 SEE SHT 3 SEE SHT 3
UNLOCK UP 47 CCW RED 14
PWR TO AC CONDENSER 192
3 9 YLW 14
PWR TO BINARY SW. 195
ORG/GRN 16 OPTIONAL
-2 +10 156 WINCH
BLK

1 11 DOWN 161
YEL/GRY 16
170
RELAY #4 YEL/BLU 16

GRY 14
171
N.C.
UP

192
RED 14
195
YLW 14 RED 000 REF
STARTER
RED 000 SOLENOID
G + S 15
SEE SHT 2
BLK 000 110
BLK 000 +
105
108 G

REF REF
143 ENGINE LIGHT RELAY
OPTIONAL REF 47840
STARTER PRESS SW.
MASTER SEE SHT 1
BLK 000 DISCONNECT SEE SHT 2 SEE SHT 2
SWITCH WHT 16
141 190

160 BLK 000

191
RED 000 142 BLK 16
107 RED 000

BAT#4 BAT#3 REF

OPTIONAL BAT#2 BAT#1
SEE SHT 2 Ref. 426455 rev. 06 (7 of 12)
BATTERIES

Electrical Components 8-33

 Electrical Schematic–SKF (Cat)
AUTOMATIC PIPE POSITIONER CONTROL WITH MANUAL OVERIDE
INDUCTIVE PROXIMITY SENSOR CONDITION
PWR HD DN > 5 FT, PROX OPEN, PIPE POSITIONER RELAY COIL DE-ENERGIZED-PIPE POSITIONER IS RETRACTED
PWR HD UP < 5 FT, PROX CLOSED, PIPE POSITIONER RELAY COIL ENERGIZED-PIPE POSITIONER IS EXTENDED

BLK 16
51
BLU
BLK BLK 16
51
BRN PIPE
POSITIONER
+ RELAY
157
NC 87a

GRN 16
30

GRN 14
TAN 16
214
NO 87
EN GND
85 86
196 ORG 16
ENGINE JUNCTION 157 215
A/C COMPRESSOR
BOX TERMINALS CLUTCH

RELAY SHOWN

BLU 16
DE-ENERGIZED

GRN 16
GRN/BRN 16 GRN/BRN 16 213
ETHER 149

GRN/BRN 16
WHT 16 216
PWR TO DC TIMER 190 WHT 16

WHT 16
BLK 16 149
GND FROM DC TIMER 191

BLK 16
GRN 14 SOL COM PIPE
AC CLUTCH 196 POSITIONER

2 3 4 5 6 7 8 9
MANUAL OVERRIDE
GRN 16
RELAY
OPTIONAL 157

GRN 14
DUST COLLECTOR NC 87a
TIMER BOX 30

1
SOL COM
OPTIONAL AUTO
ETHER NO 87
47

+ -
SOLENOID YELLOW/RED 16 EN GND BLK 16
30 51
85 86
PIPE POSITIONER
RETRACT
WHT 16 MANUAL OVERRIDE
190 (LOCATED IN CAB)
CAB JUNCTION BLK 16
191 RELAY SHOWN
BOX TERMINALS OPTIONAL
DE-ENERGIZED
+ 24 VDC + 24 VDC
E-STOP
ENGINE KILL
SWITCH
REF
P61/J61 CATERPILLAR ENGINE
BLU 16 NC BLU 16
RUN KEY 7 7 7 +BAT (SWITCHED) 26 26 PLUG ASSY
SEE SHT 2

GRY 16
47 PWR FROM CONTROL
PANEL 15 AMP BREAKER
SEE SHT 1 AND 3
WHT 16
PWR TO LUBE TMR PRS. SW. 145
WHT/BLK 16
SIGNAL FROM TMR PRS. SW. 146
TAN 16
PWR TO LUBE SOL. 147
TAN/BLK 16
SIGNAL FROM TMR SOL. 148
GRN/BRN 16
ETHER 149

WHT/BRN 16
WHT/BRN 16
OIL INJECTION 150
PNK/BLU 16
OIL INJ LIGHT 151
TAN 16
THREAD LUBE 152
ORG/GRN 16
PIPE RACK SWING LIMIT SW. 156

PNK/BLU 16
GRN 16
PIPE RACK SWING & PIPE POSITIONER PWR 157
GRY 14
5 LIGHT PACKAGE 161
ORG 14 150 214
PWR TO CAB FLOOR HEATER 164
YEL/GRY 16 215
WINCH DOWN 170

WHT/BLK 16
TAN/BLK 16
YEL/BLU 16 151

ORG/GRN 16
WINCH UP 171
WHT 16
PWR TO DC TIMER 190
GRAY 14
YEL/GRY 16

WHT 16
YEL/BLU 16

TAN 16
GRN 16
ORG 14

TAN 16
BLK 16 LIGHT
GND FROM DC TIMER 191 B A
PWR TO AC CONDENSOR RED 14 BLK WHT
192 R
YLW 14
PWR TO BINARY SW 195 148 147 146 145
GRN 14 164 161 157 156 152
PWR TO AC CLUTCH 196 BLK RED
171 170

OUT

IN
2 NC
GRN 14 B A
3 1 TIMER
196 OPTIONAL OPTIONAL REF
PUMP TIMER LINCOLN PIPE
BOX LINCOLN
LUBE LUBE POSITIONER
OPTIONAL PRES. SW.
OPTIONAL OPTIONAL SOLENOID SEE SHT 4
PIPE RACK SWING THREAD OIL
OPTIONAL FIVE (5) LIGHT PACKAGE LIMIT SWITCH LUBE
INJECTION
UP

RED 14
DOWN

192

85 87 87a 85 87 87a

M OPTIONAL
WINCH
86 30 86 30
M
RELAY RELAY
YEL 14 REF
410093 OPTIONAL CAB
195 SEE SHT 4 HEATER MOTOR
LOW HIGH
PRESS PRESS
BINARY SWITCH

A/C CONDENSOR
Ref. 426455 rev. 06 (8 of 12)

8-34 Electrical Components

 Electrical Schematic–SKF (Cat)

RED 16
211 RE REF REF
D
REF OPTIONAL OPTIONS
212 ORG RELAY
OPTIONAL 24/12 VDC
BLK CB RADIO CONVERTER SEE REF REF
ORG 16 RED 16
N SHT 1 SPEAKER OPTIONAL OPTIONS
GR 12VDC PWR RED 16 ORG 14
162 5 162 163 24/12 VDC RELAY
REF OPTIONAL 12VDC PWR 24VDC PWR
CONVERTER SEE
OPTIONS DEI POWER RED 16 OUTPUT INPUT
SHT 1
RELAY CONDITIONER
SEE 162 162 163
401337
RED RED 16 ORG 14
SHT 1
RADIO BLK
418693 YLW
OPTIONAL DRILL EFFICIENCY INDICATOR (DEI) CIRCUIT OPTIONAL CB RADIO CIRCUIT

MEMORY
MODULE
RED
SPEAKER
ORG
198
REF BLK ORG 18
OPTIONS
RELAY 421289
SEE YLW
SHT 1
REF
OPTIONS
RED 2 1
RELAY
SEE
SHT 1
L.F. JACK UP =
R.F. JACK UP = GREEN LAMP
418677
GRY/BLK 16
L.R. JACK UP = GREEN LAMP
TEST 418677
SW. R.R. JACK UP = GREEN LAMP
418677 + - PRPL/GRN 16
GRY/BLK 16
GREEN LAMP 165 PWR TO JACK LIGHT SW's 165
418677 + - TAN/RED 16
166 GND FROM L.F. JACK SW. 166
+ - TAN/RED 16
167 GND FROM R.F. JACK SW. 167
+ - TAN/RED 16 OPTIONAL SOUND SYSTEM CIRCUIT
LOOP
WHITE 16 GA 168 GND FROM L.R. JACK SW. 168
FILTER
#1 TAN/RED 16 GND FROM R.R. JACK SW. 169
169
OPTIONAL JACK SWITCHES
LOOP
WHITE 16 GA
REF
FILTER
#2 OPTIONS
RELAY
SEE
LOOP
FILTER WHITE 16 GA SHT 1
#3 GRN/GRY 16 OPTIONAL LEFT OPTIONAL RIGHT
172 PWR FROM OPTIONS RELAY TO N.O. SW's 172

GRY 16
GRY/BLK 16 WIPER/WASHER WIPER/WASHER
173 PWR FROM TEST SW. TO N.C. SW's 173
LOOP SWITCH SWITCH
WHITE 16 GA WHT 16
FILTER
#4
174 PWR FROM LOOP FILTER #1 SW. TO LIGHT 174
WHT 16
175 PWR FROM LOOP FILTER #2 SW. TO LIGHT 175 116
WHT 16
CHARGE
WHITE 16 GA 176 PWR FROM LOOP FILTER #3 SW. TO LIGHT 176
FILTER
#1 WHT 16 GRY 16 B W P HL GRY 16 B W P HL
177 PWR FROM LOOP FILTER #4 SW. TO LIGHT 177
WHT 16 117 117
178 PWR FROM CHARGE FILTER #1 SW. TO LIGHT 178 10
CHARGE
WHITE 16 GA WHT 16
FILTER 179 PWR FROM CHARGE FILTER #2 SW. TO LIGHT 179
#2 VLT/YEL BLU/YEL
WHT 16 120 L 126 L
180 PWR FROM MAIN FILTER SW. TO LIGHT 180 16 16
WHT 16 VLT/WHT H BLU/PNK H
MAIN 181 PWR FROM CASE FILTER SW. TO LIGHT 181 119 M 125 M
FILTER
WHITE 16 GA
16 P 16 P
WHT 16

YEL/BLK 16

YEL/RED 16
182 PWR FROM COMPRESSOR FILTER SW. TO LIGHT 182

GRY 16
VLT/BLU OPTIONAL LEFT BLU/WHT OPTIONAL RIGHT
118 124
16 WIPER MOTOR 16 WIPER MOTOR
CASE
WHITE 16 GA
FILTER

OPTIONAL
117
ROTARY HEAD
COMPRESSOR TACH 127 129
FILTER
WHITE 16 GA OPTIONAL REAR
414898 WIPER/WASHER
OPTIONAL FILTER BYPASS SWITCHES SWITCH
1 M M

REF A B OPTIONAL LEFT OPTIONAL RIGHT

OPTIONS YLW 16 WASHER BOTTLE WASHER BOTTLE
GRY 16

183 RELAY 184 R.H. TACH SIGNAL 184

PUMP MOTOR BW P HL PUMP MOTOR
SEE RED 16
185 R.H. TACH GROUND 185
SHT 1
PWR TO HORN 186

OPTIONAL PWR TO MAST LOCK SW's. 187 PNK/BLK

123 L
HORN 16
PWR FROM MAST LOCK SW's. 188 H
RED 16 RED 16 PNK/YEL M
PWR FROM MAST UNLOCK SW's. 189 122 P
16

YEL/GRN 16
REF 186 186
IGNITION PNK/BLU OPTIONAL REAR
121
RELAY N.O. 16 WIPER MOTOR
REF
SEE
SHT 1 58 42259

57
CAB JUNCTION 128
REF REF BOX TERMINALS
KEY SW. 16
REF M
REF OPTIONS
RELAY
OPTIONAL REAR
SEE
WASHER BOTTLE
SHT 1
MAST LOCKED = PUMP MOTOR
RED LAMP
MAST UNLOCKED =
416874
GREEN LAMP OPTIONAL WIPER/WASHER SYSTEM CIRCUIT
416873
RED 16
187
GRN 16
188
RED 16
189
Ref. 426455 rev. 06 (9 of 12)
OPTIONAL MAST LOCK SWITCH'S

Electrical Components 8-35

 Electrical Schematic–SKF (Cat)

ETHER OPTIONAL JACK LIGHT SWITCH'S

OPTIONAL REMOTE START
OPTIONAL
BL 418673 418673 LK
BLU/BRN 16 209 BLU/BRN 16 K B
BRN LEFT RIGHT BRN
FRONT FRONT BL
149 REF N.O. L U
B JACK JACK U

PRPL/GRN 16

PRPL/GRN 16
42259
REF 209
OPTIONAL
ETHER REF ENGINE REF ENGINE
SOLENOID
JUNCTION BOX JUNCTION BOX
OPTIONAL OPTIONAL REF ENGINE
BATT. 50 AMP OPTIONAL OPTIONAL TERMINAL TERMINAL
BREAKER KEY STARTER JUNCTION BOX
REF 1155171 RED 6 RED 10 GRN 12 165 165
L TERMINAL
ENGINE WHT/BLU 16
96192
203 204 205
208 50
PRESS SW. S G
16864 N.O.
166 165 167

BLU 16
42259
REF 52 9 REF GRN 12
OPTIONAL 207
ENGINE HR 206
418673 LK BL 418673
LEFT B K RIGHT
REF BRN BRN
REF REAR REAR
BL U
REF 102 JACK U BL JACK
17
109

PRPL/GRN 16
REF 108 165
53 REF TAN/RED 16
G + S STARTER 166
SOLENOID TAN/RED 16
REF 110 +
167
B+
TAN/RED 16
G B- 168
STARTER TAN/RED 16
169
ALTERNATOR
REF 105 104
TYPICAL, 9 PLCS
REF BLACK, WHITE & GREEN
210 STJO CORD, 18/3
OPTIONAL REMOTE START CIRCUIT

GREEN-16 GA B RED
NO
C FILTER
WHITE-16 GA C BLACK
TERMINAL BOX NC
COMPRESSOR

BLACK-16 GA A WHITE

GREEN-16 GA B RED
NO
FILTER
C
WHITE-16 GA C BLACK CASE
NC
PWR TO JACK LIGHT SW's 165 BLACK-16 GA A WHITE

GND FROM L.F. JACK SW. 166

GREEN-16 GA B RED
GND FROM R.F. JACK SW. 167 NO
C FILTER
WHITE-16 GA C BLACK
GND FROM L.R. JACK SW. 168 NC MAIN

A WHITE
GND FROM R.R. JACK SW. 169 BLACK-16 GA

CHARGE#2

CHARGE#2
CHARGE#1

CHARGE#1
GREEN-16 GA B RED #2

LOOP#4
LOOP#3
LOOP#2

LOOP#4
LOOP#3
LOOP#2
LOOP#1

LOOP#1
NO
FILTER

COMP
CASE

COMP
CASE
MAIN

MAIN
C
WHITE-16 GA C BLACK CHARGE
GRN/GRY 16 NC
PWR FROM OPTIONS RELAY TO N.O. SW's 172 172
BLACK-16 GA A WHITE
GRY/BLK 16
PWR FROM TEST SW. TO N.C. SW's 173 173
10 9 8 7 6 5 4 3 2 1
WHT 16
PWR FROM LOOP FILTER #1 SW. TO LIGHT 174 174 GREEN-16 GA B RED
NO #1
WHT 16 C FILTER
PWR FROM LOOP FILTER #2 SW. TO LIGHT 175 175 WHITE-16 GA C BLACK
NC CHARGE
WHT 16
PWR FROM LOOP FILTER #3 SW. TO LIGHT 176 176 BLACK-16 GA A WHITE

WHT 16
PWR FROM LOOP FILTER #4 SW. TO LIGHT 177 177
GREEN-16 GA B RED
WHT 16 NO
PWR FROM CHARGE FILTER #1 SW. TO LIGHT 178 178 C
#4
FILTER
WHITE-16 GA C BLACK
WHT 16 NC LOOP
PWR FROM CHARGE FILTER #2 SW. TO LIGHT 179 179
BLACK-16 GA A WHITE
WHT 16
PWR FROM MAIN FILTER SW. TO LIGHT 180 180
WHT 16
PWR FROM CASE FILTER SW. TO LIGHT 181 181 GREEN-16 GA B RED

CHARGE#2

CHARGE#1
NO

LOOP #1
#3

LOOP#3
WHT 16

LOOP#4

LOOP#2
C
PWR FROM COMPRESSOR FILTER SW. TO LIGHT 182 182 FILTER

COMP
WHITE-16 GA C BLACK

CASE

MAIN
NC LOOP

BLACK-16 GA A WHITE
OPTIONAL
YLW 16 ROTARY
R.H. TACH SIGNAL 184 184 10 9 8 7 6 5 4 3 2 1
RED 16 HEAD GREEN-16 GA B RED
NO
R.H. TACH GROUND 185 185 TACH C
#2
FILTER
RED 16 SENDER
WHITE-16 GA C BLACK
NC LOOP
PWR TO HORN 186 186
RED 16 OPTIONAL BLACK-16 GA A WHITE
PWR TO MAST LOCK SW's. 187 187 HORN 417219
PWR FROM MAST LOCK SW's. 188 GREEN-16 GA B RED
NO
96908 #1
PWR FROM MAST UNLOCK SW's. 189 WHITE-16 GA C BLACK
C FILTER
LOOP
NC

A WHITE
GRN 16 BLACK-16 GA
188
RED 16
189
OPTIONAL FILTER BYPASS SWITCH'S
L.H. UNPINNED R.H. UNPINNED
CAB JUNCTION 3 3
81187 81187
BOX TERMINALS
RED 16

189
1 1
RED 16

L.H. PINNED 189 R.H. PINNED

81187 1 1 81187
GRN 16

188
3 2 3
Ref. 426455 rev. 06 (10 of 12)
OPTIONAL MAST LOCK SWITCH'S

8-36 Electrical Components

 Electrical Schematic–SKF (Cat)
REF - 438737
REMOTE TRAM MODULE

PWM OUTPUT, RIGHT TRACK REV.

PWM OUTPUT, LEFT TRACK REV.

= PWM OUTPUT, LEFT TRACK FWD.

= PWM OUTPUT, RIGHT TRACK FWD
REF - CAB MOUNTED INSIDE J-BOX
ON OUTSIDE WALL OF CAB
JUNCTION BOX

= INPUT, PENDANT SELECTOR

INPUT, RIGHT TRACK REV.
INPUT, RIGHT TRACK FWD.
L/H TRAM JOYSTICK R/H TRAM JOYSTICK

INPUT, LEFT TRACK REV.

INPUT, LEFT TRACK FWD.

= INPUT, TRIGGER ENABLE

(SEE SHEET 5) (SEE SHEET 5)

INPUT, ENG. STOP UP

= OUTPUT, ENGINE RUN
WITH OPTIONAL REMOTE TRAM,
RE-ROUTE WIRING AS SHOWN,

GROUND
GROUND
GROUND
THROUGH PENDANT RELAYS

VDD
VDD
= VDD
= VDD
1066939 HARNESS PIGTAIL - REMOTE TRAM
35-PIN CONNECTOR, W/120" HARNESS

=
=
=
=
=
=
=
=
=
=
=
=
(ALL WHITE WIRES, NUMBERED 1-35)

+ - + -

J1-22
J1-23
J1-24
J1-25
J1-26
J1-27
J1-28
J1-29

J1-32
J1-33
J1-34
J1-35
B A B A

J1-20

J1-30
J1-12
J1-13
J1-14
J1-15
J1-16
J1-17
J1-18
J1-19

J1-21

J1-31
J1-10
J1-11
J1-2
J1-3
J1-4
J1-5
J1-6
J1-7
J1-8
J1-9
J1-1

BLU #9
BLK

BLK
YEL #4
BLU #5
L/H PENDANT RELAY R/H PENDANT RELAY

YEL #8
23

25
26
24

WHT 29

WHT 34
WHT 32
15
16
17
18
19
(D/C SIDE)

WHT 10
(CAB SIDE)

WHT 2
WHT 1
6 6

WHT
WHT
WHT
WHT
WHT

WHT

WHT
WHT
WHT
5 7 226 5 7 224
4 8 4 8
TERMINALS IN 227 225
CAB J-BOX
240 3 9 3 9

YEL #2
BLU #3
7 265

BLK 2
RUN KEY

BLK 1
BLK #3
BLU #1
-2 +10 -2 +10

1 11 1 11
238 239
237

244 241 242 243 RELAY SHOWN RELAY SHOWN

250 247 DE-ENERGIZED DE-ENERGIZED
252

YEL #6

YEL #9
E WHT 25
232

BLU #8A
249 246
248 236
251 245

BLU #4A

YEL #3
P
N
M
L
K
J
H
G
F

D
C
B
A

GRY #2
GRAY #1
233 229

16GA
231

P
N
M
L
K
J
H
G
F
E
D
C
B
A
REF. - 416636, 235 228
230
14-SOCKET CONN.

GRY 2
256
260 (MOUNTED IN
253 254
11 11 BOTTOM OF CAB J-BOX)

BLU #7
1066855 HARNESS, PENDANT TETHER 255
9 9 258 259
5 5 237
FROM RELAY #3 (REF.
REF - 416635, FROM RELAY#5 (REF. L/H TRAM PUMP)
3 3 R/H TRAM PUMP)
257 14-PIN PLUG SEE SHEET 5
ORG 12 12 ORG #1 SEE SHEET 5
(ON END OF HARNESS)
WHT/BLK 10 10 BRN #5
RED/BLK 8 8 YEL #1
GRN 7 7 GRN #5
WHT 6 6 GRY #7
BLU 4 4 BLU #6

BLU #3
BLK 2 2 BLK #4
RED 1 1 GRY #5

BLU #7
YELLOW #2
LEFT TRACK FWD, PWM

YEL #6
416647 12-PIN PLUG
1
9
8
7
6
5
4
3
2
11
10
12 12

416645 12-SKT RECTP. LEFT TRACK REV, PWM

416647 12-PIN PLUG

BLU #6
GRAY #3
1
9
8
7
6
5
4
3
2
11
10

416645 12-SKT RECTP. RIGHT TRACK REV, PWM

234

BLU #1
RIGHT TRACK FWD, PWM
BLU #6
262
BLU #1
265
87a NC

30
REMOTE TRAM BLU #1 87
ORG

BRN

YEL

GRN

BLU

BLK
RED
WHT

PENDANT NO

(P/N 438736) BLU #6 85 GND EN 86

GRAY #1
S4, RIGHT TRACK

S5, RIGHT TRACK

PENDANT RELAY 2, 261

16GA
BLU #2
BUTTON OUT IS NC

MOUNTED UNDER CONSOLE

S1, ENG. STOP SW

GRAY #0
FWD. (WHITE)

REV. (BLACK)

(ZIP-TIED TO HARNESS) RELAY

16GA
SHOWN
DE-ENERGIZED

OPTIONAL INSTALLATION OF: 264 236

P/N T438745, REMOTE TRAM
BLU #1 87a NC GRAY #8
265 16GA
30
S2, LEFT TRACK

S3, LEFT TRACK

87 263
NOTE: ENGINE "RUN/STOP" LOGIC - REMOTE TRAM PENDANT SYSTEM NO GRAY #1 GRAY #0
FWD. (WHITE)

REV. (BLACK)

16GA 16GA
BLK #5 85 GND EN
1) PENDANT/TRAM CONTROL SWITCH OPEN. 266
86
236
NO
NC

PENDANT RELAY 1 261

=PENDANT RELAYS 1 & 2 DE-ENTERGIZED; MOUNTED BEHIND
POWER PATH: 261-263-265-TERMINAL 7, CAB J-BOX, KEY SWITCH RELAY SHOWN
DE-ENERGIZED
PENDANT TRAM CONTROL SW -
ON INSTR. PANEL GRAY #1 (ON CONSOLE PANEL)
ENGINE CAN RUN.
NO
NC

(ZIP-TIED TO HARNESS) 16GA CLOSED = PENDANT,

2) PENDANT/TRAM CONTROL SWITCH CLOSED, AND 253 OPEN = JOYSTICK
A) PENDANT ENGINE STOP SWITCH UP/CLOSED. PWR FROM IGNITION RELAY
=PENDANT RELAYS 1&2 ENERGIZED (KEY-SWITCH OPERATED, SEE SHT 1)
POWER PATH: 261-265-TERMINAL 7, CAB J-BOX;
PENDANT TRIGGER SW.

ENGINE CAN RUN.

B) PENDANT ENGINE STOP SWITCH DOWN/OPEN.
=PENDANT RELAY 1 ENERGIZED BUT NOW
S6,

PENDANT RELAY 2 DE-ENERGIZED,

POWER PATH: 261 ONLY (STOPS AT PENDANT RELAY 2);
ENGINE WILL NOT RUN.

Ref. 426455 rev. 06 (11 of 12)

Electrical Components 8-37

 Electrical Schematic–SKF (Cat)
MASTER WIRE NO., DESCRIPTION & TERMINAL LIST
WIRE WIRE WIRE REFERENCE TERMINAL WIRE WIRE WIRE REFERENCE TERMINAL WIRE WIRE WIRE REFERENCE TERMINAL
DESCRIPTION AND/OR FUNCTION DESCRIPTION AND/OR FUNCTION DESCRIPTION AND/OR FUNCTION
NO. COLOR CODE GA. SHT/ZONE NUMBER NO. COLOR CODE GA. SHT/ZONE NUMBER NO. COLOR CODE GA. SHT/ZONE NUMBER
1 GREEN/YELLOW 16 COMPRESSOR TEMP, FROM SENDING UNIT TO MTR. 1F4 & 2F6 1 75 WHITE 16 PROPEL, FROM SW. TO RELAY #3, TERMINAL #10 3C7 & 5B5 75 147 TAN 16 POWER TO LINCOLN LUBE SOLENOID 7E3 & 8B3 147
2 WHITE 16 WATER TEMP, FROM SENDING UNIT TO MTR. 1F4 & 2F6 2 76 YELLOW 9 18 FROM RELAY #2, TERM. #9 TO PWR. ROTATE JOYSTICK 5D4 76 148 TAN/BLACK 16 SIGNAL FROM LINCOLN LUBE SOLENOID 7E3 & 8B3 148
3 BROWN 16 FUEL, FROM SENDING UNIT TO MTR. 1F4 & 2F6 3 77 WHITE 7 18 FROM RELAY #2, TERM. #8 TO PWR. L.H. JOYSTICK 5D5 77 149 GREEN/BROWN 16 ETHER, FROM ETHER SW. TO ETHER SOL. 7E5 & 8E4 149
4 BLACK/ORANGE 16 OIL PRESSURE, FROM SENDING UNIT TO MTR. 1F4 & 2F6 4 78 WHITE 6 18 FROM PWR ON L.H. JOYSITCK TO PWR ON R.H. JOYSTICK 5E6 & 6C2,E5,B6 78 150 WHITE/BROWN 16 OIL INJECTION, SW. TO OIL INJ. TIMER 7C5 & 8C3 150
5 YELLOW 16 TACH, FROM TACH SENDING UNIT TO MTR. 1E3 & 2E6 5 79 GRAY 16 FROM ING. RELAY TO 15 AMP CONTROL PANEL BREAKER 1C5 79 151 PINK/BLUE 16 OIL INJECTION LIGHT, FROM OIL INJ. LIGHT TO OIL INJ. BOX 7D3 & 8C3 151

6 RED 16 TACH, FROM MTR. TO SENDING UNIT 1E3 & 2E6 6 80 GREEN/GRAY 16 16 JUMPER FROM 50 AMP BREAKER TO PWR 15 AMP BRKR 1D5 80 152 TAN 16 THREAD LUBE, SW. TO SOL. 7C4 & 8B4 152
7 BLUE 16 RUN-KEY, FROM RUN SW. TO ENGINE ECM, PIN #26 1E3 & 2E6 7 81 BROWN 8 18 FROM RELAY #3, TERM #11 TO R.H. PUMP SOL. "A" 5C5 81 153 PINK 5 18 FROM RELAY #4, TERM. #5 TO HOIST JOYSTICK TERM. PWR 7C6 153
8 GREEN 16 DIAGNOSTIC LAMP, FROM DIAG. LAMP TO ECM, PIN #24 1E3 & 2E6 8 82 BROWN 4 18 FROM RELAY #3, TERM. #1 TO R.H. PUMP SOL. "B" 5C5 82 154 ORANGE 5 18 FROM RELAY #4, TERM #5 TO OVERIDE SW. 7C6 154
9 WHITE/GREEN 16 ENGINE HOUR, FROM ENGINE HR SW. TO MTR. 1E3 & 2E6 9 83 YELLOW 9 18 FROM RELAY #3, TERM #9 TO R.H. JOYSTICK TERM. A 5D5 83 155 ORANGE 7 18 FROM OVERIDE SW. TO RELAY #4, TERM. #7 7C6 155
10 GREEN/WHITE 16 DRILL HOUR, FROM DRILL HR. SW. TO MTR. 1E5 10 84 GREEN 8 18 FROM RELAY #3, TERM. #8 TO ROTATE JOYSTICK TERM. A 5D4 84 156 ORANGE/GREEN 16 FROM RELAY #4, TERM. #10 TO PIPE RACK LIMIT SW. 7C6 & 8B4 156
11 GREEN/BROWN 16 ETHER INJECTION 11 85 GREEN 4 18 FROM RELAY #3, TERM. #4 TO ROTATE JOYSTICK TERM. B 5D4 85 157 GREEN 16 PWR FROM OPTIONS RELAY TO OPTIONS IN MAST 7D3, 8B5 & 8D2 157
12 GREEN/BLACK 16 KEY DRILL HOUR, PWR FROM ING. RELAY TO DRILL HR SW. 1D5 12 86 YELLOW 3 18 FROM RELAY #3, TERM. #3 TO R.H. JOYSTICK TERM. B 5D6 86 158 RED 12 PWR FROM OPTIONS REALY TO OPT. 24VDC ACCESSORY 7E4 158

13 GREEN/RED 16 BACK-UP ALARM, FROM BACK-UP ALARM SW. TO ALARM 1D3, 2D7 & 2E6 13 87 BLUE 8 18 FROM L.H. JOYSTICK TERM. A TO L.H. PUMP SOL. "A" 5C7 87 159 RED 12 PWR FROM OPTIONS RELAY OPT. AC/HEATER 7D4 159
14 BLUE 16 PWR FROM RUN SWITCH TO THROTTLE POSITION SENSOR 1E5 14 88 BLUE 4 18 FROM L.H. JOYSTICK TERM. B TO L.H. PUMP SOL. "B" 5C7 88 160 BLK 000 FROM MASTER DISCONNECT SW. TO (-) LEAD BAT #1 7A5 160
15 GREEN 10 DRILL LIGHT POWER, FROM 50 AMP BRKR TO LIGHT RELAY 1C3 & 2D6 15 89 GRAY 6 18 PWR TO&FROM ROTATE JOYSTICK TO HOIST PULLDOWN JOYSTICK 5D3 & 7D7 89 161 GRY 14 POWER TO OPTIONAL 5 LIGHT PACKAGE 7C3 & 8B5 161
16 RED 10 MAIN POWER, FROM 50 AMP BREAKER TO KEYSWITCH 1C3 & 2C6 16 90 90 162 ORANGE 14 PWR FROM OPTIONS RELAY TO 24/12 VDC CONVERTER 7E4 162
17 BLUE 12 FROM ING. RELAY THRU STRTR BTN. TO STARTER SOL. 1C3 & 2C6 17 91 91 163 RED 16 PWR FROM 24/12 CONVERTER TO 5 AMP BREAKER 7E5 163
18 GREEN/GRAY 16 FRONT LIGHTS, FROM LIGHT RELAY TO FRONT LIGHTS 1C3, 2B7 & 2C6 18 92 92 164 ORANGE 14 PWR FROM OPTIONS RELAY TO OPT. CAB HEATER 7E4 164

19 RED/WHITE 16 MAST UNLOCK, SW. TO SOL."B" 3D7 & 4C2 19 93 93 165 PURPLE/GREEN 16 PWR FRO JACK LIGHT OPTION 9D5 & 10E4 165
20 GRAY/WHITE 16 MAST LOCK, SW. TO SOL. "A" 3D7 & 4C2 94 94 166 TAN/RED 16 FROM JACK SENSOR SW. TO LF LIGHT 9D5 & 10E4 166
20
21 GRAY/BLUE 16 MAIN AIR CLOSE, SW. TO SOL. "A" 3D7 & 4C5 95 PINK 2 18 FROM HOIST/PLDWN JOYSTICK TERM. B TO UP PLDWN VLV 5D3 95 167 TAN/RED 16 FROM JACK SENSOR SW. TO RF LIGHT 9D5 & 10E4 167
21
22 BLUE/YELLOW 16 MAIN AIR OPEN, SW. TO SOL. "B" 3D7 & 4C5 96 PINK 6 18 FROM HOIST/PLDWN JOYSTICK TERM. A TO DWN PLDWN VLV 5E2 96 168 TAN/RED 16 FROM JACK SENSOR SW. TO LR LIGHT 9D5 & 10E4 168
22
23 PINK/BROWN 16 DUST COLLECTOR, SW. TO SOL. "B" 3E3 & 4C6 97 PURPLE 18 FROM HOIST JOYSTICK TO AUTO SW. 3C4 & 5E2 97 169 TAN/RED 16 FROM JACK SENSOR SW. TO RR LIGHT 9D5 & 10E4 169
23
24 BROWN/WHITE 16 WATER INJECTION, SW. TO SOL "A" 3E3 & 4C6 24 98 PURPLE 18 FROM AUTO SW. TO CARD TERM. (+) 3C4 & 5E2 98 170 YELLOW/GRAY 16 WINCH DOWN, SW. TO SOL. "A" 7C3 & 8B6 170

25 PINK/BLACK 16 PIPE RACK OUT, SW. TO SOL. "A" 3D4 & 4C3 25 99 PINK 0 18 FROM AUTO CARD "A" TO HOIST/PLDWN JOYSTCIK TERM. A 5E2 99 171 YELLOW/BLUE 16 WINCH UP, SW. TO SOL. "B" 7C3 & 8B6 171
26 BLACK/PINK 16 PIPE RACK IN, SW. TO SOL. "B" 3D4 & 4C3 26 100 GRAY 16 FROM RUN START SW. TO IGNITION RELAY 1E7 100 172 GREEN/GRAY 16 PWR TO OPTIONAL FILTER LIGHT SW. 9C5 & 10C5 172
27 YELLOW/WHITE 16 PIPE RACK INDEX CW, SW. TO SOL. "A" 3D5 & 4C4 27 101 BLACK 16 FROM P61 PLUG, PIN # 27 TO COMP. TEMP. SW. 2E4 101 173 GRAY/BLACK 16 PWR FROM OPTIONAL FILTER LIGHT SW. 9D6 & 10C6 173
28 YELLOW/BLACK 16 PIPE RACK INDEX CCW, SW. TO SOL. "B" 3D5 & 4C4 28 102 RED 10 FROM POS. STARTER SOL. TO 15 AMP BREAKER 2D4 102 174 WHITE 16 PWR FROM OPTIONAL LOOP FILTER #1 TO LIGHT 9C5 & 10C5 174

29 YELLOW/BROWN 16 PIPE POSITIONER IN, SW. TO SOL. "A" 3D4 & 4C3 29 103 103 175 WHITE 16 PWR FROM OPTIONAL LOOP FILTER #2 TO LIGHT 9D6 & 10C6 175
30 YELLOW/RED 16 PIPE POSITIONER OUT, SW. TO SOL. "B" 3D4 & 4C3 30 104 BLACK 6 FROM (-) LEAD ON ALT. TO GND ON STARTER 2C3 104 176 WHITE 16 PWR FROM OPTIONAL LOOP FILTER #3 TO LIGHT 9C5 & 10C5 176
31 YELLOW/GREEN 16 AUTO TOOL IN, SW. TO SOL. "A" 3C6 & 4C1 105 BLACK 000 FROM MASTER DISCONNECT SW. TO GND LEAD ON STARTER 2C3 105 177 WHITE 16 PWR FROM OPTIONAL LOOP FILTER #4 TO LIGHT 9C6 & 10C6 177
31
32 YELLOW/ORANGE 16 AUTO TOOL OUT, SW. TO SOL "B" 3C6 & 4C1 106 106 178 WHITE 16 PWR FROM OPTIONAL CHARGE FILTER #1 TO LIGHT 9C5 & 10C5 178
32
33 YELLOW/BLUE 16 OPTIONAL WINCH UP 3E4 & 4B4 33 107 RED 000 FROM (+) LEAD ON BAT #1 TO (-) LEAD ON BAT #2 2C4 107 179 WHITE 16 PWR FROM OPTIONAL CHARGE FILTER #2 TO LIGHT 9C6 & 10C6 179
34 YELLOW/GREY 16 OPTIONAL WINCH DOWN 3E4 & 4B4 34 108 RED 000 FROM (+) LEAD ON BAT #2 TO POS. ON STARTER SOL. 2C4 108 180 WHITE 16 PWR FROM OPTIONAL MAIN FILTER TO LIGHT 9C5 & 10B5 180
35 WHITE/YELLOW 16 DUST CURTAIN DOWN, SW. TO SOL. "B" 3D6 & 4C5 35 109 RED 6 FROM (+) LEAD ON STARTER SOL. TO 50 AMP BREAKER 2C4 109 181 WHITE 16 PWR FROM OPTIONAL CASE FILTER #1 TO LIGHT 9C6 & 10B6 181

OPTIONS
36 WHITE/RED 16 DUST CURTAIN UP, SW. TO SOL. "A" 3D6 & 4C5 36 110 BLACK 000 FROM GND ON STARTER TO GND ON STARTER SOL. 2C4 110 182 WHITE 16 PWR FROM OPTIONAL CASE FILTER #2 TO LIGHT 9C5 & 10B5 182

37 WHITE/BLACK 16 PROPEL SELECT, SW. TO SOL. 3C7 37 111 111 183 GRAY 16 PWR FOR OPTIONAL ROTARY HD TACH 9B7 183
38 WHITE/BLUE 16 HAMMER LUBE 3E7 & 4B7 38 112 112 184 RED 16 ROTARY HD TACH SIG. TO MTR "B" TERM 9B6 & 10B5 184
39 ORANGE/BLACK 16 HOBO RELEASE, SW. TO SOL. "A" 3E4 & 4C2 39 113 113 185 YELLOW 16 ROTARY HD TACH GND. TO MTR "A" TERM 9B6 & 10B5 185
40 ORANGE/WHITE 3E4 & 4C2 114 114 186 RED 16 PWR FOR OPTIONAL HORN FROM MAIN PWR CIRCUIT 9B6 & 10B5 186
16 HOBO CLAMP, SW. TO SOL. "B" 40
41 BLUE/WHITE 16 HOBO SWING OUT, SW. TO SOL. "A" 3D2 & 4C1 41 115 115 187 RED 16 PWR FOR MAST LOCK INDICATOR SW. 9A5 & 10B6 187
42 BLACK/WHITE 16 HOBO SWING IN, SW. TO SOL. "B" 3D2 & 4C1 42 116 GRAY 16 PWR FROM OPTION RELAY TO 10 AMP WIPER/WASHER BRKR 9D3 116 188 GREEN 16 PWR FROM MAST LOCK SW. TO GREEN INDICATOR LIGHT 9A6 & 10B5 188
43 BLACK/YELLOW PIPE RACK LOCK, SW. TO SOL. "A" 3D6 & 4C2 117 GRAY 16 PWR FROM 10 AMP BREAKER TO WIPER SWITCHES 9C3 117 189 RED 16 PWR FROM MAST UNLOCK SW. TO RED INDICATOR LIGHT 9A6 & 10B6 189
16 43
44 GRAY/RED 16 PIPE RACK UNLOCK, SW. TO SOL. "B" 3D6 & 4C2 44 118 VIOLET/BLUE 16 PWR TO PARK LEFT WIPER MOTOR 9C3 118 190 WHITE 16 PWR FROM ENGINE PRES. SW. TO D.C. TIMER 7B3 & 8E5 190

45 BLUE/GREY 16 CAB TOP LIGHTS 1B3 & 2B6 45 119 VIOLET/WHITE 16 PWR TO HIGH SPEED LEFT WIPER MOTOR 9C3 119 191 BLACK 16 FROM STARTER GND TO GND ON D.C. TIMER 7B5 & 8D5 191
46 TAN 16 THREAD LUBE 3E7 & 4B7 46 120 VIOLET/YELLOW 16 PWR TO LOW SPEED LEFT WIPER MOTOR 9C3 120 192 RED 14 PWR FROM 10 AMP BRKR TO AC CONDENSOR 7E7 & 8B6 192
47 GRAY 16 FEED TO SWITCHES ON DRILL FUNCTIN PANEL 1B5 & 3E8 47 121 PINK/BLUE 16 PWR TO PARK REAR WIPER MOTOR 9B2 121 193 RED 14 PWR JUMPER FROM 10 TO 15 AMP BRKR 7D7 193

48 48 122 PINK/YELLOW 16 PWR TO HIGH SPEED REAR WIPER MOTOR 9B2 122 194 RED 14 PWR FROM 15 AMP BRKR TO AC HEATER 7E7 194
49 49 123 PINK/BLACK 16 PWR TO LOW SPEED REAR WIPER MOTOR 9B2 123 195 YELLOW 14 FROM THERMOSTAT SW. TO BINARY SW. 7D7 & 8A6 195
50 TAN/PINK 16 OPTIONAL PIPE POSITIONER AUTOMATIC 3D4 & 4C3 50 124 BLUE/WHITE 16 PWR TO PARK RIGHT WIPER MOTOR 9C2 124 196 GREEN 14 FROM AC RELAY TO AC COMPRESSOR CLUTCH 8B8 196

51 BLACK 16 GND - 51 125 BLUE/PINK 16 PWR TO HIGH SPEED RIGHT WIPER MOTOR 9C2 125 197 BLUE 14 FROM AC ROTARY SW. TO PRESSURIZER MOTOR 7E8 197
52 GRAY/YELLOW 16 FROM 50 AMP BREAKER TO ENGINE HR. MTR. 2D5 52 126 BLUE/YELLOW 16 PWR TO LOW SPEED RIGHT WIPER MOTOR 9C2 126 198 ORANGE 18 PWR FROM OPTION RELAY TO RADIO MEMORY MODULE 9E1 198
53 RED 6 FROM POS. ON STARTER SOL. TO (+) LEAD ON ALTERNATOR 2C3 53 127 YELLOW/BLACK 16 PWR TO LEFT WASHER PUMP MOTOR 9C3 127 199 ORANGE 18 PWR FROM OPTION RELAY TO RADIO RELAY 9E3 199
54 RED 14 FROM P61 PLUG, PIN #1 TO 15 AMP BREAKER 2E3 54 128 YELLOW/GREEN 16 PWR TO REAR WASHER PUMP MOTOR 9B2 128 200 YELLOW 18 RADIO MEMORY POWER TO RADIO RELAY 9E3 200
OPTIONS

55 RED 14 FROM P61 PLUG, PIN # 31 TO 15 AMP BREAKER 2E3 55 129 YELLOW/RED 16 PWR TO RIGHT WASHER PUMP MOTOR 9C1 129 201 RED 18 PWR FROM RELAY TO 12 VDC PWR 9D2 201
56 RED 14 FROM P61 PLUG, PIN #32 TO 15 AMP BREAKER 2E3 56 130 WHITE 7 18 PWR FROM RELAY #2, TERM. #8 TO RELAY #1, TERM. #7 6C1, 6D5 & 6B5 130 202 RED 18 PWR FROM RELAY TO MEMORY MODULE 9D2 202

57 RED 16 FROM KEYSWITCH TO INGITION & OPTIONS RELAY 1D7 57 131 WHITE 4 18 JUMPER FROM RELAY #1, TERM. #7 TO TERM. #4 6B1, 6D6 & 6B6 131 203 RED 6 PWR FROM STARTER SOL. TO REMOTE 50 AMP BREAKER 10F7 203
58 RED 10 PWR AROUND KEYSWITCH TO IGNITION & OPTIONS RELAY 1D6 58 132 WHITE 6 18 PWR FROM RELAY #1, TERM. #6 TO PWR L.H. JOYSTICK 6C2, 6E6 & 6B6 132 204 RED 10 PWR FROM 50 AMP BREAKER TO REMOTE KEY SW. 10F6 204

59 GRAY 16 PWR FROM CNTRL PANEL 15 AMP BRKR TO ENGINE GAGES 1C5 & 1E5 59 133 TAN/RED 16 FROM RELAY #1, TERM. #4 TO JACK PROX. SW. (+) LEAD 6B2 & 6D6 133 205 GREEN 12 PWR FROM REMOTE KEY SW. TO REMOTE STARTER P.B. 10F6 205
60 GRAY 16 POWER FROM TACH GAGE TO PANEL LIGHTS 1F4 60 134 TAN/RED 16 PWR FROM RELAY #1, TERM. #4 TO JACK LIGHT 6C3 & 6D6 134 206 GREEN 12 PWR FROM REMOTE STARTER P.B. TO STARTER SOL. 10E6 206
61 PINK/ORANGE 16 AUX. PSI, FROM SW. TO AUX. PUMP SOL. 3C2 & 4C6 61 135 BLACK 16 GND FROM JACK LIGHT TO JACK GND 6C3 & 6D7 135 207 BLUE 16 PWR FROM STARTER TO REMOTE VOLTMETER 10E7 207

62 PINK/YELLOW 16 HOLDBACK, FROM SW. TO HOLDBACK SOL. 3E5 62 136 PURPLE/GREEN 16 GND FROM JACK PROX SW. (-) TO RELAY #1, TERM. #2 6C3 & 6D6 136 208 WHITE/BLUE 16 PWR FROM ENGINE PRES. SW. TO REMOTE STARTER HR. MTR. 10F8 208
63 PINK/RED 16 FAST PULLDOWN SPEED, FROM SW. TO SOL. 3C4 & 4C7 63 137 WHITE 4 18 JUMPER FROM RELAY #1, TERM. #7 TO #10 6D5 137 209 BLUE/BROWN 16 PWR FROM STARTER TO REMOTE ETHER P.B. 10F6 209
64 GREEN 10 PWR FROM DRILL LIGHT 50 AMP BREAKER TO LIGHT RELAY 1C7 64 138 WHITE 18 FROM RELAY #1, TERM. #10 TO PIPE PRESENT LIGHT 6B2 & 6A6 138 210 BLK, WHT & GRN 18 STJO CORD FROM BYPASS FILTER SW's TO TERMINAL BOX 10D1 210
65 GRAY 16 PWR FROM LIGHT RELAY TO TOP LIGHTS 1C7 65 139 RED/GREEN 16 FROM RELAY #1, TERM. #10 TO PIPE PROX. SW. TERM. #2 6B2 & 6A6 139 211 RED 16 PWR TO D.E.I POWER CONDITIONER 9F8 211
66 GREEN/GRAY 16 PWR FROM LIGHT SW. TO ENERGIZE LIGHT RELAY 1C7 66 140 RED/BLACK 16 FROM RELAY #1, TERM. #4 TO PIPE PROX. SW. TERM. #1 6B3 & 6B7 140 212 ORANGE 16 PWR TO D.E.I POWER CONDITIONER 9F8 212
67 GREEN/GRAY 16 FROM LIGHT SW. TO DOME LIGHT SW. 1C6 67 141 BLK 000 FROM MASTER DISCONNECT SW. TO (-) LEAD ON BAT #3 7B6 141 213 WHITE 16 PWR TO PIPE POSITIONER RELAY 8E2 213

68 GREEN/GRAY 16 FROM DOME LIGHT SW. TO PWR DOME LIGHT 1C6 68 142 RED 000 FROM (+) LEAD ON BAT #3 TO (-) LEAD ON BAT #4 7A6 142 214 TAN 16 PIPE POSITIONER RELAY "NO" TO "A" SOL. 8E2 214
69 GREEN/GRAY 16 FROM 5 AMP BREAKER TO DRILL LIGHT SW. 1C6 69 143 RED 000 FROM (+) LEAD ON BAT #4 TO (+) LEAD ON STARTER 7B6 143 215 ORANGE 16 PIPE POSITIONER RELAY "NC" TO "B" SOL. 8E2 215

70 70 144 GREEN/BLACK 16 PWR FROM OPT. SOLENOID TO OPT. LINCOLN LUBE TIMER 7E3 144 216 BLUE 16 PIPE POSITIONER OVERRIDE RELAY "NO TO "B" SOL. 8E2 216
71 ORANGE 16 THROTTLE POSITION SENSOR, FROM SENSOR TO P61 PLUG, PIN#10 1B2 & 2C6 71 145 WHITE 16 POWER TO LINCOLN LUBE TIMER PRESSURE SWITCH 7E2 & 8C2 145 217 GRAY 0 16 PWR.FROM IGN.RELY.TO PEND.ON-OFF SW &PEND.RLY.2 TERM.30 11A1 - 11B3 217
72 GRAY 16 FROM INGITION RELAY TO DRILL/PROPEL SW. 1E7 & 3C8 72 146 WHITE/BLACK 16 SIGNAL FROM LINCOLN LUBE TIMER PRESSURE SWITCH 7E3 & 8B2 146 218 BLUE 1 16 FROM PENDANT RELY.2 TERM.87 TO CAB J-BOX TERM.7 11B2 218
73 GREEN/BLACK 16 PWR FROM IGNITION RELAY TO REALY #2, TERMINAL #11 1F8 & 5B4 73
74 WHITE/BROWN 16 DRILL, FROM SW. TO RELAY #2, TERMINAL #10 3C6 & 5B4 74 Ref. 426455 rev. 06 (12 of 12)
8-38 Electrical Components
 AC/Heater/Pressurizer Circuit

REF
OPTIONS
RED 14
RELAY
RED 12
M 192 159
BLU 14
10

197 PRESSURIZER
FAN MOTOR RED 14
194 15

193
RESISTOR
RED 14
M
HIGH (ORANGE)
LOW (YELLOW)

MED (RED)

REF
CAB JUNCTION
BOX TERMINALS
CIRCUIT
OFF

RED 14 RED 14
PWR TO AC CONDENSOR 192 BREAKERS
YLW 14 YLW 14 YLW 14
195 PWR TO BINARY SW. 195
GRN 14 GRN 14
PWR TO AC CLUTCH 196 196
ROTARY A/C THERMOSTAT CONTROL
SWITCH TOGGLE SHITCH
REF PANEL
A/C HEATER UNIT ENGINE JUNCTION
BOX TERMINAL
GRN 14
AC CLUTCH 196 196

A/C COMPRESSOR
GRN 14 CLUTCH

196

RED 14
CAB WALL
192

85 87 87a 85 87 87a

NOTES: M
1. REF ELECTRICAL SCHEMATIC #426455. 86 30 86 30

RELAY RELAY
2. XX = WIRE NUMBER ON SCHEMATIC. YEL 14
3. XX = TERMINAL STRIP CONNECTION ON SCHEMATIC. 195

LOW HIGH
PRESS PRESS
BINARY SWITCH

A/C CONDENSER

OPENS CLOSES
LOW PRESSURE PROTECTION 30-15 PSIG 40 PSIG MAXIMUM
(FALLING PRESSURE) (RISING PRESSURE)
HIGH PRESSURE PROTECTION 270-330 PSIG 70-90 PSIG BELOW
(RISING PRESSURE) (OPENING PRESSURE)

Ref. 425136 rev. G (1 of 2)

Electrical Components 8-39

 AC/Heater/Pressurizer Circuit
FRONT VIEW SIDE VIEW BACK VIEW

RED DOT #RD-R5075-0-24

HEATER-A/C UNIT

3" FLEX HOSE FROM PRESSURIZER

CONDENSATE
DRAIN HOSE

CONDENSER #942078
W/ #416970 SHOCK
MOUNT KIT 5/8" HEATER OUTLET 5/8" HEATER INLET

CAB WALL
IR
W
A

LOW PRESSURE SWITCH

O

#404279 ATTACH TO
FL

FITTING #405924 1/2" I.D. SUCTION LINE

HIGH PRESSURE
SWITCH #404274
ATTACH TO
FITTING #405903
#6 90° FEMALE
FITTING #405851 #8 90° FITTING
WITH 134a ACCESS
PORT & SWITCH
5/16" I.D. LIQUID LINE 5/16" I.D. LIQUID LINE PORT #405903

NOTE: DRYER FOUND INSIDE #10 90° FITTING

FLOW
CONDENSER BOX. WITH 134a ACCESS
#6 90° OR STRAIGHT PORT #405900
RECEIVER DRIER
FEMALE FITTING #405851 #402720
90° #405858 STRAIGHT
A/C COMPRESSOR
402828
13/32" I.D. DISCHARGE LINE
#8 90° OR STRAIGHT
FEMALE FITTING #405852
90° #405859 STRAIGHT PLUMBING DIAGRAM Ref. 425136 rev. G (2 of 2)

8-40 Electrical Components

 Remote Tram Installation
ITEM # 6 (P/N 438737)
REMOTE TRAM MODULE

PWM OUTPUT, RIGHT TRACK REV.

PWM OUTPUT, LEFT TRACK REV.

= PWM OUTPUT, LEFT TRACK FWD.

= PWM OUTPUT, RIGHT TRACK FWD
REF - CAB MOUNTED INSIDE J-BOX
ON OUTSIDE WALL OF CAB
JUNCTION BOX

= INPUT, PENDANT SELECTOR

RELAY, SPDT

INPUT, RIGHT TRACK REV.

INPUT, RIGHT TRACK FWD.
REMOTE TRAM

INPUT, LEFT TRACK REV.

INPUT, LEFT TRACK FWD.

= INPUT, TRIGGER ENABLE

L/H TRAM JOYSTICK R/H TRAM JOYSTICK
RELAY MOUNT W/DIODE, 10A

INPUT, ENG. STOP UP

= OUTPUT, ENGINE RUN
WITH OPTIONAL REMOTE TRAM,
RE-ROUTE WIRING AS SHOWN,

GROUND
GROUND
GROUND
THROUGH PENDANT RELAYS

VDD
VDD
= VDD
= VDD
ITEM# 7 (P/N 1066939)
HARNESS PIGTAIL - REMOTE TRAM

=
=
=
=
=
=
=
=

=
=
=
=
35-PIN CONNECTOR, W/120" HARNESS
(ALL WHITE WIRES, NUMBERED 1-35)
STATUS LED

OEM CONTROLS, INC.

+ - + -
3 2 1 11 10 9
1 11
2 10

3 9

J1-22
J1-23
J1-24
J1-25
J1-26
J1-27
J1-28
J1-29

J1-32
J1-33
J1-34
J1-35
4 8

B A B A

J1-20

J1-30
5 7

J1-15
MENU SAVE 6
4 5 6 7 8

J1-12
J1-13
J1-14

J1-16
J1-17
J1-18
J1-19

J1-21

J1-31
SELECT - + EXIT

J1-10
J1-11
ITEM# 10, 11
TOGGLE THROUGH
FUNCTIONS
& ADJUSTMENT
SETTINGS

J1-2
J1-3
J1-4
J1-5
J1-6
J1-7
J1-8
J1-9
SELECT FUNCTIONS & SAVES ADJUSTMENT
ADJUSTMENT SETTINGS
SETTINGS

J1-1
OCM-1

ITEM# 10, 11

BLU #9
BLK

BLK
(P/N 350471, 340440)
3 2 1 11 10 9
1 11

YEL #4
2 10

3 9

(P/N 350471, 340440)

4 8

BLU #5
5 7
6
4 5 6 7 8

L/H PENDANT RELAY

R/H PENDANT RELAY

YEL #8
(D/C SIDE)

23

25
26
24

WHT 29

WHT 34
WHT 32
15
16
17
18
19
WHT 10
(CAB SIDE)

WHT 2
WHT 1
6 6

WHT
WHT
WHT
WHT
WHT

WHT

WHT
WHT
WHT
5 7 226 5 7 224
4 8 4 8
TERMINALS IN 227 225
RELAY, SPDT CAB J-BOX
CONTROLLER 240 3 9 3 9

YEL #2
W/DIODE, 10A

BLU #3
7 265

BLK 2
RUN KEY

BLK 1
MODULE

BLK #3
BLU #1
-2 +10 -2 +10

SECTION A-A 238

1 11
239
1 11

237

244 241 242 243 RELAY SHOWN RELAY SHOWN

250 247 DE-ENERGIZED DE-ENERGIZED
252

YEL #6

YEL #9
E WHT 25
232

BLU #8A
249 246
248 236
A 251 245

BLU #4A

YEL #3
P
N
M
L
K
J
H
G
F

D
C
B
A

GRY #2
GRAY #1
233 229

16GA
231

P
N
M
L
K
J
H
G
F
E
D
C
B
A
REF. - 416636, 235 228
230
14-SOCKET CONN.

GRY 2
256
260 (MOUNTED IN
253 254
11 11 BOTTOM OF CAB J-BOX)

BLU #7
ITEM# 8, (P/N 1066855) 255
9 9 258 259
HARNESS, PENDANT TETHER 5 5 FROM RELAY#5 (REF.
237 REF - 416635, FROM RELAY #3 (REF.
3 3 14-PIN PLUG L/H TRAM PUMP) R/H TRAM PUMP)
257
ORG 12 12 ORG #1 (ON END OF HARNESS) (SEE P/N 426455 (SEE P/N 426455
WHT/BLK 10 10 BRN #5 SHEET 5) SHEET 5)
RED/BLK 8 8 YEL #1
GRN 7 7 GRN #5
WHT 6 6 GRY #7
BLU 4 4 BLU #6

BLU #3
BLK 2 2 BLK #4
RED 1 1 GRY #5

BLU #7
YELLOW #2
LEFT TRACK FWD, PWM

YEL #6
416647 12-PIN PLUG
1
9
8
7
6
5
4
3
2
11
10
12 12

LEFT TRACK REV, PWM

416645 12-SKT RECTP.

416647 12-PIN PLUG

BLU #6
GRAY #3
1
9
8
7
6
5
4
3
2
11
10

416645 12-SKT RECTP. RIGHT TRACK REV, PWM

234

BLU #1
RIGHT TRACK FWD, PWM
BLU #6
262
BLU #1
265
87a NC

30
BLU #1 87
ITEM# 5
ORG

BRN

YEL

GRN

BLU

BLK
RED
WHT

NO
BLU #6 85 GND EN 86

GRAY #1
(P/N 438736)
S4, RIGHT TRACK

S5, RIGHT TRACK

ITEM# 12 (P/N 403689) 261

16GA
BLU #2
BUTTON OUT IS NC

PENDANT RELAY 2,
S1, ENG. STOP SW

GRAY #0
REMOTE TRAM
FWD. (WHITE)

REV. (BLACK)

MOUNTED UNDER CONSOLE RELAY SHOWN

16GA
A PENDANT (ZIP-TIED TO HARNESS) DE-ENERGIZED
264 236

BLU #1 87a NC GRAY #8

265 16GA
OPTIONAL INSTALLATION OF: 30
S2, LEFT TRACK

S3, LEFT TRACK

87 263
GRAY #1 GRAY #0
P/N T438745, REMOTE TRAM NO
FWD. (WHITE)

REV. (BLACK)

86 16GA
16GA
BLK #5 85 GND EN
266 236
NO
NC

261
NOTE: ENGINE "RUN/STOP" LOGIC - REMOTE TRAM PENDANT SYSTEM ITEM #12 (P/N 403689)
PENDANT RELAY 1 RELAY SHOWN
PENDANT TRAM CONTROL SW -
MOUNTED BEHIND KEY DE-ENERGIZED (ON CONSOLE PANEL)
NO
NC

SWITCH ON INSTR. PANEL CLOSED = PENDANT,

1) PENDANT/TRAM CONTROL SWITCH OPEN. (ZIP-TIED TO HARNESS)
GRAY #1
OPEN = JOYSTICK
16GA
=PENDANT RELAYS 1 & 2 DE-ENTERGIZED; 253
POWER PATH: 261-263-265-TERMINAL 7, CAB J-BOX, PWR FROM IGNITION RELAY
(KEY-SWITCH OPERATED, SEE SHT 1)
ENGINE CAN RUN.
2) PENDANT/TRAM CONTROL SWITCH CLOSED, AND
A) PENDANT ENGINE STOP SWITCH UP/CLOSED.
TRIGGER SW.
PENDANT

=PENDANT RELAYS 1&2 ENERGIZED

S6,

POWER PATH: 261-265-TERMINAL 7, CAB J-BOX;

ENGINE CAN RUN.
B) PENDANT ENGINE STOP SWITCH DOWN/OPEN.
=PENDANT RELAY 1 ENERGIZED BUT NOW
PENDANT RELAY 2 DE-ENERGIZED,
POWER PATH: 261 ONLY (STOPS AT PENDANT RELAY 2);
ENGINE WILL NOT RUN.
Ref. 438745

Electrical Components 8-41

 Notes

8-42 Electrical Components

 Section 9

Lubrication and Preventative Maintenance

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

SKF Lubrication and Preventative Maintenance 9-1

Notes

9-2 SKF Lubrication and Preventative Maintenance

 Service Points–Mainframe

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

Auto Lube System

The auto lube system consists of an air powered pump assembly which is fitted to 120 lb. (54 kg.)
grease container (Fig. 9-1). The pump supplies grease under pressure (2500 PSI [172 bar]) to manifolds
containing injectors which supply grease to points required. A filter/regulator/lubricator supplies 90–100
PSI (6.2–7 bar) to the pump.
The system is controlled by a lube & sensor controller mounted in the operator's cab. The controller
controls the lubrication system and also will verify delivery of lubricant into a bearing. See Section 10 in the
Service Manual for component service information.

Auto Lube System

Description No. of Lube Points
Mast Crown Sheaves 2
Mast Lower Sheaves 2
Pipe Rack Bearing–Upper 1
Pipe Rack Bearing–Lower 1
Carousel–Upper 1
Carousel–Lower 1
Pipe Rack Roller 1
Mast Pivot Pins 2
Mast Elevating Cylinders 4
Rear Axle 2
Front Axle–Center 1
Front Axle–Ends 2
Jacks–Rear 2
Jacks–Front 2
Fig. 9-1 Auto Lube Pump and Grease
Container Regulator

Lubricator
Fig. 9-2 Auto Lube Pump Water
Controller in Cab Trap

Fig. 9-3 Auto Lube Regulation

SKF Lubrication and Preventative Maintenance 9-3

Auto Lube System

Fig. 9-4 Auto Lube Point Locations

NOTE Lubrication points may vary by location and/or quantity based upon drill model.

9-4 SKF Lubrication and Preventative Maintenance

 Manual Lube System

Manual Lube System

R.H. Pump Drive Mount (11) Points
Description No. of Lube Points
Jacks–Front 2
Jacks–Rear 2
Front Axle 3
Rear Axle 2
Lower Mast Raise Cylinder 2

Mast (16) Points

Description No. of Lube Points
Upper Mast Raise Cylinder 2
Mast Pivot 2
Pulldown Sheaves 4
Pipe Rack Bearings 4
Pipe Rack Roller 1
Rotary Air Swivel 1
Mast Lock 2

PUMP DRIVE MOUNT-DUST COLLECTOR SIDE

LOWER LEFT ELEV.

LEFT REAR JACK
LEFT REAR AXLE
LOWER RIGHT ELEV.
UPPER LEFT ELEV.
RIGHT REAR JACK UPPER LEFT SHEAVE
UPPER RIGHT SHEAVE
RIGHT REAR AXLE UPPER CAROUSEL
LEFT FRONT JACK UPPER PIPE RACK
UPPER RIGHT ELEV.
LEFT FRONT AXLE RIGHT MAST PIVOT
LOWER RIGHT SHEAVE
RIGHT FRONT JACK RIGHT MAST LOCK
RIGHT FRONT AXLE CAROUSEL ROLLER
ROTARY AIR SWIVEL
FRONT AXLE CENTER CAROUSEL LOCK BOTTOM PLATE
LOWER PIPE RACK
LOWER LEFT SHEAVE
LEFT MAST LOCK
LEFT MAST PIVOT

NOTE: ROTATED 90° FOR CLARITY

Fig. 9-4a Manual Lube Bulkhead Locations

SKF Lubrication and Preventative Maintenance 9-5

Service Points

ENGINE AIR FILTER

ENGINE COOLANT FAN DRIVE

COMPRESSOR
AIR CLEANER
COMPRESSOR
OIL FILTER

COMPRESSOR AIR/OIL
SEPARATOR TANK

DRIVE SHAFT DIESEL ENGINE

ENCLOSURE
FUEL FILL

PUMP DRIVE
CHARGE FILTER CHARGE FILTER
(LOOP FILTERS OPTIONAL) (LOOP FILTERS OPTIONAL)

DUST COLLECTOR RETURN FILTERS

FILTERS
HYDRAULIC
OIL TANK

PRESSURE/VACUUM
FILTER

PIPE
CAROUSEL WINDOW
WASHER
BOTTLE

Fig. 9-5 SKF Service Points

9-6 SKF Lubrication and Preventative Maintenance

 Service Points

ROTARY DRIVE

BATTERY BOX

TRACK FINAL DRIVE

HYDRAULIC OIL
FILLER PUMP

A/C UNIT

Fig. 9-6 SKF Service Points

SKF Lubrication and Preventative Maintenance 9-7

Lubrication–General

Recommended lubrication instructions provided herein are based upon normal opera-
tion, and should be varied in accordance with other than normal operating conditions.

After lubrication and filling, remove excess spills. Always keep fittings, caps and fill
plugs clean of foreign matter.

Equipment Lubrication
Determination of when oil changes are made, filters and filter elements are to be cleaned and/or replaced,
and lubrication of equipment is required, should be based on the severity of operation.
Equipment photo's and drawings have been included to show the general location of points and equip-
ment which require scheduled and periodic lubrication. The lubrication charts list the various lube and check
points, filters and filter elements, and provides data such as quantities, types of lubricants recommended,
and the recommended frequency of lubrication.

Care of Lubrication Points

Before lubricating, or filling hydraulic fluids, the fittings, caps, and filler plugs should be thoroughly
cleaned to prevent contamination.

NOTE For additional lubrication information, refer to vendor manuals provided with the drill.

9-8 SKF Lubrication and Preventative Maintenance

 Lubrication and Maintenance Chart
C/A = Check/Add if required

Interval Service Point Service Required Lubricant Required 5 Capacity

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

SKF Lubrication and Preventative Maintenance 9-9

Lubrication and Maintenance Chart

C/A = Check/Add if required

Interval Service Point Service Required Lubricant Required 5 Capacity

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

9-10 SKF Lubrication and Preventative Maintenance

 Lubrication and Maintenance Chart
C/A = Check/Add if required

Interval Service Point Service Required Lubricant Required 5 Capacity

Hydraulic Fluid Initial Change, then every 1000 hrs Chevron AW MV ISO 32 3 223.5 gal. (846 L)
Hydraulic Filters Replace ––––– –––––
Engine Air Filter (safety) Replace ––––– –––––
Engine Crankcase Breather Check/Clean ––––– –––––
Comp. Control Air Filter Replace ––––– –––––
Comp. Air Filter (safety) Replace ––––– –––––
Air Filter Housings Clean ––––– –––––
500 Pump Drive Gearbox Drain/Replace Oil 80W-90 Gear Oil 6.75 gal. (6.4 L)
Hrs Water Pump (vertical) Change Oil (every 3 months) 80W-90 Gear Oil 1 qt. (.95 L)
Water Injection Pump Strainer Replace ––––– –––––
Dust Collector Check Timer Cycle ––––– –––––
(3.2 sec. between pulses)
Check air pressure ––––– –––––
(approx. 40 psi [2.8 bar])
Air Conditioner Filter Replace ––––– –––––
Winch Drain Gear Oil/Replace 80W-90 Gear Oil 4 pints (1.9 L)
Rotary Drive Spindle Check–adjust as necessary ––––– –––––
PLUS ALL ITEMS LISTED IN DAILY/150–250/300 HRS
1000 Track Final Drive Gearbox 6 Drain/Replace 80W-90 Gear Oil see daily
Hrs or Hydraulic Tank Drain, Clean, Replace Oil Chevron AW MV ISO 32 223.5 gal. (846 L)
Yearly
PLUS ALL ITEMS LISTED IN DAILY/150–250/300/500 HRS
2000 Comp. T-Tank Separator Replace ––––– –––––
Hrs Comp. Return Strainer Replace ––––– –––––
or Engine Coolant Drain/Flush/Replace Water/Anti-freeze 50/50 see daily
Two All Pump Pressure Settings Check/Adjust per Service Manual ––––– –––––
Years All Valve/Other Settings Check/Adjust per Service Manual ––––– –––––

PLUS ALL ITEMS IN DAILY/150–250/300/500/1000 HRS

NOTES:
1. No. 1-D or No. 2-D diesel fuels as listed in ASTM D975 are acceptable fuels.
2. Distilled water or deionized water is recommended for use in engine cooling systems. Do not use hard water,
softened water that has been conditioned with salt or sea water. Use a 1:1 mixture of water/glycol for opti-
mum performance.
3. Chevron AW MV ISO 32 is the standard factory fill for hydraulic fluid. Other fluids may be used if they meet
the specifications listed in this section.
4. Indicators may show change or by-pass when fluid is cold; reset and check again.
5. For severe operating conditions (extreme cold or tropical), use appropriate viscosity of lubricants or use fully
synthetic lubricants as shown on the Cold Weather Lubricants chart is this section..
6. Tropical conditions require initial change at 50 hours then every 250 hours.
7. Optional for use with down-the-hole hammer.
8. See compressor oil lubrication chart for alternate oils and change intervals.
9. Lithium Base with 3% Molydbenum Disulfide.

SKF Lubrication and Preventative Maintenance 9-11

Lubricant Specifications

Hydraulic System
Selection of Hydraulic Oil
These selections assume "normal operating conditions" as expected in quarry or quarry-like opera-
tions.
Hydraulic oils meeting the following specifications will be acceptable for use in the drill. Machines
are factory filled with ISO 32 oil, unless specified otherwise when ordered. Consult manufacturer before
switching to an oil of different viscosity.

CHEVRON AW MV or EQUAL
ISO Grade 15 32 46 68 100
CPS Number 232953 255678 255679 232952 232950
API Gravity 27.3 32.6 31.9 30.9 30.7
Viscosity, Kinematic
cSt at 40oC 15.8 30.4 43.7 64.6 95.0
cSt at 100oC 4.0 6.1 8.0 10.6 13.5
Viscosity, Saybolt
SUS at 100oF 85.3 155 222 329 487
SUS at 210oF 39.7 46.6 53.0 62.3 73.4
Viscosity Index 159 153 157 154 143
oC (oF)
Pour Point, -54 (-65) -48 (-54) -42 (-44) -42 (-44) -39 (-38)
oC (oF),
Flash Point, min. 150 (302) 190 (374) 186 (367) 212 (414) 232 (450)
Oxidation Life
ASTM D 943 hr.1 _ 3000+ 3000+ 3000+ 2000+
DO NOT use these products in high pressure systems in areas subject to fire hazard.
1
6000+ hours for IS0 32, 46 & 68 from the West Coast (Richmond, El Segundo and Willbridge).

NOTE Diesel fuel or kerosene used as dilutants for cold weather operation are not recom-
mended, as they are not sufficiently refined products. Do not use any fire resistant
fluids or non-petroleum oils without consulting the manufacturer.

Hydraulic Tank Capacity

Model Capacity Notes

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

9-12 SKF Lubrication and Preventative Maintenance

 Lubricant Specifications

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

Ambient Change Interval Hours

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

Compressor Lubricant Specifications

Compressor oil should conform to the following specifications:
A. Non-Detergent Turbine or Hydraulic Type Oil

Viscosity @ 100oF 160–200 SSU

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

B. Automatic Transmission Fluid (ATF)

Viscosity @ 100oF 184.2 SSU

Viscosity @ 210oF 49.1 SSU
Viscosity Index 150
o
Pour Point F -40
Flash Point 390

C. Premium quality heavy-duty engine oil which meets the performance classification, letter
designation, SE or CD of SAE J183 or MIL-L-210.

Ambient Temperature Grade

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

SKF Lubrication and Preventative Maintenance 9-13

Lubricant Specifications

Track Final Drive Gearbox

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

Recommended Oils (per ISO Specifications)

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

9-14 SKF Lubrication and Preventative Maintenance

 Lubricant Specifications

Track Final Drive Gearbox (cont.)

Recommended Oils (per API/MIL Specifications)

For heavy duty gearbox operation use fully synthetic oils only.

SKF Lubrication and Preventative Maintenance 9-15

Lubricant Specifications

Lubricating Grease
Use SAE designation MPGM which contains 3–5% Molybdenum disulfide conforming to MIL-M-7866
and a suitable corrosion inhibitor.

From 30 to 125oF (-1 to 51.6oC) ambient use NLGI No. 2

From 10 to 100oF (-12 to 37.7oC) ambient use NLGI No. 1
From -20 to 50oF (-289 to 10oC) ambient use NLGI No. 0
From -65 to 50oF (-54 to 10oC) ambient use Mobiltemp SHC 32 synthetic

Gear Lubricant
Use any oil which meets EP gear lubricant specification MIL-L-2105C or API-GL-5 of SAE J3083C.

Lubricant Grades:
Below -10oF (-23oC) ambient use 40W
Above -10oF (-23oC) and up to 100oF (37.8oC) ambient use 80W-90 or EP90
Above 100oF (37.8oC) ambient use 85W-140
Optional: Mobil SHC 635 synthetic or equivalent (all temperature ranges)

9-16 SKF Lubrication and Preventative Maintenance

 Lubricant Specifications

Engine Oil (Caterpillar)

Caterpillar Diesel Engine Oil (DEO) is the preferred oil for use in Caterpillar engines. If Caterpillar DEO
multigrade is not used, use only commercial oils that meet the following classifications.

• API CH-4 multigrade oils and API CI-4 multigrade oils are acceptable if the requirements of Cat-
erpillar's ECF-1 (Engine Crankcase Fluid-1 specification) are met. API CH-4 oils and API CI-4 oils
that have not met the requirements of ECF-1 specification may cause reduced engine life.
• API CG-4 multigrade oils are acceptable for all Caterpillar diesel engines. When API CG-4 oils are
used, the oil drain interval should not exceed the standard oil drain interval for your engine.

Engine Oil Viscosities For Ambient Temperatures

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

Engine Oil (Cummins)

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

SKF Lubrication and Preventative Maintenance 9-17

Extreme Weather Lubricants

The following chart lists replacement lubricants that are recommended for the temperature ranges
shown, typically in extreme cold or tropical weather operating conditions. Consult manufacturer for proper
application.

Operating Temperature
Component Description Lubricant Required Range (Ambient)

Compressor Mobil SHC 1024 Synthetic Below -20 to 100oF (-28.9 to 37.8oC)

Engine Crankcase Oil SAE 15W-40 5 to 120oF (-15 to 48.9oC)

Hydraulic Tank Mobil Synthetic ATF Below -10 to 100oF (-23 to 37.8oC)

Pump Drive Gearbox Mobil Delvac 75W-90 Synthetic -67 to 100oF (-55 to 37.8oC)

Rotary Head Mobil Delvac 75W-90 Synthetic -67 to 100oF (-55 to 37.8oC)

Undercarriage Final Drive Mobil Delvac 75W-90 Synthetic -67 to 100oF (-55 to 37.8oC)

General Grease NLGI 10 to 100oF (-12 to 37.8oC)

Lubrication Points MobilTemp SHC32 -65 to 50oF (-54 to 10oC)

Drill Rod Thread Grease Mobil CM-L NLGI 1 -30 to 350oF (-34.4 to 177oC)
Citgo Lithoplex CM1

DTH Hammer Oiler Rock Drill Oil All

Note: These recommendations are based on each systems component manufacturer's recommenda-
tions, requirements and/or manufacturer's requirements for maximum and minimum oil viscosity values
during start-up and continuous operation.

9-18 SKF Lubrication and Preventative Maintenance

 Preventative Maintenance

In order for an operator to be sure his drill is ready for operation at any time, a regular program of preven-
tive maintenance should be adopted. It is recommended that such a maintenance program be established
on the basis of the operator and/or maintenance personnel performing specific maintenance work during
various periods of equipment operations, at intervals during which the equipment will be idle, and during
extended periods of time when the equipment will be in storage.

When the drill is in continual, daily use, it is further recommended that a program of daily service re-
quirements be established with preventive maintenance being performed on a "before operation", "during
operation", and "after operation" schedule.

NOTE For additional preventive maintenance information, refer to vendor manuals provided
in the drill Service Manual.

Mast Trunnion Bolt Torque

Model Dry Torque Lube Torque
SKF 1820 ft. lbs. (2468 Nm) 1360 ft. lbs. (1844 Nm)
1-1/4-7 UNC Gr8 (4)

SKFX 3160 ft. lbs. (4284 Nm) 2360 ft. lbs. (3200 Nm)
1-1/2-6 UNC Gr8 (4)

Fig. 9-7 Mast Trunion Assembly

Check Torque

NOTE See additional bolted joint maintenance guidelines in this section.

SKF Lubrication and Preventative Maintenance 9-19

Preventive Maintenance

Fig. 9-8 Hydraulic Tank Oil Level and

Temperature Gauge

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

Fig. 9-10 Hydraulic Pump Charge Filter–One filter

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

9-20 SKF Lubrication and Preventative Maintenance

 Preventive Maintenance
Hydraulic System Maintenance
The hydraulic components of the drill are built for many years of trouble-free operation. Only one pre-
ventive maintenance step is necessary to ensure the expected life of the system—CLEANLINESS.
When dirty filters are indicated, change the filter as follows:
• Clean the area around the filter covers to prevent dirt entering the filter housings.
• Pull filters from the housings. Install new filter and install the covers making sure the cover O-ring is
in place.
Sight gauges are provided on the sides of the tank for
checking oil levels.
• Oil level should be at the halfway point of the
sight gauge when all cylinders are extended.
• A temperature gauge is also provided on the
sight gauge.
CLEANLINESS cannot be overstressed:
• Use new oil only from previously unopened con-
tainers.
• Clean all tank openings.
• Fill tank through return filter.
Service Indicators
Compressor Lubrication Procedure
• Drain Receiver Condensate Fig. 9-11 Return Filters Mounted on Hydraulic Tank
In periods of cold weather and/or high humid-
ity, crack receiver drain valve prior to start-up to Tabbed Nut
remove water. Close when oil appears.
• Check Oil Level
The oil level is checked at the sight glass with
machine level at each shift. The machine must be
shut down long enough to permit oil foam to settle
or check before start-up at the beginning of the
shift. Oil level should be at the center of the sight
glass.
• Change Oil
Every 300 hours or as specified in compressor
lubrication chart. Use Dexron III ATF or consult
factory for specific recommendations if extremely
severe duty is encountered. Change oil filter ele-
ment.
• Lubricate control and linkage. Clean oil return line
strainer.
Compressor Oil Filter
• Blocked filter indicator will pop up red if the ele-
ment needs changing.
• If the filter bowl is leaking, the O-ring needs to be Fig. 9-12 Compressor Oil Filter
changed. Flogging up the tabbed locking nut will
not stop the leak.

SKF Lubrication and Preventative Maintenance 9-21

Cat Pump Oil Specifications

9-22 SKF Lubrication and Preventative Maintenance

 Preventative Maintenance

Winch Lubrication
• Check oil level every 3 months or 500 operating hours whichever occurs first. Remove the large
plug located in the center of the drum support. Oil level should be at the bottom of this opening.
• Gear housing should be drained and filled with new oil after the first 100 hours of operation. Then
oil should be changed every 1000 hours of winch operating time or every six (6) months, whichever
occurs first.
• Remove and clean vent plug in solvent every time oil is changed. Vent plug must be kept clean and
free from obstructions.
• The standard factory fill from Braden for the BG8 winch is Texaco Meropa150. Other oils may be
used if they meet the following specifications: Do not mix different kinds of oil.
AGMA 4EP or API GL-2 with ISO viscosity grade 150.
The following are recommended oils:
Texaco Exxon Mobil Shell Chevron
Meropa 150 Spartan EP 150 Mobilgear 629 Omala 150 American Industrial Oils 150
Meropa 220 Spartan EP 220 Mobilgear 630 Omala 220 American Industrial Oils 220
NOTE: All gearcases are factory filled with Mobillube SCH 75W-90 Synthetic gear lube for cold weather operation.

Water Pump (Cat Pump)

The Cat Pump, Model 1050 is factory filled with Mobil SHC 626. This is suitable for temperatures below
0oF (-17.8oC). Special oil is available from Cat Pump dealers. If another type oil is used, be sure it meets
the specifications on the "Crankcase Oil" sheet for Cat Pumps.

• Fill with oil to red dot in sight window on back of pump (Fig. 9-13).
• Lubricate the wicks monthly with 2-3 drops of oil in each hole on top of the crankcase (Fig. 9-14).
DO NOT lubricate the wicks at initial start-up. Operate pump for 10–15 minutes, then lubricate the
wicks. Use crankcase oil as lubricant.

Fig. 9-13 Cat Pump Oil Level Sight Window Fig. 9-14 Cat Pump Oil Filler Cap
(back of pump) and Wick Lubrication Points

SKF Lubrication and Preventative Maintenance 9-23

Preventive Maintenance
Remove the radiator pressure cap slowly and only when the engine is cool or serious
burns could result.

Cooling System–Cummins
The engine's cooling system is designed to provide adequate cooling during all normal operating con-
ditions. Engine overheating can become the primary cause for extensive repair work, lost operating time,
and possibly result in eventual complete engine failure. Cooling system maintenance should, therefore,
hold an important place in the drill maintenance program.
The engine cooling system is filled with a 50/50 mix of anti-freeze and water. Refer to engine operating
manuals for complete cooling system specifications and maintenance. The Cummins QST30 is equipped
with two coolant filters (Fig. 9-15). These are to be changed every 250 hours of operation. Cooling system
is to be drained, flushed, and refilled every 2 years, or 6000 hours of operation, whichever occurs first. Cum-
mins recommends filling system with Fleetguard® Compleat, a fully formulated anti-freeze which contains
supplemental coolant additive

Every 250 Hours: Change Coolant Filters

1. Turn valve to OFF position, and remove filters.

2. Clean mounting base and be sure old gasket is not stuck to it.
3. Apply a thin film of oil to the gasket and install new filters. Screw filter on until gasket contacts
base, then tighten 1/2 to 3/4 turn by hand. Turn valve to ON position.

Fig. 9-15 Cummins QST30 Engine–right side Fig. 9-16 Engine Radiator
1. On/Off Valve
2. Coolant Filters

Cooling System–Caterpillar
Caterpillar recommends the following coolant types:
• Preferred–Caterpillar Extended Life Coolant (ELC) or a commercial extended life coolant that
meets the Caterpillar EC-1 specification.
• Acceptable–Caterpillar Diesel Engine Antifreeze/Coolant (DEAC) or a commercial heavy-duty
coolant/antifreeze that meets ASTM D4985 or ASTM D5345 specifications.

9-24 SKF Lubrication and Preventative Maintenance

 Preventive Maintenance
Supplemental Coolant Additive (SCA)

Cummins recommends DCA4 as the supplemental coolant additive. DCA4 is compatible with all type
of coolant except Methoxy Propanol. Supplemental coolant additive prevents the buildup of corrosion and
scale deposits in the cooling system. The correct concentration is 1.5 units for each gallon (3.8 L) of cool-
ant. Concentration must never drop below 1.2 units, nor exceed 3 units per gallon (3.8 L).
If coolant is added between drain intervals, the SCA concentration must be checked, and added, if
required. A coolant test kit no. CC2626 is available from Cummins dealers.
When the system is initially filled, the correct amount of liquid SCA is added to make 1.5 units of SCA
per gallon (3.8 L) of coolant. In this case, total system capacity is 71 gallons (269 L), so 47.3 SCA units are
required. When changing coolant filters at 250 hours, normally 4 SCA units will bring the system up to the
required amount. Filters contain SCA in crystal form that dissolves in the system. Filters come in 2, 4, 6,
8, 12, 15, and 23 SCA units. A filter is also available with no SCA units.
At each filter change, check the system with a Cummins coolant test kit. This kit contains strips, to dip
in the coolant that will determine the SCA level. If additional SCA is required, add liquid SCA to bring up to
correct concentration.

Air Cleaners
The air cleaner should be inspected periodically
to maintain engine and compressor protection and
maximum service life. These inspections should
include the following points:
1. Inspect the air transfer duct between the air
cleaner and the engine to be sure all clamps
are tight, all flange joints are tight, and there
are no cracks in the ducting.
2. Air cleaner mounting bolts and clamps must
be tight to hold the air cleaner securely.
3. Check the dust cup to make sure it is seal-
ing 360o around the air cleaner body.
4. Vacuator valve must be in place, not invert-
ed, and free from obstruction.
5. Check for dents and damage to the air Fig. 9-17 Air Cleaner Assembly
cleaner which could mean a leak.

Air Filter Elements

Replace air filter elements as required per maintenance schedule, or when indicated by pressure dif-
ferential indicator on filter.

DO NOT clean filter element with high pressure air (30 PSI maximum). Advise replace-
ment of filter element.
DO NOT start engine when the filter element(s) is removed from the air cleaner
NEVER attempt to clean the element by rapping it. Rapping the element will dent the
metal covering. The inner paper element will in turn rub this dent, causing the element to
puncture.

SKF Lubrication and Preventative Maintenance 9-25

Notes

9-26 SKF Lubrication and Preventative Maintenance

 Preventive Maintenance

Track Final Drive Gearbox

Recommended Service for F130 Gearbox

Oil Change
1. See Lubrication and Maintenance Chart in this section.

Oil Analysis
1. Oil analysis should be performed on a regular basis (example: quarterly).
2. Particle ppm levels should be compared to Warning Level Guidelines below and necessary actions
should be taken.
3. Upon high Fe-Cr contamination levels, the sun gear/input shaft should be inspected for wear and
replaced as necessary. If the sun gear is ok, further internal gearbox inspection should be per-
formed.

Sun Gear
1. The sun gear/input shaft should be changed out upon initial wear indication.
2. The sun gear/input shaft generally has the highest wear rate and needs to be replaced periodically
to prevent other gearbox component failures. It is suggested that a maintenance program should
consider replacing the sun gear at 6,000–8,000 machine hours.

Warning Level Guidelines for Contamination and Wear Metals

Normal Caution Serious

Si (Silicon) 200 ppm >400 ppm >600 ppm

Fe (Iron) 500 ppm >1500 ppm >3000 ppm

Cu (Copper) 80 ppm >160 ppm >240 ppm

Cr (Chromium) 10 ppm >15 ppm >25 ppm

Al (Aluminum) 50 ppm >100 ppm >150 ppm

Caution: In this case the gearbox must be kept under control.

Serious: In this case the gearbox manufacturer suggests changing the oil and repeating the tests after
a short period of work. If the values are still serious, the manufacturer suggests rebuilding or
replacing the gearbox.
These values are only guidelines and can be modified due to specific applications.

Notes:
Si-Al Contamination also from external sources
Fe-Cr Wear metals by gears and bearings
''Cu Wear metal be brake discs

SKF Lubrication and Preventative Maintenance 9-27

Preventative Maintenance–Mast Pivot
Mast Pivot Shaft Inspection and Repair Procedure
A visual inspection should be performed with the SHAFT DETAIL
mast in the horizontal position by removing the trunnion
cap and bushing. Clean the shaft and shoulder radius
free of lubricant and inspect visually for any indication
of cracking in the radius. Perform visual inspection at
the mid point of non-destructive test (NDT) interval #1
and #2.
Intervals for magnetic particle inspection will be in
accordance with AS1171 or a dye penetrant test, post
repair. Same inspection intervals apply to new machines
or replaced shafts. Intervals are operating hours on
shaft.

SKFX
Interval #1
<15,000 Hours
Inspect every 3000 Hours

Interval #2
>15,000 Hours but <25,000 Hours SKF/SKS
Inspect every 1500 Hours
Interval #1
Interval #3
<15,000 Hours
>25,000 Hours
Inspect every 5000 Hours
Inspect every 1000 Hours
Interval #2
SHAFT DETAIL RO.25 ORIGINAL RADIUS >15,000 Hours but <30,000 Hours
Inspect every 3000 Hours
Interval #3
RO.38 MAXIMUM RADIUS >30,000 Hours
30˚ MAX ANGLE
Inspect every 2000 Hours

Approved Pivot Shaft Repair Procedure

Fatigue cracking in the A-Frame pivot shaft radius of an SKS, SKF, or SKFX 12/15 meter drill may be
repaired by completely grinding out cracks up to a maximum depth of 0.12 in. or 3mm. This approved re-
pair method is intended only to extend the service life of a shaft that is in the first stages of fatigue where
the cracking is not extensive and is just becoming visible. Shafts with more extensive cracking, i.e. crack
depths exceeding 0.12 in. (3mm) should be replaced by removing the shaft from the A-Frame structure
and rewelding a new shaft in place in accordance with the factory repair procedure.
Unapproved Repair
No grinding that undercuts the diameter of the bearing
surface is allowed. Cracking outside of the hatched area
is not repairable by grinding and requires replacement of
the shaft. All known fatigue cracking has occured in the
hatched area. NON-REPAIRABLE
FATIGUE CRACK
9-28 SKF Lubrication and Preventative Maintenance
 ALL CONNECTING ALL JOINTS CONNECTING MAST CYLINDER
JOINTS TO THE PIVOT SHAFT LUGS TO THE MAIN FRAME

MAIN FRAME CROSSMEMBER WELDS

WELDS CONNECTING LEVELING CONNECTING CROSSMEMBER TO MAIN
JACKS TO MAIN FRAME BEAMS AND GUSSETS AT OSCILLATION YOKE

C A
A A CURSORY VISUAL INSPECTION SHOULD BE PERFORMED BY THE OPERATOR AT THE
B START OF EACH OPERATORS SHIFT.

INTERVALS FOR MAGNETIC PARTICLE INPECTION IN ACCORDANCE WITH AS1171

MACHINE SERVICE HOURS:
C
LESS THAN 30,000 HOURS GREATER THAN 30,000 HOURS
A INSPECT EVERY 3000 HRS A INSPECT EVERY 1500 HRS

B INSPECT EVERY 6000 HRS B INSPECT EVERY 3000 HRS

C INSPECT EVERY 9000 HRS C INSPECT EVERY 4500 HRS

SKF Lubrication and Preventative Maintenance

A
WELDS CONNECTING LEVELING
C JACKS TO MAIN FRAME

ALL A-FRAME WELDS AND WELDS ALL LACING JOINTS TO MAIN MAST CHORDS
CONNECTING A-FRAME TO MAIN FRAME BETWEEN PIVOT SHAFT AND LIFT
CYLINDER AND THE NEXT HIGHER CELL BEYOND
THE LIFT CYLINDER LUGS

ALL UPPER MAST LACING JOINTS

A B C

A
MAST PIVOT TRUNION &
CYLINDER LUG WELDS THIS WELD INSPECTION SCHEDULE DOES NOT REPLACE
A ANY INSPECTION OR MAINTENANCE INTERVALS ALREADY
IDENTIFIED IN THE OPERATION AND MAINTENANCE
MANUAL(S) FOR THE MACHINE.
ALL INSPECTION AND MAINTENANCE ITEMS
INDENTIFIED IN THE OPERATION AND MAINTENANCE
MANUAL(S) MUST CONTINUE TO BE PERFORMED.

C
C
MAIN SHAFT TO MAIN FRAME MAIN FRAME CROSSMEMBER WELDS
WELDS AND GUSSETS CONNECTING CROSSMEMBER TO MAIN
BEAMS AND GUSSETS AT OSCILLATION YOKE
Preventive Maintenance–Weld Inspection

9-29
Preventative Maintenance–Bolted Joints

Bolted Joint Maintenance for Rotary Drills

Introduction

To properly maintain bolted joints, some technical understanding of threaded fasteners will be helpful.
Threaded fasteners are often taken for granted and are seldom viewed as the highly engineered
items that they are. Their proper selection and proper joint design are critical to ensure structures and
machine elements perform as intended. This is a detailed subject and what is intended here, is to
present a few highlights to assist with good maintenance practices for rotary drills. This guide is not
all inclusive.

Proper Bolt Tension

Proper “Preload” or residual tension in a tightened bolt means more to assembly strength than
actual bolt strength. In a bolted joint, a bolt torqued to its proper load level can resist a maximum
amount of external load without loosening. Ensuring that the intended preload is achieved and
maintained is the objective of this guide.

These rotary drills typically use SAE guidelines which are commonly recognized throughout most
industries, for non-permanent connections. All bolted joints in the drills are non-permanent joints
(bolted joints of a bridge or building structure would be considered permanent joints.) Standard SAE
torque specifications for bolt tensioning recommends that bolts be pre-tensioned to 75% of yield
strength or “Proof Load.” Bolts torqued to this level are re-useable if in good condition otherwise.
There are a couple of exceptions in these drills where bolts are tightened beyond this value, and
these will be identified. See the following chart for recommended torque values for different bolt sizes.

Reasons Properly Tensioned Bolts Loose their Preload and Require Maintenance

x Surface Degradation
Surfaces under bolt heads can degrade due to creep failure, embedment, high bearing stress,
corrosion or a combination of these. These rotary drills use hardened washers in many situations to
help prevent surfaces from degrading. Critical joints may use “Nordlock” washers which are a
hardened, zinc coated, two-piece serrated washer incorporating inclined planes at the mating
boundary of the two pieces. To loosen a bolt using this locking device, the bolt must be significantly
stretched. Critical bolted joints are identified in the “Critical Fastener ID & Inspection Schedule”
drawing in this manual. Joints that are assembled with Nordlock washers and hardened washers are
less likely to experience surface degradation, as the hardness of the washer is close to the hardness
of the fastener and is harder than the surface of most nuts used in these drill assemblies.

x Corrosion
Most critical bolted joints on these rotary drills contain components that are made from steel. Most
bolts used are also steel, and therefore susceptible to rusting. Water is a small molecule and can find
its way into the smallest spaces to attack the surfaces of a bolted joint and the bolt head, body and
threads. We recommend that all critical fasteners be lubricated using a lubricant that contains
Molybdenum Disulfide (NLGI 2 Molycoat or Never-Seize are readily available Worldwide. Good
quality NLGI 2 grease can be substituted if a Moly product is not available at the time of service.)

9-30 SKF Lubrication and Preventative Maintenance

 Preventive Maintenance–Bolted Joints
x Vibratory Overload
Abusive, unusual or unforeseen loads can cause bolted joint separation. This can result in the
loosening of bolts, which in turn can cause bolt fatigue failure. Bolt fatigue will generally result in a
fracture surface and ultimately failure at the first engaged thread of the bolt or sometimes in the fillet
under the bolt head. Loose bolts can also fail quickly in fatigue. As an example, tests conducted by a
bolt manufacturer indicated that a bolt tightened to 1420 lb tension and stressed cyclically to 9215 lb
failed after 5960 load cycles. Identical bolts tightened to 8420 lb and stressed to the same 9215 lb
survived 4.65 million cycles before failure. If the bolts had been tightened beyond 9215 lb, it would
have been impractical to cycle them to failure.

x Thermal Relaxation
Bolted joints exposed to high temperatures or thermal cycling have a tendency relax or lose bolt
tension over time, due to stress creep. Since pre-loading stretches bolts, and only stretches them a
few thousandths of an inch. It is easy to imagine that a bolt heated to the operating temperature limits
of an air compressor could increase the plasticity of the bolt material, allowing it to lose some of its
initial loading. Bolted joints of a new machine that are subjected to high heat should be checked and
re-torqued to specification after the first 500 hours of operation.

Critical Bolted Joint Maintenance

Critical bolted joints are those joints which hold major structures together or hold overhead loads.
Failure of these joints could endanger personnel or seriously damage equipment. As stated earlier,
these are identified in the drawing “Critical Fastener ID & Inspection Schedule. We recommend that
critical bolted joints of drills should be checked for proper torque every 120 days or 2000
operating hours for machines that have less than 10,000 operating hours, and every 90 days or
1500 operating hours for machines that have greater than 10,000 operating hours.

If a bolt is found to be loose (less than 90% of specified torque value), it should be removed and
replaced. If the joint contains more than one bolt, all bolts in the joint should be replaced. The joint
mating surfaces and bolts should be inspected for signs of corrosion, surface degradation, and the
presence of hardened washers or Nordlock washers. Joints with Nordlock washers require the
replacement of the washers as well. Hardened washers can generally be reused as long as the
washer is undamaged. The new bolts should be lubricated with NLGI2 molycoat grease and torqued
to the proper specification. Bolts should be replaced with the same grade bolt that was originally in
the assembly. These drills primarily use SAE Grade 5 and Grade 8 bolts. These are identified by the
markings on the head of the bolt. Chart #1 of the drawing for each machine titled “Critical Fastener
Torque Values” graphically depicts the standard indentifying bolt markings.

Bolts in critical joints should also be removed and visually inspected for corrosion and re-
lubricate every 2.5 years or 15,000 hours of operation. If bolts are not damaged, they maybe re-
installed and returned to service. Any damaged or corroded bolts should be discarded and replaced.
In addition, bolts in critical joint should be replaced every 5 years or 30,000 hours of operation,
regardless of apparent condition.

Other Bolt Maintenance

All bolts contained in these drills are subject to the same topics described above, but generally do not
have the same degree of risk involved should a bolt failure occur. Every machine should have a
“walk-around” inspection performed at the beginning of each operating shift, which includes looking
for loose hardware. Other significant bolted joints include all pressurized fittings, flange connections
and all bolted pin retainer/keeper plate bolts. All machine bolts should be inspected for proper torque
specification annually at a minimum.

SKF Lubrication and Preventative Maintenance 9-31

Preventative Maintenance–Bolted Joints

SAE Recommended Torque Values

SAE Grade 5 SAE Grade 8

Tightening Torque Tightening Torque
Size Dry K=.2 Lub K=.15 Dry K=.2 Lub K=.15
(Ft lb) (Ft lb) (Ft lb) (Ft lb)
3/8-16 UNC 30 23 45 35
3/8-24 UNF 35 25 50 35

7/16-14 UNC 50 35 70 55
7/16-20 UNF 55 40 80 60

1/2-13 UNC 75 55 110 80

1/2-20 UNF 90 65 120 90

5/8-11 UNC 150 110 220 170

5/8-18 UNF 170 130 240 180

3/4-10 UNC 260 200 380 280

3/4-16 UNC 300 220 420 320

7/8-9 UNC 430 320 600 460

7/8-14 UNF 470 350 660 550

1-8 UNC 640 480 900 680

1-12 UNF 700 530 1000 740

1-1/8-7 UNC 800 600 1280 960

1-1/812 UNF 880 660 1440 1080

1-1/4-7 UNC 1120 840 1820 1360

1-1/4-12 UNF 1240 920 2000 1500

1-1/2-6 UNC 1940 1460 3160 2360

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

9-32 SKF Lubrication and Preventative Maintenance

 CRITICAL FASTENER ID & INSPECTION SCHEDULE

MAST RAISE/LOWER HYDRAULIC CYLINDER

AFRAME PIVOT CAP FASTENERS PIN RETAINER FASTENERS
MAST PIVOT CAP FASTENERS
ROTARY HEAD MOUNTING FASTENERS
ROTARY HEAD WEAR PAD MOUNTING FASTENERS

LEVELING JACK CAP FASTENERS

WINCH MOUNTING FASTENERS

SKF Lubrication and Preventative Maintenance

UNDERCARRIAGE MAIN AXLE FASTENERS SEE MACHINE PARTS BOOK FOR PART NUMBERS
OF SPECIFIC FASTNERS, WASHERS AND NUTS.
SEE BOLTED JOINT MAINTENANCE IN THIS MANUAL FOR ADDITIONAL
INFORMATION CONCERNING BOTH GENERAL AND CRITICAL FASTENERS.

A CURSORY VISUAL INSPECTION SHOULD BE PERFORMED BY THE OPERATOR AT THE

START OF EACH SHIFT.
RECOMMENDED INTERVALS FOR PRE-LOAD VALIDATION BY VERIFYING FASTENER TORQUE
RECOMMENDED INTERVALS FOR VISUAL INSPECTION AND RE-LUBRICATION
RECOMMENDED INTERVALS FOR REPLACEMENT
MACHINE SERVICE HOURS:
LESS THAN 10,000 HOURS GREATER THAN 10,000 HOURS
VERIFY EVERY 120 DAYS OR 2000 HRS VERIFY EVERY 90 DAYS OR 1500 HRS

INSPECT AND RE-LUBRICATE OR REPLACE

IF DAMAGED EVERY 2.5 YEARS OR 15000 HRS
REPLACE EVERY 5 YEARS OR 30000 HRS
Preventive Maintenance–Bolted Joints

9-33
Preventive Maintenance

Electrical System
Be sure battery is filled and kept charged. A discharged battery will freeze at much higher temperatures
than a fully-charged battery.
Battery terminals should be kept clean and tight for dependable operation.
See engine manual for engine electronics and diagnostic codes for electronic engines.

Extended Machine Shutdown

If machine is to be shut down for a long period of time (more than 30 days), there are certain precau-
tions that should be followed to minimize the possibility of damage to the machine.

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

Scheduled Oil Sampling Analysis

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

Sampling Criteria

• Recommended interval for oil samples is every 200 hours.

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

9-34 SKF Lubrication and Preventative Maintenance

 Drill Stem Thread Lubricator

Description and Adjustments

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

Thread Lube Pump Thread Lube Pump Regulation

Fig. 9-18 Drill Stem thread Lubricator System

Lubricator Water Trap

SKF Lubrication and Preventative Maintenance 9-35

Notes

9-36 SKF Lubrication and Preventative Maintenance

 Metric Conversions
METRIC CONVERSION TABLE
En g l i s h to Me tr i c Me tr i c to E n glish
LINEAR
inches (in.) X 25.4 = millimeters (mm) millimeters (mm) X 0.3937 = inches (in.)
feet (ft.) X 0.3048 = meters (m) meters (m) X 3.281 = feet (ft.)
miles (mi.) X 1.6093 = kilometers (km) kilometers (km) X 0.6214 = miles (mi.)

AREA
2 2 2
inches (s q.in. ) X 645.15 = millimeters (mm ) millimeters 2 (mm 2) X 0.000155 = inches 2 (s q.in. )
feet 2 (s q.ft.) X 0.0929 = meters 2 (m 2) meters 2 (m 2) X 10.764 = feet 2 (s q.ft.)

VOLUME
3
inches (cu.in. ) X 0.01639 = liters (l) liters (l) X 61.024 = inches 3 (cu.in. )
qua rts ( qts . ) X 0 . 9 4 6 3 5 = lite rs ( l) lite rs ( l) X 1. 0567 = qua rts ( qts . )
ga llons ( ga l. ) X 3. 7854 = lite rs ( l) lite rs ( l) X 0. 2642 = ga llon ( ga l. )
inches 3 (cu.in. ) X 16.39 = centimeters 3 (cc ) centimeters3 (cc ) X 0.06102 = inches 3 (cu.in. )
feet 3 (cu.ft. ) X 28.317 = liters (l) liters (l) X 0.03531 = feet 3 (cu.ft. )
feet 3 (cu.ft. ) X 0.02832 = meters 3 (m 3) meters3 (m3) X 35.315 = feet 3 (cu.ft. )
fluid ounce (fl.oz.) X 29.57 = millileters (ml) milliliters (ml) X 0.03381 = fluid ounce (fl.oz.)

MASS
ounces (oz.) X 28.35 = grams (g) grams (g) X 0.03527 = ounces (oz.)
pounds (lbs.) X 0.4536 = kilograms (kg) kilograms (kg) X 2.2046 = pounds (lbs.)
tons (2000 lbs.) X 907.18 = kilograms (kg) kilograms (kg) X 0.001102 = tons (2000 lbs.)
tons (2000 lbs.) X 0.90718 = metric tons (t) metric tons (t) X 1.1023 = tons (2000 lbs.)
tons (long) (2240 lbs.) X 1013.05 = kilograms (kg) kilograms (kg) X 0.000984 = tons (long) (2240 lbs.)

PRESSURE
inches H g (60 oF ) X 3600 = kilo pascals (kPa ) kilopascals (kPa ) X 0.2961 = inches H g (60 oF )
pounds/sq.in. (PSI) X 6.895 = kilopascals (kPa) kilopascals (kPa) X 0.145 = pounds/sq.in. (PSI)
pounds/sq.in. (PSI) X 0.0703 = kilograms/s q.cm. (kg/cm 2) kilograms/s q.cm. (kg/cm2) X 14.22 = pounds/s q.in. (PSI )
pounds /s q. in. ( P S I ) X 0. 069 = ba rs ba rs X 14. 5 = pounds /s q. in. ( P S I )
o o
inches H 2O (60 F ) X 0.2488 = kilo pascals (kPa ) kilopascals (kPa ) X 4.0193 = inches H 2O (60 F )
bars X 100 = kilopascals (kPa) kilopascals (kPa) X 0.01 = bars

POWER
horsepower (hp) X 0.746 = kilowatts (kW) kilowatts (kW) X 1.34 = horsepower (hp)
ft.-lbs./min. X 0.0226 = watts (W) watts (W) X 44.25 = ft.-lbs./min.

TORQUE
pound-inches (in.-lbs.) X 0.11298 = newton-meters (N-m) newton-meters (N-m) X 8.851 = pound-inches (in.lbs.)
pound-feet (ft.-lbs.) X 1.3558 = newton-meters (N-m) newton-meters (N-m) X 0.7376 = pound-feet (ft.-lbs.)
pound-feet (ft.-lbs.) X .1383 = kilograms/meter (kg-m) kilogram/meter (kg-m) X 7.233 = pound-feet (ft.-lbs.)

VELOCITY
miles/hour (m/h) X 0.11298 = kilometers/hour (km/hr) kilometers/hour (km/hr) X 0.6214 = miles/hour (m/h)
feet/second (ft./sec.) X 0.3048 = meter/second (m/s) meters/second (m/s) X 3.281 = feet/second (ft./sec.)
feet/minute (ft./min.) X 0.3048 = meter/minute (m/min) meters/minute (m/min) X 3.281 = feet/minute (ft./min.)

TEMPERATURE
o o o
Celsius = 0.556 ( F - 32 ) Fahrenheit = (1.8 oC ) + 32

COMMON METRIC PREFIXES

me ga ( M) = 1 , 0 0 0 , 0 0 0 or 1 0 6 de c i ( d) = 0.1 or 10 -1
kilo (k) = 1,000 or 10 3 centi (c) = 0.01 or 10 -2
hecto (h) = 100 or 10 2 milli (m) = 0.001 or 10 -3
deka (da) = 10 or 10 1 micro ( m) = 0.000.001 or 10 -6

SKF Lubrication and Preventative Maintenance 9-37

Torque Values for Split Flange Connections

The following chart provides the tightening torques for split flange connections used in hydraulic systems.
Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then torque evenly.

NOTE Over-torquing bolts will damage the flanges and/or bolts, which may cause leakage.

Bolt Torque
Flange Size Bolt Size Newton Meter Pound-Force/Foot
in Inches (*) in Inches (Nm) (ft. lb.)
1/2 5/16 20–24 15–18
3/4 3/8 30–37 22–27
1 3/8 37–47 27–35
1-1/4 7/16 47–61 35–45
1-1/2 1/2 62–79 46–58
2 1/2 75–88 55–65
2-1/2 1/2 107–123 79–91
3 5/8 187–203 138–150
3-1/2 5/8 159–180 117–133
(*) Inside diameter of hydraulic tube or hose fitting.

9-38 SKF Lubrication and Preventative Maintenance

Torque Values for Hydraulic Tubes & Fittings

O-Rings Boss Plugs

Tube Nuts and Swivel Nuts
for 37o Flared Fittings JIC 37o Seat

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

SKF Lubrication and Preventative Maintenance 9-39

Maintenance Record

WORK WORK
DATE HOUR METER MAINTENANCE PERFORMED PERFORMED AUTHORIZED
BY BY

9-40 SKF Lubrication and Preventative Maintenance

 Maintenance Record

WORK WORK
DATE HOUR METER MAINTENANCE PERFORMED PERFORMED AUTHORIZED
BY BY

SKF Lubrication and Preventative Maintenance 9-41

Maintenance Record

WORK WORK
DATE HOUR METER MAINTENANCE PERFORMED PERFORMED AUTHORIZED
BY BY

9-42 SKF Lubrication and Preventative Maintenance

 Maintenance Record

WORK WORK
DATE HOUR METER MAINTENANCE PERFORMED PERFORMED AUTHORIZED
BY BY

SKF Lubrication and Preventative Maintenance 9-43

Maintenance Record

WORK WORK
DATE HOUR METER MAINTENANCE PERFORMED PERFORMED AUTHORIZED
BY BY

9-44 SKF Lubrication and Preventative Maintenance

 Section 10

Optional Equipment

SKF Optional Equipment 10-1

Auto Lube System

Description
The auto lube system consists of an air powered pump assembly (fig. 10-1) which is fitted to 120 lb.
(54 kg.) grease container. The pump supplies grease under pressure (2500 PSI [172 bar]) to manifolds
containing injectors which supply grease to point required.
A filter/regulator/lubricator supplies 90 - 100 PSI (6.2 - 7 bar) to the pump.
The system is controlled by a lube & sensor controller mounted in the operator's cab (fig. 10-2). The
controller will verify delivery of lubricant into a bearing and also controls the lubrication system.
There is one manifold with five SL1 injectors, five manifolds with four SL1 injectors, and two mani-
folds with two SL1 injectors, for a total of 28 lube points. The lube points are as follows:
Mast Crown Sheaves (4) Mast Pivot (2)
Mast Lower Sheaves (4) Mast Elevating Cylinders (4)
Pipe Rack Bearing - Upper (1) Rear Axle (2)
Pipe Rack Bearing - Lower (1) Front Axle - Center (1)
Carousel - Upper (1) Front Axle - Ends (2)
Carousel - Lower (1) Jacks - Rear (2)
Pipe Rack Roller (1) Jacks - Front (2)

Fig. 10-1 Air Powered Lube Pump Fig. 10-2 Lube System Controller
(Terex Part No. 425924)

10-2 SKF Optional Equipment

 Lube Pump Air Motor

SKF Optional Equipment 10-3

Lube Pump Air Motor

10-4 SKF Optional Equipment

 Lube Pump Air Motor

SKF Optional Equipment 10-5

Lube Pump Air Motor

10-6 SKF Optional Equipment

 Lube Pump Air Motor

SKF Optional Equipment 10-7

Lube Pump Tube

10-8 SKF Optional Equipment

 Lube Pump Tube

SKF Optional Equipment 10-9

Lube Pump Tube

10-10 SKF Optional Equipment

 Lube Pump Tube

SKF Optional Equipment 10-11

Auto Lube Injectors

SL-1 Injector Assembly

Fig. 10-6 SL1 Injector Assembly
1. Adjusting Screw
2. Lock Nut
3. Piston Stop Plug
4. Gasket (2)
5. Washer
6. O Ring
7. Injector Body Assembly
8. Piston Assembly
9. Fitting Assembly
10. Plunger Spring
11. Spring Seat
12. Plunger
13. Packing
14. Inlet Disc
15. Packing
16. Washer
17. Gasket
18. Adapter Bolt
19. Adapter
20. Packing

SL-1 Injector Specifications

• DO NOT exceed N.L.G.I. No. 1 Grade Grease.
• Minimum operating pressure 1850 PSI (128 bar).
• Maximum operating pressure 3500 PSI (241 bar).
• Normal operating pressure 2500 PSI (172 bar).
• Maximum vent (recharge) pressure 600 PSI (41 bar).
• Lubricant output is adjustable from 0.008 cu. in. to 0.08 cu. in. (0.13 cu. cm. to 1.3 cu. cm.).

10-12 SKF Optional Equipment

 Auto Lube Injectors

Fig. 10-7 SL-1 Injector Operation

SKF Optional Equipment 10-13
Auto Lube System

Filter/Regulator/Lubricator
Refer to following pages for maintenance and repair of individual units.

Fig. 10-8 Filter/Regulator/Lubricator Combination

10-14 SKF Optional Equipment

 Auto Lube System

Filter Maintenance and Repair

SKF Optional Equipment 10-15

Auto Lube System

Regulator Maintenance and Repair

10-16 SKF Optional Equipment

 Auto Lube System

Lubricator Maintenance and Repair

SKF Optional Equipment 10-17

Notes

10-18 SKF Optional Equipment

 Auto Lube System

SKF Optional Equipment 10-19

Auto Lube System

10-20 SKF Optional Equipment

 Auto Lube System

SKF Optional Equipment 10-21

Auto Lube System

10-22 SKF Optional Equipment

 Auto Lube System

SKF Optional Equipment 10-23

Auto Lube System

10-24 SKF Optional Equipment

 Auto Lube System

SKF Optional Equipment 10-25

Auto Lube System

10-26 SKF Optional Equipment

 Auto Lube System

SKF Optional Equipment 10-27

Auto Lube System

10-28 SKF Optional Equipment

 Auto Lube System

Fig. 10-9 Lube Controller Components

ITEM LISTING
Item Qty. Description
1 1 Jumper Shunt (strip of 10)
2 1 Green LED, Green Lens and Chrome Bezel
3 1 Amber LED, Amber Lens and Chrome Bezel
4 1 Red LED, Red Lens and Chrome Bezel
5 4 Standoff & Screw
6 1 Ribbon Cable Assembly
7 1 Seal for Switches
8 1 Processor Board Assembly
9 1 Power Supply Board Assembly

SKF Optional Equipment 10-29

Drill Stem Thread Lubricator

Fig. 10-10 Drill Stem Lubricator System (ref. 401973)

Description & Adjustments

The SKF Rotary Drill can be equipped with an optional automatic
drill string thread greasing system. The system uses an air powered
grease pump attached to a 35 lb. (15.9 kg.) grease container. The
system is activated by a switch on the drill control console, and the
pump delivers grease to the nozzle mounted adjacent to the drill
stem.
Air supply is filtered, lubricated and regulated by the filter/regula-
tor/lubricator mounted on the left rear jack housing (fig. 10-11).
Normal pressure setting is 80 PSI (5.5 bar).
The following pages give maintenance and repair instructions.
Refer to parts manual for repair part numbers and kits.
Turning the knurled knob on the 3-way air valve (item 4, fig. 10-
11) increases or decreases the duration of the grease when the
switch is activated.

Fig. 10-11 Left Rear Jack Housing

1. Filter/Water Separator
2. Regulator
3. Lubricator
4. 3-Way Air Valve

10-30 SKF Optional Equipment

 Drill Stem Thread Lubricator

Filter Assembly
WARNING:
DO NOT operate without metal bowl
guards in place on lubricator and filter
with plastic bowls.

Maintenance
Every time the bowl is cleaned or the filter is
replaced:

1. Relieve pressure from unit.

2. Inspect and replace crazed, cracked, damaged or
deteriorated seals and bowls with original
manufacturer's approved parts only.
3. If unit has a rigid (felt) element, remove and clean
periodically by tapping on a hard surface and blow-
ing off with an blow gun.
4. If unit has a oil removing cloth filter element, replace
it with a new element every six months or sooner if it
becomes dirty or causes a pressure drop of 10 PSI
(0.7 bar) or more at rated flow.
5. Drain bowl at least once per shift

Fig. 10-11a Filter Assembly

(ref. no. 1417102)
NNR - Not Normally Replaced

SKF Optional Equipment 10-31

Drill Stem Thread Lubricator

Air Pressure Regulator

NOTE The regulator is installed upside-down
from view shown in fig. 10-11b.
Maintenance
1. The regulator can be disassembled for
servicing without removal from the line.
2. Occasionally remove the bottom plug (top, as
installed) and clean plug, body and valve seat
(vent air line on both sides of regulator).
To Disassemble
1. Shut off air to regulator and vent air line on
both sides of regulator.
2. Turn adjusting knob counterclockwise to
relieve compression on spring. Remove
screw, lock knob, adjusting knob, panel mount
nut (if used), tamper resistant kit (if used) and
cover cap.
3. Remove the four screws, cover and regulating
spring.
4. Diaphragm can be removed by removing
bottom plug and spring, valve stem can be
removed from the bottom of regulator.
5. Assembly is the reverse of disassembly.

Troubleshooting
If unit will not regulate to pressure
needed or if pressure becomes exces-
sive:
Remove bottom plug, spring and valve assem-
bly. Clean and check o ring, valve stem and valve
seat for water damaged parts. Replace worn or dam-
aged parts.

If unit leaks at relief port:

Install repair kit.

Refer to parts manual for repair part numbers.

Fig. 10-11b Air Pressure Regulator

(ref. no. 1417102)
NNR - Not Normally Replaced
10-32 SKF Optional Equipment
 Drill Stem Thread Lubricator

Lubricator Assembly
WARNING:
DO NOT operate without metal bowl
guards in place on lubricator and filter
with plastic bowls.

Maintenance

1. Drain off any contaminants from the bottom of the bowl

and wipe it clean with a soft cloth.
2. If oil delivery rate drops, the lubricator should be
cleaned.
• Shut off air supply and relieve pressure from
unit.
• Remove the adjusting screw and clean the
needle and seat in the body.
• Inspect and clean the passage from the needle
seat down into the siphon tube adapter.
• Remove the Flow-Guide® variable orifice screw
and clean its passage with a small wire. Check
the bore for contaminants and clean it if neces
sary.
• Be sure the passageway from the sight dome
cavity into the Flow-Guide® variable orifice post is
open.
Lubricator - Operation
1. The maximum pressure rating is 150 PSIG (10.3 bar),
o o
maximum temperature rating is 125 F (52 C).
2. The lubricator may be filled under pressure by slowly remov-
ing the fill plug and pouring oil into the bowl through the fill
port (as the fill plug is removed, the air pressure in the bowl
will be relieved). The bowl may be taken off after removing
the fill plug, if a more rapid fill is required. DO NOT replace
the fill plug until the bowl and guard are in position and the
clamp ring is securely locked in place.
3. Use clean oil (SAE 10 or lighter). The rate of oil delivery may
be controlled by turning the adjusting screw counterclock-
wise for more and clockwise for less oil delivery. The lubrica-
tor delivers all the oil downstream that passes through the Fig. 10-11c Lubricator Assembly
sight dome. The oil delivery rate will change automatically to (ref. no. 1417102)
deliver more oil during higher airflows and less oil for airflows NNR - Not Normally Replaced
lower than the one at which the setting was made.

SKF Optional Equipment 10-33

Coupling Grease System

3-Way Air Valve

WARNING:
HIGH ENERGY LEVEL - Compressed air systems con-
tain high levels of stored energy. Any attempt to
connect, disconnect or repair these products when a
system is under pressure can lead to serious personal
injury. Do not attempt to install, operate or repair
these products unless you are trained in the proper
techniques for working on fluid power systems, or are
under competent supervision.

CODE COMPLIANCE - The user of these products is

cautioned to conform to all applicable electrical,
mechanical, and other codes in the installation and
operation of these products.

FAILURE MODES - Through wear or malfunction, these

valves can fail in modes which can simultaneously
pressurize all ports to the highest applied pressure
level. They can also fail to shift as expected upon the
application or removal of operator signals. These
failure modes must be considered in the use of these
valves, and all appropriate safeguards to prevent
personal injury or property damage in the event of
such failures must be provided.

Basic Valve - Maintenance

Refer to the exploded view illustration for your particular valve Fig. 10-11d Basic Valve
body (main valve) and disassemble in the general order of the item (ref. no. 330617)
numbers assigned to the various parts. Reassemble in reverse order
of the item numbers. At time of reassembly apply a light coat of sili- 1. Retaining Ring
cone base grease (Dow Corning 44 or equivalent) item 12, O- Ring. 2. Plug
3. Seat
*4. O-Ring
*5. O-Ring
6. Spring
7. Poppet
8. Retainer
*9. Seal
10. Piston
11. Pushrod
*12. O-Ring
13. Body
*14. Operator/Valve Gasket
(not shown)
*Included in Service Kit
No. 0022485
10-34 SKF Optional Equipment
 Coupling Grease System

3-Way Air Valve

Auxiliary Operator - Maintenance
Refer to the exploded view illustration below and disassemble in the general order of the item
numbers assigned to the various parts. Reassemble in reverse order.

AUXILIARY OPERATOR (0-60 sec.)

1. Screw
2. Lockwasher
*3. Top Gasket (-01 thru -10 Timers.
2 req'd for -22 Timer)
*4. Top Gasket (-22, -23 & -24 Timers.
2 req'd for -22 Timer)
*5. Bottom Gasket (Part of Operator)
6. Check Valve (Position B)
*7. Packing (Position B)
8. Locknut
9. Adjustment Screw
*10. O-Ring
11. Body (0-5 Second Timers)
12. Snap Ring
13. Plug
*14. O-Ring
15. Piston (Normally Closed)
(-03 thru -05, -22 & -24 Timers)
16. Piston (Normally Open)
(-09, -10, -22 & -23 Timers)
*17. O-Ring
*18. O-Ring
19. Pipe Plug
20. Body (0-60 Second Timers)

*Included in Service Kit 0022486 as

appropriate for 0-to-5 second or
0-to-60 second timers.

Service kits are universal and contain

extra parts, match new parts from kit
with those removed at time of
disassembly.

Fig. 10-11e Auxiliary Operator (0-60 Sec.)

(ref. no. 330617)

SKF Optional Equipment 10-35

Coupling Grease System

Auxiliary Operator (3-Way Air Valve)- Adjustment

Turn the adjustment screw clockwise to increase the delay time, counterclockwise to decrease the
time. Adjustment is non-linear. Five to six Counterclockwise turns from the full clockwise position will
normally give the minimum time delay, additional turns will have no other effect.

Fig. 10-11f Auxiliary Operator (ref. no. 330617)

Fig. 10-11g Auxiliary Operator Schematic (ref. no. 330617)

Time Delay on Release (TDR) - Normally Closed

LEGEND
SIG Pilot Signal
IPS Internal Pilot Supply
EPS External Pilot Supply (shown plugged)
EXH Exhaust
MV Main Valve (piston)
ACT Actuated
REL Released

10-36 SKF Optional Equipment

 Coupling Grease System

3-Way Air Valve

"CF" Solenoid with Junction Box

Fig. 10-11h "CF" Solenoid with Junction Box (ref. no. 330617)
1. Screw (4)
2. Lockwasher (4)
3. Gasket
4. Connector (includes 4-6)
5. Screw
6. Gasket
7. Coil, 24VDC
8. Solenoid Base
9. Screw (2)
10. Diffuser
11. Coil Retaining Clip
12. O Ring (large)
13. O Ring (small)
14. Pipe Plug
15. Base

See parts manual for repair part numbers.

SKF Optional Equipment 10-37

Drill Stem Thread Lubricator

Grease Pump
The grease pump is shown below (fig. 10-12). For operation and repair information, refer to the
following Lincoln Owner/Operator Manual for Model 82716 Series "F".

Fig. 10-12 Grease Pump and Cover (ref. 1417103)

10-38 SKF Optional Equipment

SKF Optional Equipment 10-39
10-40 SKF Optional Equipment
SKF Optional Equipment 10-41
10-42 SKF Optional Equipment
SKF Optional Equipment 10-43
10-44 SKF Optional Equipment
SKF Optional Equipment 10-45
10-46 SKF Optional Equipment
 DEI + LOGGER —
Drilling Efficiency Indicator
Installation and
Operations Guide
The information in this manual is subject to change without notice and
Thunderbird Mining Systems cannot be held liable for any errors that may
appear in it. No information in the manual may be reproduced without the prior
written permission of Thunderbird Mining Systems.

Drilling Efficiency Indicator, DEI Plus, and DEI + LOGGER are trademarks of
Thunderbird Mining Systems

 2001 Thunderbird Mining Systems

2609 – 151st Place N. E.
Redmond, Washington 98052-5522 U.S.A.
TEL: (425) 869-2727
FAX: (425) 869-2735
www.tbirdpac.com

Part Number 0150-035-001

This manual was written and illustrated by Ellen Theisen, Port Ludlow,
Washington.
Complete this System Configuration Information Now

Mine Drill ID __________________________________

Manufacturer ________________________________

Model ________________________________

Manufacturer’s Serial Number ________________________________

Circle or complete the part number for the DEI + LOGGER components on this
drill and record the serial numbers of all major components.

DEI + LOGGER System Part Number Serial Number

Component

DEI Plus 6523-109-001 ___________________

Mounting system 3142500

Air pressure switch 3700-_______-001 ___________________

Optical shaft encoder 4500630 ___________________

Encoder mounting kit 6041-018-001 Not applicable.
6041-018-002

Encoder drive kit (optional) 9001-_______-_______ Not applicable.

Cables: Not applicable.

DC input power 7070-191-_______

Air switch signal 7070-189-_______

Encoder sensor 7060-190-_______

______ = Enter the cable length in feet
(for example, 025 = 25 feet).
 Contents

Using This Manual ix

Chapter 1 Introducing the DEI + LOGGER 1

A Stand-Alone, Graphic Information Display 2
Current Hole Depth 2
Target Depth 3
Rate of Penetration 4
Distance from Bottom 4
Pipe-In-Hole (PIPE) Notification 5
Drill Time 5
Time to Complete 5
Production Statistics 6
Logger Error! Bookmark not defined.
System Management Features 6
Components of the DEI + LOGGER System 7
DEI + LOGGER Display Module 8
Air Pressure Switch 9
Optical Shaft Encoder 9
Encoder Mounting Kit 9
Encoder Drives 9
Cables 10

Chapter 2 Installing the DEI + LOGGER 33

Unpacking the Components 33
Laying Out and Tracking the Components 34
Installing the DEI + LOGGER Display Module 36
Installing the Air Pressure Switch 38
Installing the Optical Shaft Encoder 39
Direct Sprocket Drive 40
Indirect Sprocket Drive 42
Indirect Split Sprocket Drive 44
Indirect Torque Reel 45
Connecting to the External Alarm/Tram Circuit 47
Installing a Remote Zero Hole Depth Switch 48

v
DEI + LOGGER Installation and Operations Guide

Verifying the Installation 49

Calibrating the DEI + LOGGER 49

Chapter 3 Operating the DEI + LOGGER 33

Turning the DEI + LOGGER On and Off 33
DEI + LOGGER Control Elements 34
Graphical Display 34
Control Buttons 36
Logging On and Off 39
Reference to Statistics Screens 40
Statistics: Current Hole 41
Navigating Through Statistics Screens 46
Production Statistics 47
ROP Graphic Screens 48
Statistics: Previous Holes 51
Shift Screens 53
Production Time Screens 55
Reference to Data Entry Screens 57
Data Entry Menu 57
Navigating Through Data Entry Screens 59
Delay Code Screen 60
Operator Screen 61
Drill Conditions Screen 63
Bit Details Menu 64
Target Depth Screen 70
Hole Number Screen 71
Pattern Number Screen 73
Drill String Screen 77
Fluids 81
Consumables 84
Reference to System Screens 85
System Menu 85
Navigating Through System Screens 87
Mast Level Screen 88
Brightness Screen 89
Shift Times Screens 90
Alarms Screen 91
Graphic Scaling Screen 93
Configuration Menu 95

vi
 Illustrations

Calibration Screens 96
Mast Adjustment Screen 96
System Parameters Screen 96
Diagnostics Menu 97
Detailed System Status Menu 99
System Status: Memory Test Screens 100
System Status: Display Test Screens 102
System Status: Bit Air Switch Status Screen 104
System Status: Tram Switch 105
System Status: Zero Hole Button Status Screen 106
System Status: External Alarm Status Screen 107
System Status: Encoder Status Screen 108
System Status: Data Port Screen 109
System Status: Mast Level Screen 110
Troubleshooting Screens 111
General Info Menu 112
General Info: Hardware 113
General Info: Software 117

Chapter 4 Troubleshooting 118

Prerequisite Troubleshooting Information 118
The DEI + LOGGER 120
Air Pressure Switch 121
Optical Shaft Encoder 121
Chain and Sprocket Encoder Drives 122
Torque Reel Encoder Drive 122
Interconnecting Cables 122
Troubleshooting Procedures 123
Typical Symptoms 123
Power Circuit Tests 124
Air Circuit Tests 126
Encoder Circuit Tests 130
Re-Calibrate 134

Appendix A Cable Pinouts 135

Appendix B Mounting Templates 137

vii
 Illustrations
Figure 1. DEI + LOGGER (Front) 8
Figure 2. DEI + LOGGER (Rear) 8
Figure 3. Air Pressure Switch 9
Figure 4. Optical Shaft Encoder 9
Figure 5. DEI + LOGGER System and Connections 35
Figure 6. DEI + LOGGER and RAM Mount Assembly 37
Figure 7. DEI + LOGGER Installed on RAM Mount Assembly 37
Figure 8. Air Pressure Switch Connections 38
Figure 9. Installing the Encoder — Direct Sprocket Drive Method 41
Figure 10. Installing the Encoder — Indirect Sprocket Drive Method 43
Figure 11. Installing the Split Sprocket 44
Figure 12. Installing the Torque Reel (a) 45
Figure 13. Installing the Torque Reel (b) 45
Figure 14. Increasing and Decreasing Cable Tension 46
Figure 15. Remote External Alarm and Tram Connections 47
Figure 16. Remote Zero Hole Depth Switch Connections 48
Figure 17. DEI + LOGGER Power Button 33
Figure 18. DEI + LOGGER Control Elements 34
Figure 19. Typical Installation on Electric Machine 119
Figure 20. DEI + LOGGER Air Switch Cable Connector 127
Figure 21. Air Pressure Switch Front Panel 129
Figure 22. DEI + LOGGER Encoder Cable Connector 131
Figure 23. Cable to Optical Shaft Encoder 132
Figure 24. 7070-189-xxx Cable Assembly — DEI + LOGGER to Air Pressure Switch 135
Figure 25. 7060-190-xxx Cable Assembly — DEI + LOGGER to Optical Shaft Encoder 135
Figure 26. 7070-191-xxx Cable Assembly — DC Power to DEI + LOGGER 135
Figure 27. Mounting Template — Air Pressure Switch 138
Figure 28. Mounting Template — RAM Mount 139

viii
 Using This Manual
This manual describes Thunderbird Mining Systems’ DEI + LOGGER (Drilling
Efficiency Indicator), gives instructions for installing and operating it, and
includes a troubleshooting guide to help you solve problems that may occur.

It should be noted that a printed copy of this manual will accompany the
shipment of a DEI + LOGGER stand-alone system.

ix
 Chapter 1
Introducing the DEI + LOGGER
The DEI + LOGGER is an instrument that is installed on the drills in a mining,
water well, exploration, or construction operation. It helps the drill operator
know, at every moment, what is occurring in the drill hole by providing
information that is not normally available.

The DEI + LOGGER eliminates the need for manual drill reports and provides
all of the data required to monitor the performance of a single drill or an entire
drill fleet. Manual data is entered into the DEI + LOGGER using the buttons
below the display. Data is retrieved from the DEI + LOGGER using a PDA and
connecting cable and transferred to the office PC using a USB cradle.

Thunderbird provides a sample suite of Windows-based reporting software to

convert the logged data. These reports are used by operations and maintenance
personnel to assess the performance and productivity of the drill fleet and drill
operators. Reports provide information about the drillability of the patterns, the
drilling consumables replaced and replenished, and the delay code operating
hours – thus allowing asset utilization to be readily evaluated.

The DEI + LOGGER is the newest generation of Drilling Efficiency Indicators.

Earlier DEI instruments have been installed on nearly all makes and models of
drills. Today they are operating on hundreds of drills in mines throughout the
world. Whether installed in a coal, metal, quarry, or other operation, the DEI has
proven that it will increase productivity by reducing overall drilling costs and
improving the blasting efficiency.

The DEI + LOGGER provides all the capabilities of its predecessors, PLUS:

♦ Even more information about the current drilling operation, instantaneously,

on a much larger and easier-to-read display.
♦ Drilling statistics about the previous three holes, the current shift, the three
previous shifts, and a production period you define.
♦ Features that allow you to set up the system, check the status of system
elements, and do troubleshooting procedures. For example, the DEI +
LOGGER leads you through the calibration procedure in a sequence of
interactive screens.
The rest of this chapter gives you an overview of the information and system
management features available on the DEI + LOGGER.

1
DEI + LOGGER Installation and Operations Guide

A Stand-Alone, Graphic Information Display

On its single graphic display, the DEI + LOGGER provides the following
information about the current drilling operation, allowing the operator to
monitor the drilling as it occurs:

♦ Current operator ID
♦ Current hole depth
♦ Target hole depth
♦ Rate of penetration, while the drill is moving downward
♦ Distance from the bottom of the hole, while the drill bit is lifted
♦ On-screen alarm flashing “PIPE” when there is a pipe-in-hole condition
♦ Drilling time so far on this hole
♦ Estimated time to complete the hole
♦ Graphic depiction of the current depth in relation to the target depth
This information gives the drilling and blasting personnel the ability to “see”
beyond the drill collar and into the hole, allowing them to work more efficiently.

In addition to the current drilling information, the DEI + LOGGER provides

details about the previous three holes and summary statistics about a production
period, the current shift, and the three previous shifts.

It also shows a graph of the rate of penetration at each depth reading — for the
current hole and for each of the three previous holes.

Current Hole Depth

The depth display on the DEI + LOGGER constantly shows the exact depth of
the hole that is being drilled, to the nearest tenth of a meter or foot (according to
your calibration). This information helps the drill operator drill to the precise
depth specified on the drilling plan, without stopping to measure the hole. The
DEI + LOGGER even tracks the hole depth in multiple-pass drilling as pieces of
pipe are added.

This precision saves time and cuts costs by:

♦ Eliminating overdrilling, which can be costly in time, in wear on bits, and in

the effort required to backfill the blasthole so the drilling plan can be met.

♦ Ensuring that the floor is level after blasting, so the mine does not have to
bear the cost of either leveling it or reducing the life of its loading and hauling
equipment by having them operate on a rough floor.

♦ Ensuring that the hole depth is precise in the critical and difficult task of angle
drilling.

2
 Chapter 1 Introducing the DEI + LOGGER

Target Depth
As each hole is started, the operator enters the target depth on a system
management screen. Then, the target depth appears on the display beside the
current hole depth as the operator drills, thus ensuring against overdrilling.

The display of current hole information also shows a graphic

representation of the target depth in relation to the current depth.
For example, in the sample to the left, the current depth is indicated
by the pointers at 43.7, and the target depth is indicated by the solid
line at 65.2.

3
DEI + LOGGER Installation and Operations Guide

Rate of Penetration

The rate of penetration (ROP) value displayed on the DEI + LOGGER

shows constant information about the drilling speed, thus also helping the
operator drill more efficiently. Knowing the ROP, the operator can make
timely adjustments in the pulldown pressure, RPM, torque, or air pressure
in order to optimize the drilling rate for the particular conditions.
Increasing the overall drilling rate significantly increases the number of
feet or meters drilled per hour.

In coal mines, the ROP information is especially important. If the engineer

has determined the approximate depth of the coal, the drill operator can
watch for an increase in ROP at that depth and stop drilling when the drill
bit is only a tenth of a foot (or meter) into the coal, instead of drilling into it
far enough to identify the coal dust at the hole collar.

This sample graph shows the difference in the rate of penetration at

different hole depths. Engineers can use this detailed information to help
them refine their conclusions about the strata layers.

With the press of a button on the front panel of the DEI + LOGGER, the
operator can change the display to show a graph of the ROP vs. the hole
depth for the current hole – and still monitor the current depth, ROP, and
drill time. This sample shows how the graph appears on the display of the
DEI + LOGGER.

Distance from Bottom

When the operator lifts the drill bit off the bottom of the hole, the ROP display
changes to a display of the distance from the bottom. When drilling is resumed,
this information helps the operator avoid slamming the bit into the hole bottom
and possibly damaging the drill bit and steel.

When the bit reaches the bottom of the hole and drilling is resumed, the ROP
display once again shows the drilling rate of penetration.

4
 Chapter 1 Introducing the DEI + LOGGER

Pipe-In-Hole (PIPE) Notification

The DEI + LOGGER provides functionality to help you prevent damage to
equipment often caused by retracting the jacks or moving the drill when pipe is
still in the hole.

When you calibrate the DEI + LOGGER, you specify the distance you want the
bit to clear the ground for the pipe to be considered fully out of the hole, that is,
how far above the ground you want the bit to be before the jacks are retracted so
the drill can be moved. This distance is the PIH (pipe-in-hole) offset.

Then, during operation, the information screen for the current hole flashes the
word “PIPE” whenever there a pipe-in-hole condition, that is, whenever there is
any chance the operator might think the bit is out of the hole.

The Pipe-In-Hole alert occurs whenever the following three conditions are met:

♦ Drilling air is turned off.

♦ Drill feed direction is reversed relative to the normal drilling direction (as
indicated by encoder data).

♦ The distance from bottom value is greater than 85% of the hole depth.

“PIPE” remains flashing until the DEI + LOGGER reports that the distance from
the bottom of the hole equals the hole depth plus the PIH offset, that is, the bit is
above the ground by a distance equal to the PIH offset.

Drill Time
The DEI + LOGGER tracks the time spent drilling on each hole. A status line on
the DEI + LOGGER display shows the status at all times, displaying “Drilling”
during all drilling time and “Non Drilling” or “Idle” when drilling is not in
progress. Drilling time is considered to be the time when the drill is moving
downward plus any delays of less than 60 seconds.

Time to Complete
Once 5% of the target depth has been drilled, the DEI + LOGGER calculates and
displays the estimated time required to complete the hole. This information is on
the display while drilling is in progress, giving the operator even more
information to help prevent overdrilling.

5
DEI + LOGGER Installation and Operations Guide

Production Statistics
The control buttons on the front panel of the DEI + LOGGER allow the operator
to quickly display statistical information about previous holes, current and
previous shifts, and any other specific time period. This is convenient for tracking
the production per day. It may also be used to give valuable feedback when drill
personnel are testing new bits or different drilling procedures.

The DEI + LOGGER’s memory is backed up by a battery, so that the historical

information is retained even if power to the DEI + LOGGER or drill is turned off
or lost.

Historical information about previous holes includes:

♦ Depth
♦ Average rate of penetration
♦ Drilling time

Information about shifts includes:

♦ Total holes started during the shift.

♦ Average depth of all holes drilled or partially drilled during the shift.
♦ Total depth drilled during the shift.
♦ Average time to drill a hole, in minutes and seconds.
♦ Total time drilling during the shift.
♦ Average ROP during the drilling.

Production information about a time period you define includes the same
statistics as shift information, except for the total time.

System Management Features

The DEI + LOGGER provides over 30 different screens that allow you to set up
and manage your DEI + LOGGER system. For example:

♦ Set up operating parameters, such as the target depth, alarm conditions.

♦ View the status of system elements, such as the external alarm’s state, the
condition of the memory, the DEI + LOGGER software version.

♦ Calibrate the DEI + LOGGER by following a sequence of interactive screens.

♦ Perform diagnostics, such as troubleshooting procedures and testing system

components.

6
 Chapter 1 Introducing the DEI + LOGGER

Components of the DEI + LOGGER System

The DEI + LOGGER system is made up of several components. The components
for each drill vary somewhat depending on what is needed to make the system
work on that specific drill. The components include:

♦ DEI + LOGGER display module

♦ Display mounting system
♦ Air pressure switch
♦ Optical shaft encoder
♦ Encoder mounting kit (direct or indirect)
♦ Encoder drives (if necessary)
♦ Cables
♦ Dual axis inclinometer (optional)

7
DEI + LOGGER Installation and Operations Guide

DEI + LOGGER Display Module

This is the main module of the system. It is mounted on the drill rig in
a location that is easily visible to the operator during operation of the
drill.

This unit receives the signals produced by the optical shaft encoder to
calculate and display the current hole depth, current rate of
penetration, distance from bottom, and other production statistics.

The rear panel of the DEI + LOGGER (Figure 2) contains the

connectors for connecting it up to a DC power source, the air pressure
switch, the optical shaft encoder, the remote zero hole button, tram
Figure 1. DEI + LOGGER
switch, inclinometer, and external alarms, as well as additional
(Front)
connectors for the DEI + upgrade systems: Logger, Strata, and GPS.

Some of the DEI + LOGGER design features include:

♦ Housing is machined aluminum (6.17” H x 7.31” W by 3.11” D),

water-tight to NEMA 4 standards.

♦ Accepts power input from 21 to 30 VDC.

♦ Operating temperatures from -40° C to +80° C.

♦ Polycarbonate display window with anti-glare coating and viewing

angle greater than 160°.
Figure 2. DEI + LOGGER
(Rear) ♦ 512KB or 1MB battery-backed SRAM for storing system settings
and logged data such as historical production information.

♦ Real Time Clock/Calendar (RTC) with second resolution,

programmed for leap years, and accurate to within one minute per
month.

♦ Lithium battery to provide a minimum of 5 years of non-volatile

memory and RTC operation.

♦ 2KB of EPROM for fail save boot code

8
 Chapter 1 Introducing the DEI + LOGGER

Air Pressure Switch

The air pressure switch indicates the presence or absence of bailing air
pressure to the DEI + LOGGER, allowing it to determine whether or
not the drill stem column is connected to the rotary head. This helps
the DEI + LOGGER determine when a drill stem is being added or
removed.

When air is on in the drill stem column and the drill head is moved up
from the bottom of the hole, the DEI + LOGGER displays the distance
moved as the distance from the bottom.

When air is not on, the DEI + LOGGER interprets long distances of
movement away from the bottom as adding new steel for multiple-
pass drilling. When drilling resumes, the DEI + LOGGER accounts for
Figure 3. the length of the new pipe in its calculations of the hole depth.
Air Pressure Switch
The standard air pressure switch is for machines with up to 150 psi of
bailing air. Air pressure switches are available for high-pressure drill
rigs.

Optical Shaft Encoder

The optical shaft encoder is connected to the pulldown system, either directly
or indirectly, so that it can sense the movement of the drill bit. As the drill bit
moves, the encoder sends signals to the DEI + LOGGER to indicate the
amount and direction of the movement. It is from these signals that the DEI +
LOGGER computes the hole depth and rate of penetration.

Figure 4.
Optical Shaft Encoder

Encoder Mounting Kit

The mounting kit includes the brackets and coupling necessary for securing the
encoder to the drill. The content of the kit varies depending on the way in which
the encoder will be mounted.

Encoder Drives
On some drills, the pulldown sprocket shaft does not rotate, or the encoder shaft
cannot be coupled directly to the pulldown sprocket shaft. On these drills, the
encoder shaft must be rotated indirectly by means of an intermediary sprocket
rotated by the pulldown sprocket shaft or hub. This calls for a special encoder
mounting kit. This mounting kit provides the parts necessary for installing the
encoder on such drills.

Some systems may require a torque reel or a custom installation.

9
DEI + LOGGER Installation and Operations Guide

Cables
Three cable assemblies are typically included with a DEI + LOGGER system.

♦ DC input power cable to connect the DEI + LOGGER to the 21 to 30 VDC

power source.
Note: Cable lengths vary ♦ Air switch signal cable to connect the air pressure switch to the DEI +
depending on the drill model LOGGER.
and the locations where the
components are installed: ♦ Encoder sensor cable to connect the optical shaft encoder to the DEI +
LOGGER.

Dual Axis Inclinometer (Optional)

An optional dual axis inclinometer kit is available for establishing mast leveling
and accurate angle drilling. Leveling information is displayed on the screen with
an accuracy within 0.1 degree of angle.

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 Chapter 2
Installing the DEI + LOGGER

Unpacking the Components

Before you begin the installation, make sure you have all the components you
need for your system. The table that follows lists the most commonly used of
components used for DEI + LOGGER installation and gives their part numbers
and the conditions under which you need each one.

Component Part Number Conditions for Use

DEI + LOGGER 6523-109-001 Unit required on all systems.

Display mounting system 3142500

Air pressure switch 3700-030-001 Standard, 12 - 150 psi.

(See note in “Laying 3700-031-001 Optional, 20 - 350 psi.
Out and Tracking the 3700-032-001 Optional, 50 - 450 psi.
Components”) 3700-033-001 Optional, 60 - 650 psi.

Optical shaft encoder 4500630 40-pulse, standard, for most drills.

Encoder mounting kit 6041-018-001 For indirect connection to the pulldown system.
6041-018-002 For direct connection to the pulldown system.

Encoder drive kit For indirect connection to pulldown system:

9001-097-002 ANSI 40 sprocket drive.
9001-097-003 ANSI 35 sprocket drive.
9001-116-001 ANSI 35 6.32” split sprocket drive.
9001-116-002 ANSI 35 5.002” ID sprocket drive.
9001-117-001 ANSI 40 5.50” split sprocket drive.
9001-117-002 ANSI 40 4.88” split sprocket drive.
9001-117-003 ANSI 40 5.125” split sprocket drive.
9001-117-004 ANSI 40 6.50” split sprocket drive.
9001-117-005 ANSI 40 5.25” split sprocket drive.
9001-117-00X ANSI 40 split sprocket drive (special order only).
9001-119-002 Torque reel drive.
Cables:
DC input power 7070-191-xxx For systems connecting to a 21 to 30 VDC power source.
Air switch signal 7070-189-xxx For all systems.
Encoder sensor 7060-190-xxx For all systems.
xxx = Cable length in feet (for example, 025 = 25 feet).

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DEI + LOGGER Installation and Operations Guide

Laying Out and Tracking the Components

Before you begin installing the DEI + LOGGER on the drill, use this procedure to
avoid time-consuming errors during installation and to simplify the re-ordering
of parts in the future. Refer to Figure 5.

1. Lay out all the components on the ground, a work table, or the bed of a truck.

2. Temporarily connect the cables to their respective ports. Determine where

each component will be installed, and measure all the cables to make sure
they are the lengths you require.

Do not connect power to the system at this time.

3. Complete the system configuration information in the front of this manual.

4. Complete and mail the Warranty Registration Card.

IMPORTANT NOTE:

If your drill uses varying lengths of drill stems, contact Thunderbird Mining
Systems about installing a manual air switch.

When the drill stems used on the drill are always the same length, that length is
entered into the DEI + LOGGER when it is calibrated. Then, when the optical
shaft encoder detects movement that is approximately the same as the calibrated
stem length, and the air pressure is off, the DEI + LOGGER interprets this
movement as the addition or removal of a drill stem and adjusts its hole depth
calculations accordingly.

However, when varying stem lengths are used, the drill stem length is declared
to be zero during calibration, so the DEI + LOGGER has no approximate length
to compare to movement that occurs when the air is off. For this reason, the
DEI + LOGGER cannot distinguish between a temporary obstruction of the air
pressure switch (which would appear as air pressure loss) and actual steel
changes. This could result in false hole-depth readings.

Therefore, when you use varying stem lengths, it is recommended that the air
pressure switch be replaced by a manual switch, which must be closed by the
operator before steel is changed and then opened again before drilling is
resumed.

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 Chapter 2 Installing the DEI + LOGGER

Figure 5. DEI + LOGGER System and Connections

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DEI + LOGGER Installation and Operations Guide

Installing the DEI + LOGGER Display Module

To install the DEI + LOGGER display module:

1. Locate a position in the cab that gives the operator a convenient view of the
unit.

Note: Before you mount the unit, be sure to determine how the cables will be
routed to it.

2. Using the template in Appendix B or the mounting base plate itself as a guide,
mark the positions of only four of the twenty four available mounting-bracket
holes on the mounting surface.

3. Drill 1/4-inch (6.4mm) clearance holes for bolts at the marked positions.

4. Secure one of the rectangular mounting plates with ball to the mounting
surface with the supplied sets of mounting bolts (10-32 by 1-inch), washers,
and nuts (four sets supplied).

5. Secure the other rectangular mounting plate with ball to the bottom surface of
the DEI + LOGGER with the four supplied bolts (10-32 by 5/8-inch) and lock
washers. See Figure 6.

Caution: Do not use bolts over 5/8-inch long.

6. Pinch one end of the mounting arm to open the opposite end, and place the
open end over the ball on the rectangular mounting plate.

7. Place the other end of the mounting arm over the ball on the rectangular plate
attached to the DEI + LOGGER. See Figure 7.

8. Position the DEI + LOGGER at an angle that provides the operator the best
view, and turn the mounting arm knob to secure the balls in this position.

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 Chapter 2 Installing the DEI + LOGGER

Figure 6. DEI + LOGGER and

RAM Mount Assembly

Figure 7. DEI + LOGGER Installed

on RAM Mount Assembly

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DEI + LOGGER Installation and Operations Guide

Installing the Air Pressure Switch

You should not need to adjust the air pressure switch since it was pre-set by
Thunderbird Mining Systems. To install it:

1. Determine where you will tie into the bailing air line. The air pressure switch
must be installed on the bailing air line between the drill head and the check
valve. It can be done in any of the following ways:
♦ Install a tee at the operator’s gauge (see Figure 8).
♦ Or, drill and tap a 1/4-inch NPT hole.
♦ Or, install a tee with reducers to 1/4-inch NPT. The tee must have an ID
equal to the air line.

Figure 8.
Air Pressure Switch
Connections

2. Determine where to mount the air pressure switch. It should be near the
location where you plan to tie into the bailing air line. Mount it so that the
connectors to the air switch signal cable and the air input line are on the
bottom of the air pressure switch. It need not be visible during operation, but
you must be able to access it in the future.
3. Using the template in Appendix B or the air pressure switch itself as a guide,
mark the positions of the two holes you will use to mount the switch.
4. Drill 1/4-inch (6.4 mm) clearance holes for bolts at the two marked positions.
5. Bolt the air pressure switch to the mounting surface using the supplied bolts,
washers, and nuts.
6. Tie into the bailing air line at the point you determined in Step 1.
7. Attach the socket end of the air switch signal cable (7070-189-xxx) to the
2-pin connector on the air pressure switch.
8. Route the cable away from moving equipment toward the DEI + LOGGER.
Use tie wraps to secure any excess cable.
9. Connect the other, 2-pin end of the air switch signal cable to the BIT AIR
connector on the rear panel of the DEI + LOGGER.

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 Chapter 2 Installing the DEI + LOGGER

Installing the Optical Shaft Encoder

The design of the drill’s pulldown system determines the way the optical shaft
encoder must be mounted. There are four general methods of installation. The
instructions for these methods are given in this section.

Direct Drive The encoder is flexibly coupled to the pulldown sprocket

shaft and senses its rotation directly.

Use this direct method of installation if both these

conditions are true:

• The pulldown sprocket shaft rotates in proportion to

the movement of the drill bit.

• The end of the pulldown sprocket shaft is accessible for

attaching a shaft adapter.

Indirect Drive The encoder is attached to an intermediary sprocket that is

rotated by the movement of the pulldown sprocket. The
and encoder senses the rotation of the pulldown sprocket
indirectly through the rotation of the intermediary
Indirect Split
sprocket.
Sprocket Drive
Use one of these indirect methods of installation if both
these conditions are true:

♦ There is at least 10 inches (25 cm.) of clearance above or

below the pulldown sprocket.

♦ The pulldown sprocket shaft or hub is less than 6.5

inches (16.5 cm.) in diameter.

Use the Indirect Sprocket Drive method if you can access

the end of the pulldown sprocket shaft or hub to slide the
instrumentation sprocket over it.

Use the Indirect Split Sprocket Drive method if you cannot

access the end of the pulldown sprocket shaft or hub.

Indirect Torque Reel The encoder is enclosed within the torque reel box. The
box is mounted at the top of the mast, and its tension cable
is connected to the drill head or carriage. As the drill head
moves up and down, the encoder inside the torque reel
senses the movement of the drill head indirectly through
the winding or unwinding of the tension cable.

If your drill does not satisfy the conditions for any of these methods, contact your
DEI + LOGGER distributor.

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DEI + LOGGER Installation and Operations Guide

Direct Sprocket Drive

To install the encoder using the direct sprocket drive method (refer to Figure 9):

1. Locate the pulldown sprocket shaft most suitable for mounting the encoder,
where the encoder will be best protected from physical damage.

2. Tack weld the shaft adapter to the center of the pulldown sprocket shaft.

3. Weld or bolt the encoder bracket in a position that supports the encoder in the
alignment described in Step 5.

Important: Do not weld the bracket after the encoder is attached.

4. Secure the encoder to the encoder mounting bracket or brackets, using the
hardware provided. Use one or both brackets as required to position the
encoder as described in Step 5.

5. Position the encoder so that the shaft adapter and the encoder are 3 to 5 inches
(7 - 13 cm.) apart and closely aligned along the centerline axis of the pulldown
sprocket shaft (1/16-inch runout maximum).

6. Connect the shaft adapter to the encoder by means of the flexible coupling
and hose clamps provided.

NOTE: Periodically during operation, check that the hose clamps are tight.

7. Connect the 7-socket end of the encoder cable assembly (7060-190-xxx) to the
cable port on the encoder.

8. Route the cable away from moving equipment, making sure there is sufficient
allowance for lowering the mast. Use tie wraps to secure any excess cable.

9. Make the sure power to the DEI + LOGGER is turned off.

10. Connect the 7-pin end of the encoder cable assembly (7060-190-xxx) to the
ENCODER port on the rear panel of the DEI + LOGGER.

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 Chapter 2 Installing the DEI + LOGGER

Figure 9. Installing the Encoder — Direct Sprocket Drive Method

Using the 6041-018-002 Kit

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DEI + LOGGER Installation and Operations Guide

Indirect Sprocket Drive

Installing the encoder using this method requires an encoder mounting kit (6041-
018-001) and an encoder drive kit (9001-097-00x). You can purchase these parts
from your DEI + LOGGER distributor . This installation may also require
machine shop facilities.

To install the encoder using the indirect sprocket drive method (see Figure 10):

1. Measure the diameter of the pulldown sprocket hub.

2. Obtain the 48-tooth instrumentation sprocket from the mounting kit, and
machine the inside diameter of the hole to 0.005 inch greater than the hub
diameter measured in Step 1.

NOTE: If there is not enough clearance beside the pulldown sprocket and
above or below it to use the 48-tooth instrumentation sprocket, or if there is
not enough clearance for the ANSI 40 roller chain, you can use a 72-tooth
sprocket in this step, a 24-tooth sprocket in Step 6, and an ANSI 35 chain in
Step 8. However, Thunderbird Mining Systems strongly recommends using
the ANSI 40, since it is stronger and alignment problems are more likely to
occur with the ANSI 35.

3. Slide the 48-tooth sprocket over the hub of the pulldown sprocket, making
sure it is perpendicular to the hub and that there is clearance between the
chains. Then tack-weld the sprocket onto the hub.

4. Weld the encoder bracket to the mast in a position that supports the encoder
in the alignment described in Step 7. Make sure your bracket set up allows
you to slide the encoder toward or away from the pulldown sprocket, so that
you can tighten the roller chain (Step 9).

Important: Do not weld the bracket after the encoder is attached.

5. Secure the encoder to the encoder mounting bracket or brackets, using the
hardware provided. Use one or both brackets as required to position the
encoder, as described in Step 7.

6. Slide the supplied 16-tooth instrumentation sprocket onto the encoder shaft
and tighten the set screw to secure it in place.

7. Position the encoder above or below the pulldown sprocket and on the mast
so that the two instrumentation sprockets are precisely aligned and not more
than 10 inches (25 cm.) apart.

Note: The preferred method is below the pull-down sprocket since it

minimizes the load on the encoder shaft.

IMPORTANT: The alignment of the two sprockets is critical. Misalignment

might cause the chain to come off or break, or, more importantly, it might
damage the encoder.

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 Chapter 2 Installing the DEI + LOGGER

8. Using the ANSI 40 roller chain, connect the two instrumentation sprockets.
Remove links as necessary to tighten the chain.

9. Slide the encoder bracket (with the encoder on it) as necessary until the chain
is snug but not overtight, and secure the brackets.

10. Connect the 7-socket end of the encoder cable assembly (7060-190-xxx) to the
port on the encoder.

11 Route the cable away from moving equipment. Use tie wraps to secure any
excess cable.

12. Make the sure power to the DEI + LOGGER is turned off.

13. Connect the 7-pin end of the encoder cable assembly to the ENCODER port on
the rear panel of the DEI + LOGGER.

Figure 10. Installing the Encoder — Indirect Sprocket Drive Method

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DEI + LOGGER Installation and Operations Guide

Indirect Split Sprocket Drive

Installing the encoder with this method requires an encoder mounting kit (6041-
018-001) with a split sprocket drive (9001-117-00x). Several sizes of sprockets are
available from your DEI + LOGGER distributor. Make sure the one you have has
an internal diameter the same as the diameter of the pulldown sprocket shaft.

To install the encoder using the indirect split sprocket drive method (refer to
Figure 11):

1. Assemble the sprocket onto the shaft using the supplied hardware and
sprocket assembly plates. Finger tighten the nuts to allow for play. Shim the
gap between the sprocket halves as necessary to obtain the correct tooth
orientation.

2. Shim the sprocket against the tube shaft as necessary to ensure that it is
concentric with the shaft (within 0.015 inch), perpendicular to it, and far
enough away from the pulldown sprocket so there is clearance between the
chains.

3. Secure the split sprocket to the shaft by welding a minimum of three places on
each side of the sprocket.

4. Finish the installation by following steps 4 through 12 of the instructions for

the “Indirect Sprocket Drive” method (refer to Figure 10).

Figure 11. Installing the Split Sprocket

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 Chapter 2 Installing the DEI + LOGGER

Indirect Torque Reel

If you ordered a torque reel drive kit with the DEI + LOGGER, the encoder is
already installed in the box. Because of the great variation in drill design,
Thunderbird Mining Systems does not supply the brackets to attach the torque
reel to the mast and to attach the cable to the drill head or carriage.

To install the torque reel and encoder (refer to Figure 12 and Figure 13):

1. Determine the design of the brackets you need and fabricate them.
Design the bracket so that you can weld it to the mast and then bolt the
torque reel box to it using the four mounting holes on the box. The box
must be directly above the drill head so the tension cable coming out of
the box can be connected to the drill head and aligned so it is parallel to
the movement of the drill head.
2. Determine the maximum length of cable that must extend from the
torque reel. Pull out that amount plus about 4.5 feet (1.5 meters). The
tension should be tight enough that no more cable can be pulled out. To
adjust the tension, refer to the following subsections.
3. Mount the torque reel box at the top of the mast so that the tension
cable exits the bottom of the box and is directly above the drill head.
Make sure the cable moves perpendicular to the bottom of the box to
minimize wear on the cable.
4. Attach the end of the tension cable to the drill head. A common method
of doing this is to weld an eye bolt to the drill head and then use cable
clamps to attach the cable to the eye bolt. Make sure the cable is
precisely parallel to the movement of the drill head.
Important: Make sure there is sufficient cable before you lower the
drill head.

Figure 12. Installing the

Torque Reel (a)

Figure 13. Installing the Torque Reel (b)

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DEI + LOGGER Installation and Operations Guide

Increasing the Tension on the Tension Cable

If the cable from the torque reel to the drill head is not taut enough to move the
pulley inside the torque reel box, use the following instructions to increase it:

1. Lift off the clamps that hold the lid on the torque reel box (refer back to Figure
13), and remove the lid.

2. Use a wrench to rotate the mainspring shaft counter-clockwise until the

tension is correct. Do not over tighten the tension (see Figure 14).

3. Increasing the tension decreases the length of the cable, so verify the length
before you move the drill head.

Decreasing the Tension on the Tension Cable

If the cable from the torque reel to the drill head is too tight, the torque reel will
not allow enough cable to be released. Use the following instructions to decrease
the tension on the cable:

1. Lift off the clamps that hold the lid on the torque reel box (refer back to Figure
13), and remove the lid.

2. Reach behind the torque reel and carefully press the tension lock spring on
the bottom of the reel. Do not press it too hard or too long, or too much
tension will be released. Then check the tension again. If it is still too tight,
briefly press the spring again. If you decrease it too much, use the previous
procedure to increase it.

Figure 14. Increasing and Decreasing Cable Tension

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 Chapter 2 Installing the DEI + LOGGER

Connecting to the External Alarm/Tram Circuit

You can connect components on your drill to the external alarm circuit, so that
their operation is controlled by the rate of penetration (ROP) and hole depth
alarms set up on the Alarms system screen of the DEI + LOGGER. For example,
you could set up a light or an audible alarm to signal when the hole depth
reaches a specified distance or the ROP reaches a specified rate.

The port on the back panel of the DEI + LOGGER provides access to an internal
relay which has two isolated contact sets. Each set contains a normally closed and
a normally open circuit. Each relay contact provides a 2-Amp maximum current
capability. These normal positions occur when the alarms are off and the DEI +
LOGGER power is off.

1. Connect the 6-pin end of the external alarm cable to the ALARM/TRAM port
on the rear panel of the DEI + LOGGER.

2. Connect your remote components according to the instructions in Figure 15.

Figure 15. Remote

External Alarm and
Tram Connections

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DEI + LOGGER Installation and Operations Guide

Installing a Remote Zero Hole Depth Switch

You can install a remote access switch for resetting the hole depth to zero. This is
in addition to the reset button on the front of the DEI + LOGGER.

The port on the DEI + LOGGER provides a parallel connection to the front panel
ZERO HOLE DEPTH switch. The connector has a 5 VDC pull-up on the A pin, with an
internal ground on the B pin. The contact is normally open. Closing the
connection resets the hole depth.

1. Connect the 2-pin end of the remote control cable (available from
Thunderbird Mining Systems) to the ZERO HOLE port on the rear panel of the
DEI + LOGGER.

2. Connect your remote switch (available from Thunderbird Mining Systems)

according to the instructions in Figure 16. Connect to any open and unused
contacts.

Warning: Do not apply power or an external ground to the ZERO HOLE contacts.
Doing so will damage the DEI + LOGGER and void the warranty.

Figure 16. Remote Zero Hole Depth Switch Connections

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 Chapter 2 Installing the DEI + LOGGER

Verifying the Installation

In order to avoid damage to the DEI + LOGGER components, it is very
important to ensure that the DEI + LOGGER is installed correctly before you
calibrate it.

Follow these instructions.

1. Tighten all nuts and bolts.

2. Check all electrical connections and make sure the MS connectors are tight.

3. Check the routing of the cables to make sure they are away from moving
equipment, and make sure all excess (loose) cable is secured.

4. Make sure cables are long enough to allow for the mast to be lowered.

Note: As you check the installation, make sure you have accurately completed
the System Configuration Information sheet in the front of the manual.

Calibrating the DEI + LOGGER

Calibration is necessary to suit the DEI + LOGGER to the particular drill rig on
which it is installed. Normally, it is only necessary when the DEI + LOGGER is
first installed on the drill (or moved from a different drill). However, if the DEI +
LOGGER detects a calibration failure during operation, it flashes a warning
screen on the display, and you must re-calibrate before you continue.

During calibration, the DEI + LOGGER counts the number of pulses sent from
the optical encoder as the drill head moves the distance you specify. So, it
equates that number of pulses to that distance. For example, if the DEI +
LOGGER counts 2000 pulses, and you record the distance moved as “20,” the
DEI + LOGGER operates on a scale of 2000 pulses to 20 units of distance.

The units of measure you use during calibration (meters or feet) are the units
used throughout operation. When you calibrate the DEI + LOGGER, you specify
only the numerical value of the distance the drill head moves, not the units. So, if
you calibrate using feet, the DEI + LOGGER operates in feet and feet per hour. If
you calibrate using meters, the DEI + LOGGER operates in meters and meters
per hour.

The Calibration screens lead you through the calibration procedure.

To display the first Calibration screen:

1. Press the System button to display the System Menu.

2. Use the Left, Up, Down, and Right arrow buttons on the DEI + LOGGER to
move the highlight to “Configuration”.

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DEI + LOGGER Installation and Operations Guide

3. With “Configuration” highlighted, press the Enter button to display the

Configuration menu.

4. Move the highlight to “Calibration” and press the Enter button.

Sample Screen
Operator ID

Screen Title

Procedural
Instructions for
the Calibration
Process
Appear Here

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Using the Screens

BEFORE YOU BEGIN CALIBRATION: Make sure the DEI + LOGGER is completely
and correctly installed.

To calibrate the DEI + LOGGER:

1. On the first Calibration screen, use the Left arrow button to highlight the
“Yes” box. Then press the Enter button to begin the procedure.

Steps 2 through 10 are given on the screens. The screens are reproduced below
with notes to the right of some screens.

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Chapter 2 Installing the DEI + LOGGER

Steps 2 through 7 lead you

through a method of accurately
measuring the distance the drill
head moves from one position
(entered in Step 4) to another
(enter in Step 6). This process
allows the DEI + LOGGER to
set up the ratio of encoder pulses
to units of distance.

These instructions assume the

drill is in the field. However, it is
not necessary to use a drilled
hole.

In this step, you position the drill

head as low as possible to ensure
that the distance used for
calibration is 18 feet (6 meters) or
more. The greater the distance
the more accurate the calibration
will be.

In this step you record the initial

position of the drill head by
entering its distance from the
drill deck.

Use the Left and Right arrow

buttons to move the pointer to
the digit you want to change.
Then use the Up arrow button to
increase the value of the digit, or
use the Down arrow button to
decrease its value.

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DEI + LOGGER Installation and Operations Guide

In this step, you move the drill

head as high as possible.

The DEI + LOGGER counts the

encoder pulses that correspond
to the distance the head moves
from the first recorded position.

Now you record the second

position, again by entering the
distance of the drill head from
the drill deck.

Use the Left and Right arrow

buttons to move the pointer to
the digit you want to change.
Then use the Up arrow button to
increase the value of the digit, or
use the Down arrow button to
decrease its value.

The DEI + LOGGER calculates

the distance moved as the
difference between the first
measurement and this
measurement.

If this value is not correct, press

the System button to return to
System Menu. Then begin the
calibration procedure again. All
the values you already entered
are saved and appear on the
calibration screens, so you can
simply change them as required.

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Chapter 2 Installing the DEI + LOGGER

This is the length of pipe in the

rack, not the first pipe with bits,
sub, stabilizers, and other
components.

NOTE: In cases where the drill

stems in the pipe rack or
carousel vary in length by 0.5
feet (15 cm) or more, set the
length to “0.00”. If the hole
depth reading is inaccurate
during hole reaming or cleaning
or during excessive on-and-off
cycling of the bailing air, contact
Thunderbird Mining Systems.
You may need to install a
manual air switch.

This offset is the distance the bit

must be raised above the collar
of the hole for the DEI +
LOGGER to consider the pipe
out of the hole and turn off the
PIPE (pipe-in-hole) notification.
A normal value for this offset is
½ the distance between the
bottom of the bit and the ground
when the drill is on the level and
the jacks and power head are
fully retracted. You can adjust
this value to increase or decrease
the sensitivity of the PIPE alarm
function.

The PIPE notification turns off

only when drilling resumes or
after the distance from the
bottom of the hole is equal to the
hole depth plus this offset.

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DEI + LOGGER Installation and Operations Guide

Press the Enter button to return

to the System Menu.

NOTE: If the drill head drifts or moves during the calibration, you must repeat the
calibration.

Chapter 3
Operating the DEI + LOGGER
This section explains how to operate the DEI + LOGGER and how to read and
use the graphical screens.

NOTE: If the distance recorded in the calibration procedure was measured in feet,
all readings on the DEI + LOGGER are in feet or feet per hour. If the calibration
was done in meters, all readings are in meters or meters per hour.

Turning the DEI + LOGGER On and Off

When the DEI + LOGGER is on, the graphical screen is

illuminated. When it is off, the screen is blank.

To turn the DEI + LOGGER on:

♦ Press the Power button on the front of the DEI +

LOGGER. The graphical screen becomes illuminated and
the logo screen appears.

To turn it off:

♦ Press the Power button. The screen becomes blank.

Figure 33. DEI + LOGGER Power Button

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 Chapter 3 Operating the DEI + LOGGER

DEI + LOGGER Control Elements

This section explains the function of each element on the front of the DEI +
LOGGER. The elements include the graphical display, ten control buttons, and
the power button.

Statistics
Data

System
Help
Enter

Power

Left Down Zero Hole

Depth
Up Right

Figure 34. DEI + LOGGER Control Elements

Graphical Display
The display area of the DEI + LOGGER is your window into the operation of the
system. It shows statistics about your current and previous drilling operations,
help information, and alarm warnings. This area also displays system screens
you can use to check and change the setup of the system and perform
troubleshooting procedures. For illustrations and explanations of the screens,
refer ahead to “Reference to Statistics Screens” (page 60), “Reference to System
Screens” (page 106), and “Reference to Data Entry Screens” (page 77).

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DEI + LOGGER Installation and Operations Guide

The bottom line of most screens is the status line. For example:

Operator ID

Screen Title

Specific
Screen
Content

Status Line

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Current Hole The number of holes started during the current shift.
Number
This value increases by one each time the Zero Hole Depth
button is pressed if any depth has been recorded since the last
time the button was pressed. This value is reset to zero after a
shift change.

Current Drill The drill status, which is one of the following:

Status
Drilling: Any time the pipe is making downward drilling
progress in the hole. Note that a drilling delay is counted as
drilling until the length of the delay reaches the “non-drilling
time threshold” set up for your system. Then the status changes
to “Non drilling”. The default threshold is 60 seconds.

Non drilling: Any time the drill pipe is in the hole and not
making downward progress for a period longer than the “non-
drilling time threshold.”

Idle: Any time the drill pipe is out of the hole.

Current Time The system time in hours and minutes, as on a 24-hour clock.

NOTE: The battery inside the DEI + LOGGER maintains the

system clock even when the DEI + LOGGER is not connected
to a power source.

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Control Buttons
You use the control buttons below and to the right of the display to request
information to view and to enter setup information into the DEI + LOGGER.

Button Meaning Function

Statistics Press this button to access the statistics screens showing

information about the current drilling operation and historical
statistics. The default statistics screen appears:

You can use the Left, Up, Down, and Right arrow buttons to move
to other statistics screens. For details on displaying and reading the
statistics screens, refer ahead to ”Reference to Statistics Screens” on
page 60.

Data Press this button to display the Data Entry Menu

From this menu, you display screens on which you can enter
information about the current drilling operation. For details on
using the screens, refer ahead to “Reference to Data Entry Screens”
on page 77.

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Button Meaning Function

System Press this button to display the System Menu screen.

From this menu, you display screens on which you can view and
change the system setup. For details on using the system screens,
refer ahead to “Reference to System Screens” on page 106.

Help Press this button to display help information about the screen
currently displayed. For example, if you press the Help button
when the default statistics screen is displayed, the following help
information appears.

A down arrow at the bottom of a help screen indicates this

is the first page of a multi-page help screen. Press the Down
arrow on the DEI + LOGGER to move to the next page.

Both arrows at the bottom of a help screen indicate that this

is a middle page in a multi-page help screen. Press the Up
arrow on the DEI + LOGGER to move back to the previous
page, or press the Down arrow to move to the next page.

An up arrow indicates that this is the last page in the multi-

page help screen.

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Button Meaning Function

Enter Use this button to make selections on certain screens. The specific
use varies from screen to screen. Instructions for using this button
are included with the instructions for all screens to which it applies.

Left Use these buttons to navigate on certain screens and to navigate

between certain screens. For example, when the System Menu
screen is displayed, use the appropriate one of these keys to move
Up to the screen you want to view; then press the Enter key to display
the selected screen.
Down
Instructions for using these buttons are included with the
instructions for all screens to which they apply.
Right

Zero Hole Whenever you start a new hole, press this button. If any depth has
Depth been recorded since the last time the button was pressed, the DEI +
LOGGER does the following:

• Increases the hole count by one, and zeros the hole depth so all
new drilling applies to the new hole.

• Moves the readings for previous holes to the appropriate

historical screens.

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Reference to Statistics Screens

Statistics screens provide information about the drilling operation.

♦ Continually updated details about the current hole allow the operator to
know, at every moment, what is occurring in the hole – the current depth,
target depth, rate of penetration, the distance from the bottom when the bit is
raised, whether or not the pipe is still in the hole, the time spent drilling the
hole, and the time required to complete the hole.

♦ Historical statistics (that is, production during a given period, statistics about
previous holes and previous shifts) provide supervisors with a summary of
drilling data.

When you press the Statistics button on the DEI + LOGGER, the display shows
the default statistics screen which gives statistics for the current hole, that is, the
hole currently being drilled (or most recently drilled). Once this screen is
displayed, you can use the arrow buttons to display other statistics screens.

This section explains each of the statistics screens, tells how to display each one,
and details the function of each navigation control button on each screen. Refer
ahead to “Navigating Through Statistics Screens” for a summary diagram
showing all statistics screen and how to navigate from one to another.

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Statistics: Current Hole

The Statistics: Current Hole screen shows details about the hole currently being
drilled. It allows you to monitor the drilling as it occurs.

To display this screen, from any screen, press the Statistics button.

Sample Screen
A sample screen is shown and explained below.

Graphic Display of Current Depth and Target Depth

Operator ID

Screen Title

Statistics for
Current Hole

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Display Details
NOTE: If the distance recorded in the calibration procedure was measured in feet,
all readings on the DEI + LOGGER are in feet. If the calibration was done in
meters, all readings are in meters.

DEPTH Current Hole Depth. The display shows the actual

depth of the hole presently being drilled, in meters or
feet (to the nearest tenth). Values range from 0.0 to
999.9.

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ROP Rate of Penetration. While the pipe is making

downward progress (the status is “Drilling”), the
display shows the actual rate of drill penetration in
meters or feet per hour.

Whenever the drill bit is raised from the bottom of the

hole, the label changes to read “Distance From
Bottom,” and the display shows the distance the drill
bit is raised from the hole bottom (in meters or feet).
This helps the operator avoid slamming the bit into the
hole bottom and possibly damaging the drill bit and
steel.

When the bit air is turned off, the displayed “Distance

From Bottom” value freezes, showing the value when
the air was turned off.

When the drill bit is returned to the hole bottom and

drilling is resumed, the label returns to “ROP”, and the
display reverts to showing the rate.

DRILL TIME The length of time, in minutes and seconds, spent

drilling on the current hole. That is, the time when
downward progress is being made, including delay
periods of less than the non-drill time threshold set up
for your system. (Status in the status line says
“Drilling.”)

TARGET The target depth for the current hole, in meters or feet
(to the nearest tenth).

Note: You can change the target depth on the Target

Depth system screen.

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PIPE When the drill is moving downward, this area is blank.

When the ROP display is showing the “Distance From

Bottom, and there is a Pipe-In-Hole condition, the word
“PIPE” flashes in this area of the display to alert the
operator to the condition. This features helps you
prevent damage to equipment often caused by
retracting the jacks or moving the drill when pipe is
still in the hole.

The Pipe-In-Hole alert occurs whenever the following

three conditions are met:

♦ Drilling air is turned off.

♦ Drill feed direction is reversed relative to the

normal drilling direction (as indicated by encoder
data).

♦ The distance from bottom value is greater than 85%

of the hole depth.

TIME TO COMPLETE The estimated time remaining to finish drilling the

current hole is based on the distance remaining and the
current rate of penetration. The value is calculated as
the difference between the target depth and the current
depth, divided by the current ROP. This value is
displayed after 5% of the hole has been drilled.

Graphic Display Right and left arrows on the graph show the current
depth. A dark line shows the target depth.

Note: You can change the minimum and maximum

values on the scale through the Graphic Scaling system
screen.

Button Usage

Enter No function on this screen.

Left Displays the Shift Screen: Current Shift.

Up Displays the Production Screen.

Down Displays the Statistics Screen: 1st Previous Hole.

Right Displays the ROP Graphics Screen: Current Hole.

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Alarm Screens
When any of three possible alarm conditions occur, the DEI + LOGGER
interrupts the current display by flashing a screen with appropriate alarm
information until the alarm condition no longer exists. Since these alarm
conditions are detected during drilling, normally it is the Statistics: Current Hole
screen that is interrupted.

The three alarm conditions are:

♦ ROP is too high. If the ROP exceeds the rate set up on the Alarms screen
(discussed in “Reference to System Screens”), and the ROP alarm is enabled,
the DEI + LOGGER flashes a warning screen on the display, telling you the
ROP has reached or exceeded your specified maximum. Once the alarm
condition is corrected, the screen is removed from the display. For example:

♦ Hole is too deep. If the drilling reaches the depth set up on the Alarms screen,
and the depth alarm is enabled, the DEI + LOGGER flashes a warning screen
telling you the depth has reached or exceeded your specified distance. Once
the alarm condition is corrected, the screen is removed from the display. For
example:

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♦ Calibration has failed. If the DEI + LOGGER detects a calibration failure

during drilling, it flashes a warning screen on the display, and you must re-
calibrate before you continue, or your data will be unreliable. The warning is
shown below.

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Navigating Through Statistics Screens

The following diagram shows all the available statistics screens. Note that the
default screen is highlighted in black. It is the screen that appears whenever you
press the Statistics button on the DEI + LOGGER.

On the diagram, the arrows between screens indicate the DEI + LOGGER control
buttons you use to move from one screen to another. For example, if the
Statistics: Current Hole screen is currently on the display, press the Left arrow
button to display the Current Shift screen; then press the Right arrow button to
return to the Statistics: Current Hole screen.

The following subsections explain these screens:

♦ Production Statistics
♦ ROP Graphic Screens
♦ Statistics: Previous Holes
♦ Shift Screens
♦ Production Time Statistics

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Production Statistics
Use the Production Statistics screen to track the cumulative statistics during some
period, such as a shift or a day. The screen displays combined statistical data for
all holes drilled since the last time the values were reset to zero through the Reset
Production Statistics screen.

To display this screen:

1. Press the Statistics button to display the default statistics screen — Statistics:
Current Hole.

2. Press the Up arrow button.

To return to the default statistics screen, press the Down arrow button.

Sample Screen
A sample screen is shown and explained below.

Operator ID

Screen Title

Statistics for
Current Hole

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Display Details
TOTAL HOLES Number of holes started during the production period.

AVERAGE DEPTH Average depth of all holes partially or completely drilled

during the production period, in meters or feet (to the
nearest tenth).

AVERAGE TIME Average time spent drilling on each hole.

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TOTAL DEPTH The total depth drilled during the production period, in
meters or feet (to the nearest tenth).

AVERAGE ROP The average rate of penetration per hour during the
production period.

Button Usage

Enter No function.

Left No function.

Up No function.

Down Displays the Statistics: Current Hole screen.

Right No function.

ROP Graphic Screens

The ROP Graphic Screen displays depth, ROP, and drill time for the hole
currently being drilled. It also graphically displays the ROP in relationship to the
depth.

To display this screen:

1. Press the Statistics button to display the default statistics screen — Statistics:
Current Hole.

2. Press the Right arrow button.

You can move through the three Statistics screens for previous holes by pressing
the Down arrow one, two, three times. Then use the Up arrow button to move
back to a more recent hole.

NOTE: From the ROP Graphics screen, press the Left arrow button to return to the
Statistics: Current Hole screen.

Sample Screen
A sample screen for the Current Hole is shown and explained below.

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ROP vs. Depth Graph

Operator ID

Screen Title

Statistics for
the Hole

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Display Details
DEPTH Current Hole Depth. The display shows the actual
depth of the hole presently being drilled, in meters or
feet (to the nearest tenth). Values range from 0.0 to
999.9.

ROP Rate of Penetration. While the pipe is making

downward progress (the status is “Drilling”), the
display shows the actual rate of drill penetration in
meters or feet per hour.

Whenever the drill bit is raised from the bottom of the

hole, the label changes to read “Distance From
Bottom,” and the display shows the distance the drill
bit is raised from the hole bottom (in meters or feet).
This helps the operator avoid slamming the bit into the
hole bottom and possibly damaging the drill bit and
steel.

When the bit air is turned off, the displayed “Distance

From Bottom” value freezes, showing the value when
the air was turned off.

When the drill bit is returned to the hole bottom and

drilling is resumed, the label returns to “ROP”, and the
display reverts to showing the rate.

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DRILL TIME The length of time, in minutes and seconds, spent

drilling on the current hole. That is, the time when
downward progress is being made, including delay
periods of less than the non-drill time threshold set up
for your system. (Status in the status line says
“Drilling.”)

ROP Graphic Shows the rate of penetration (on the X axis) plotted
against the depth (on the Y axis). For example, the
sample screen shows that when the hole depth was
approximately 35 feet (or meters), the ROP was
approximately 122 feet (or meters) per hour.

Note: You can change the minimum and maximum

values on either scale through the Graphic Scaling
system screen.

Button Usage

Enter No function.

Left Displays the Statistics screen for the current hole.

Up No function.

Down Displays the Statistics screen for the previous hole.

Right No function.

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Statistics: Previous Holes

Three different screens show the statistics for the three holes drilled immediately
previous to the current hole. You can access these screens from either the default
statistics screen (Statistics: Current Hole) or the ROP Graphic screen.

To display this screen:

1. Press the Statistics button to display the default statistics screen — Statistics:
Current Hole.

2. Press the Right arrow button to display the ROP Graphic screen.

3. Press the Down arrow button to display the statistics screen for the hole of
interest (once for the 1st previous hole screen, twice for the 2nd previous hole
screen, or three times for the 3rd previous hole screen).

You can move through the three statistics screens by pressing the Up arrow
button to move to a screen for a more recent hole and by pressing the Down
arrow button to move to a screen for a previous hole.

Sample Screen
A sample screen is shown and explained below.

ROP vs. Depth Graph

Operator ID

Screen Title
Shows the
Hole Number

Statistics for
the Hole

Current Hole Current Drill Current Time

Number Status (24-hour clock)

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Display Details
DEPTH Hole Depth. The display shows the final depth of the hole,
in meters or feet (to the nearest tenth). Values range from 0.0
to 999.9.

AVERAGE ROP Average Rate of Penetration.

DRILL TIME The length of time, in minutes and seconds, spent drilling on
the indicated hole. Drilling time is the time when downward
progress was being made, including delay periods of less
than 60 seconds. (Status in the status line says “Drilling.”)

ROP Graphic Shows the rate of penetration (on the X axis) plotted against
the depth (on the Y axis). For example, the sample screen
shows that when the hole depth was approximately 35 feet
(or meters), the ROP was approximately 122 feet (or meters)
per hour.

Note: You can change the minimum and maximum values

on either scale through the Graphic Scaling system screen.

Button Usage

Enter No function.

Left No function.

Up On screens for 2nd previous and 3rd previous holes, this

button displays the Statistics for a more recently drilled hole.
On the screen for the 1st previous hole, it displays the
Statistics: Current Hole screen.

Down On screens for 1st and 2nd previous holes, this button
displays the Statistics for a previous hole. On the screen for
the 3rd previous hole, it has no function.

Right On the Statistics: Current Hole screen only, displays the

ROP Graphic Screen

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Shift Screens
There are four shift screens. Each one displays cumulative statistical data for all
holes worked on during the selected shift — current shift or one of the three
previous shifts. Starting and ending times for shifts are set up on the Shift Times
system screens.

To display one of the shift screens:

1. Press the Statistics button to display the default statistics screen — Statistics:
Current Hole.

2. Press the Left arrow button to display the shift screen for the current shift.

3. Press the Left arrow button to display the screen for a different shift (once for
the previous shift, twice for the 2nd previous, or three times for the 3rd
previous shift).

You can move through the four shift screens by pressing the Right arrow button
to move to a screen for a more recent shift and by pressing the Left arrow button
to move to a screen for a previous shift.

Sample Screen
A sample screen for the current shift is shown and explained below.

Operator ID

Screen Title
Indicates the
Shift

Statistics for
the Shift

Current Hole Current Drill Current Time

Number Status (24-hour clock)

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Display Details
TOTAL HOLES Number of holes started during the shift.

TOTAL TIME Total drilling time on holes finished during the shift.

AVERAGE ROP The average rate of penetration during the drilling of all
holes worked on during the shift.

TOTAL DEPTH The total depth drilled during the shift, in meters or feet
(to the nearest tenth).

AVERAGE DEPTH Average depth of all holes worked on during the shift, in
meters or feet (to the nearest tenth).

AVERAGE TIME Average drilling time per hole worked on during the shift.

Button Usage

Enter No function.

Left Displays the Shift screen for a previous shift. No

function on the Shift screen for the 3rd previous shift.

Up Displays the Production Time screen for the selected

shift.

Down No function.

Right Displays the Shift screen for a later shift. On the Shift
screen for the current shift only, displays the Statistics:
Current Hole screen.

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Production Time Screens

There are four production time screens. Each one displays cumulative statistical
data for all holes worked on during the selected shift — current shift or one of the
three previous shifts. Starting and ending times for shifts come from the PDA
system setup.

To display one of the production time screens:

1. Press the Statistics button to display the default statistics screen — Statistics:
Current Hole.

2. Press the Left arrow button to display the shift screen for the current shift.

3. To display the screen for an earlier shift, press the Left arrow button (once for
the previous shift, twice for the 2nd previous, or three times for the 3rd
previous shift).

4. Press the Up arrow button to display the production time screen for the
selected shift.

Sample Screen
A sample screen for the current shift is shown and explained below.

Operator ID

Screen Title
Indicates the
Shift

Statistics for
the Shift

Current Hole Current Drill Current Time

Number Status (24-hour clock)

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Display Details
DRILL Total drilling time on holes finished during the shift,
including all non-drilling time up to the non-drill time
threshold.

NON DRILL TIME Non-drilling time in any hole during the shift.
IN HOLE

TOTAL TIME The sum of Drill, Non-Drill, Delay, and Tram time.

DELAY Total time for which any delay code was in effect.

TRAM Total time the tram switch was on.

Button Usage

Enter No function.

Left No function.

Up No function.

Down Displays the Shift screen for the selected shift.

Right No function.

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Reference to Data Entry Screens

Data entry screens allow you enter information into the DEI + LOGGER for use
in tracking and reporting. For example:

♦ Operator number at login

♦ Hole number, pattern number, and hole numbering scheme.

♦ Drill conditions and target depth

♦ Serial numbers of components used on the drill

♦ Items and quantities replenished or replaced on the drill

When you press the Data button on the DEI + LOGGER, the display shows the
Data Entry Menu screen, through which you access all other system screens.

This section explains each of the data entry screens and tells how to display and
use each one. Refer ahead to “Navigating Through Data Entry Screens” for a
summary diagram showing all data entry screens and how to navigate to each
one.

Data Entry Menu

The Data Entry Menu provides an entry into the other data entry screens. Note
that the Bit Details item displays an additional menu from which you choose.

From any screen, press the Data button to display this screen. The most recently
used option is highlighted when the menu appears.

IMPORTANT: The drill must be idle or not drilling before you use some of the
system screens. Refer to the instructions for each system screen to determine if it
should be used while drilling

The menu is shown and explained below.

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Operator ID

Screen Title

Options to
Display Data
Entry Screens

Current Hole Current Drill Current Time

Number Status (24-hour clock)

To select an item on the menu:

1. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to the
item you want to select.

2. Press the Enter button.

Button Usage

Enter Selects the highlighted option, and displays the

appropriate screen.

Left Moves the highlight to the left column.

Up Moves the highlight up one row.

Down Moves the highlight down one row.

Right Moves the highlight to the right column.

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Navigating Through Data Entry Screens

The following diagram shows all the available data entry screens and how to get
to each of them from the Data Entry Menu. Note that the screens containing
additional menus are highlighted with black title bars.

On the diagram, the arrows between screens indicate the item to highlight on the
menu before you press the Enter button to display the corresponding screen. For
example, on the Data Entry Menu, highlight “Delay” and press the Enter button
to display the Delay Code Screen.

The following subsections explain each menu and screen shown in the diagram.

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Delay Code Screen

Whenever you stop drilling, use this screen to select a delay code for the current
drilling delay. You can select this screen from the Data Entry Menu, and it also
automatically appears after a period of time during which there has been no
significant movement of the bit head and the tram switch indicates the drill is not
tramming. The length of that time period is the “non-drill time threshold”
determined by the PDA system setup. The default threshold is 60 seconds. If no
delay code is entered before drilling resumes, the delay code is “Unknown
Delay.” The list of the delay codes on this screen comes from the PDA system
setup.

Note: The delay code selected on this screen is canceled when the DEI +
LOGGER detects an ROP.

To display the Delay Code screen:

1. Press the Data Entry button to display the Data Entry Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Delay”. Then press the Enter button.

To return to the Data Entry Menu, press the Data Entry button.

Sample Screen
Operator ID

Screen Title
Selector

Delay Codes
from the PDA
system setup

Current Hole Current Drill Current Time

Number Status (24-hour clock)

To select a delay code:

1. Use the arrow buttons (Left, Up, Down, Right) to move the selector to the
code you want to select.

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There can be up to three screens of delay codes. When the highlight reaches
the last menu item on a screen, pressing the Down arrow button displays the
next screen of items. When the highlight is on the first item of a screen,
pressing the Up arrow button returns to the previous screen of items. You can
cycle through the screens in either direction. For example, pressing the Down
arrow button on the last item of the last screen returns to the first item on the
first screen.

2. Press the Enter button.

Button Usage

Enter Changes the delay code to the selected code and

displays an acknowledgment screen for 3 seconds. Then
the Data Entry menu reappears.

Left Moves the selector to the left column.

Up Moves the selector up one row.

Down Moves the selector down one row.

Right Moves the selector to the right column.

Operator Screen
Whenever you begin drilling on a new drill, use this screen to log onto the drill
and into the database. The operator ID you enter appears in the upper right
corner of most DEI + LOGGER screens and remains in effect until you log off or
a new operator logs on.

To display the Operator screen:

1. Press the Data Entry button to display the Data Entry Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Operator”. Then press the Enter button.

To return to the Data Entry Menu, press the Data Entry button.

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Sample Screen
Operator ID

Screen Title

Current ID

and

New ID
Entry Area

Entry Position
Pointer
Current Hole Current Drill Current Time
Number Status (24-hour clock)

To enter your operator ID in the lower box:

1. Use the Left and Right arrow buttons to move the pointer to each position
you need to change.

2. At each position, use the Up and Down arrow keys to scroll through the
numbers and letters until you reach the correct one. Blanks appear between
“Z” and zero and between “9” and “A”.

3. Once the New Operator No. is correct, press the Enter button.

Button Usage

Enter Logs in the new operator number, and displays the

acknowledgment screen for 3 seconds. Then the Data
Entry Menu appears.

Left Moves the pointer to the left one position.

Up Scrolls up to the next letter or number.

Down Scrolls down to the previous letter or number.

Right Moves the pointer to the right one position.

Logging Off
If your system is set up for auto-logoff, the DEI + LOGGER automatically logs
you off at the end of the shift.

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If your system is not set up

for auto-logoff, at the end of
your shift, a screen appears
asking if you want to log off.

♦ To log off, press the

Enter button.

♦ Or, to remain logged on,

press the Right arrow
button to highlight “No”,
and then press the Enter
button.

Drilling Conditions Screen

Whenever the drilling conditions change, use this screen to select the current
drilling conditions. The list of conditions on this screen comes from the PDA
system setup.

Note: The drill condition selected on this screen is canceled each time you press
the Zero Hole Depth button and the drilling statistics will indicate "unknown
drilling conditions" if you do not select the condition from this screen.

To display the Drilling Conditions screen:

1. Press the Data Entry button to display the Data Entry Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to “Drill
Conditions”. Then press the Enter button.

To return to the Data Entry Menu, press the Data Entry button.

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Sample Screen
Operator ID

Screen Title
Selector

Drill
Conditions
from the PDA
system setup

Current Hole Current Drill Current Time

Number Status (24-hour clock)

To select the drilling condition:

1. Use the arrow buttons (Left, Up, Down, Right) to move the selector to the
condition you want to select.

There can be up to three screens of drilling conditions. When the highlight

reaches the last menu item on a screen, pressing the Down arrow button
displays the next screen of items. When the highlight is on the first item of a
screen, pressing the Up arrow button returns to the previous screen of items.
You can cycle through the screens in either direction. For example, pressing
the Down arrow button on the last item of the last screen returns to the first
item on the first screen.

2. Press the Enter button.

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Button Usage

Enter Changes the drilling conditions to the selected condition

and displays an acknowledgment screen for 3 seconds.
Then the Data Entry menu reappears.

Left Moves the selector to the left column.

Up Moves the selector up one row.

Down Moves the selector down one row.

Right Moves the selector to the right column.

Bit Details Menu

This screen provides a menu of three bit details you can change: the diameter, the
vendor, and the serial number.

To display the Bit Details Menu:

1. Press the Data Entry button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to “Bit
Details”. Then press the Enter button.

Screen
Operator ID

Screen Title

Bit Detail
Entry Options

Current Hole Current Drill Current Time

Number Status (24-hour clock)

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Button Usage

Enter Selects the highlighted option, and displays the

appropriate screen.

Left No function.

Up Moves the highlight up one row.

Down Moves the highlight down one row.

Right No function.

Bit Details: Bit Diameter Screen

Whenever a new bit is installed on the drill, use this screen to select the diameter
of the bit. The list of diameters on this screen comes from the PDA system setup.

Note: The bit diameter selected on this screen remains in effect until it is changed
through this screen.

To display the Bit Diameter screen:

1. Press the Data Entry button to display the Data Entry Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to “Bit
Details”. Then press the Enter button to display the Bit Details Menu.

3. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to “Bit
Diameter”. Then press the Enter button.

To return to the Data Entry Menu, press the Data Entry button.

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Sample Screen
Operator ID

Screen Title
Current
Diameter
Setting

and

Bit Diameter
Options from
the PDA
system setup

Selector

Current Hole Current Drill Current Time

Number Status (24-hour clock)

To select the diameter of the newly installed bit:

1. Use the arrow buttons (Left, Up, Down, Right) to move the selector to the
correct diameter.

2. Press the Enter button.

Button Usage

Enter Changes the bit diameter to the selected New Bit

Diameter and displays an acknowledgment screen for 3
seconds. Then the Data Entry menu reappears.

Left Moves the selector to the left column.

Up Moves the selector up one row.

Down Moves the selector down one row.

Right Moves the selector to the right column.

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Bit Details: Bit Vendor Screen

Whenever a new bit is installed on the drill, use this screen to select the vendor of
the bit. The list of vendors on this screen comes from the PDA system setup.

Note: The vendor selected on this screen remains in effect until it is changed
through this screen.

To display the Bit Vendor screen:

1. Press the Data Entry button to display the Data Entry Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to “Bit
Details”. Then press the Enter button to display the Bit Details Menu.

3. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to “Bit
Vendor”. Then press the Enter button.

To return to the Data Entry Menu, press the Data Entry button.

Sample Screen
Operator ID

Screen Title
Current
Vendor
Setting

and

Vendor
Options from
the PDA
system setup

Selector

Current Hole Current Drill Current Time

Number Status (24-hour clock)

To select the vendor of the newly installed bit:

1. Use the arrow buttons (Left, Up, Down, Right) to move the selector to the
correct vendor.

2. Press the Enter button.

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Button Usage

Enter Changes the bit vendor to the selected New Bit Vendor
and displays an acknowledgment screen for 3 seconds.
Then the Data Entry menu reappears.

Left Moves the selector to the left column.

Up Moves the selector up one row.

Down Moves the selector down one row.

Right Moves the selector to the right column.

Bit Details: Bit Serial Number Screen

Whenever a new bit is installed on the drill, use this screen to enter the serial
number of the bit.

Note: The serial number selected on this screen remains in effect until it is
changed through this screen.

To display the Bit Serial Number screen:

1. Press the Data Entry button to display the Data Entry Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to “Bit
Details”. Then press the Enter button to display the Bit Details Menu.

3. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to “Bit
Serial Number”. Then press the Enter button.

To return to the Data Entry Menu, press the Data Entry button.

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Sample Screen
Operator ID

Screen Title

Current Serial
Number

and

Entry Area for

New Number

Position
Pointer

Current Hole Current Drill Current Time

Number Status (24-hour clock)

When the screen first appears, the most recent serial number appears in both ID
boxes. To enter the new bit’s serial number in the lower box:

1. Use the Left and Right arrow buttons to move the pointer to each position
you need to change.

2. At each position, use the Up and Down arrow keys to scroll through the
numbers and letters until you reach the correct one. Blanks appear between
“Z” and zero and between “9” and “A”.

3. Once the New Serial Number is correct, press the Enter button.

Button Usage

Enter Changes the serial number to the value in the New

Serial Number box and displays an acknowledgment
screen for 3 seconds. Then the Data Entry menu
reappears.

Left Moves the pointer to the left one position.

Up Scrolls up to the next letter or number.

Down Scrolls down to the previous letter or number.

Right Moves the pointer to the right one position.

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Target Depth Screen

Whenever you start a new hole with a new target depth, use this screen to specify
the target depth for the current hole. The new target depth will appear on the
Statistics: Current Hole screen next time that screen is displayed.

To display the Target Depth screen:

1. Press the Data Entry button to display the Data Entry Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Target Depth”. Then press the Enter button.

To return to the Data Entry Menu, press the Data Entry button.

Sample Screen
Operator ID

Screen Title

Current Depth
Setting

and

Entry Area for

New Target
Depth

Position
Pointer

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Using the Screen

When the screen first appears, the current target depth appears in both boxes. To
change the New Target Depth:

1. Use the Left and Right arrow buttons to move the pointer in the New Target
Depth box to each digit you want to change.

2. At each position, use the Up or Down arrow buttons to increase or decrease

(respectively) the value of the selected digit. For the left-most digit of an
entry, blanks appear between “9” and zero.

The maximum depth you can set is 999.9.

3. Press Enter to apply the new setting.

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Button Usage

Enter Changes the target depth to the value in the New Target
Depth box and displays an acknowledgment screen for
3 seconds. Then the Data Entry menu reappears.

Left Moves the pointer left one digit.

Up Increases the value of the selected digit by one.

Down Decreases the value of the selected digit by one.

Right Moves the pointer right one digit.

Hole Number Screen

Whenever you start a new hole, use this screen to specify the new hole number.
You can select this screen from the Data Entry Menu, and if Alpha-Numeric Hole
Entry has been selected, it also appears automatically whenever you press the
Zero Hole button. The hole number appears in the bottom left corner of most
DEI + LOGGER screens.

To display the Hole Number screen:

1. Press the Data Entry button to display the Data Entry Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Hole Number ”. Then press the Enter button.

To return to the Data Entry Menu, press the Data Entry button.

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Sample Screen
Operator ID

Screen Title

Previous and
Current Hole
Numbers

and

Entry Area for

New Hole
Number

Position
Pointer
Current Hole Current Drill Current Time
Number Status (24-hour clock)

Using the Screen

When the screen first appears, the previous and current hole numbers appear in
the top two boxes, and the current hole number appears in the bottom box. To
change the New Hole number:

1. Use the Left and Right arrow buttons to move the pointer in the New Hole
box to each digit you want to change.

2. At each position, use the Up or Down arrow buttons to increase or decrease

(respectively) the letter or number in the selected position. Blanks appear
between “Z” and zero and between “9” and “A”.

3. Press Enter to apply the new setting.

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Button Usage

Enter Changes the hole number to the value in the New Hole
box and displays an acknowledgment screen for 3
seconds. Then the Data Entry menu reappears.

Left Moves the pointer left one digit.

Up Scrolls up to the next letter or number.

Down Scrolls down to the previous letter or number.

Right Moves the pointer right one digit.

Pattern Number Screen

Whenever you start a new pattern, use this screen to specify the new pattern
number. Once you enter the pattern number, the Hole Numbering screen
appears (refer ahead to the end of this subsection).

To display the Pattern Number screen:

1. Press the Data Entry button to display the Data Entry Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Pattern Number ”. Then press the Enter button.

To return to the Data Entry Menu, press the Data Entry button.

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Sample Screen
Operator ID

Screen Title

Previous and
Current Pattern
Numbers

and

Entry Area for

New Pattern
Number

Position
Pointer

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Using the Screen

When the screen first appears, the previous and current pattern numbers appear
in the top two boxes, and the current pattern number appears in the bottom box.
To change the New Pattern Number:

1. Use the Left and Right arrow buttons to move the pointer in the New Pattern
Number box to each digit you want to change.

2. At each position, use the Up or Down arrow buttons to increase or decrease

(respectively) the letter or number in the selected position. Blanks appear
between “Z” and zero and between “9” and “A”.

3. Press Enter to apply the new setting.

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Button Usage

Enter Changes the pattern number to the value in the New

Pattern Number box and displays the Hole Numbering
screen (see below).

Left Moves the pointer left one digit.

Up Scrolls up to the next letter or number.

Down Scrolls down to the previous letter or number.

Right Moves the pointer right one digit.

Hole Numbering Screen

After you enter a new pattern number, the Hole Numbering screen appears. Use
it to specify how hole numbers are generated.

Auto-Incremental Hole Numbering. Hole numbering begins at “1” and the

number of each subsequent hole is incremented by 1 until one of the
following occurs:

♦ A new pattern number is entered.

♦ The hole numbering selection is changed to Alpha-Numeric.

Once you change to Alpha-Numeric, you cannot change back to

Auto-Incremental until you change the pattern number.

Alpha-Numeric Hole Entry. Each time you use the Zero Hole Depth button, the
Hole Number screen appears, and you manually enter the hole
number (see page 92).

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Sample Screen
Operator ID

Screen Title

Hole
Numbering
Options

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Using the Screen

1. Use the Up or Down arrow button to highlight the box beside your choice.

2. Press the Enter button.

Button Usage

Enter Changes the hole numbering scheme to the one you

selected and displays the acknowledgment screen for 3
seconds. Then the Data Entry Menu reappears.

Left No function.

Up Moves from one selection to the other.

Down Moves from one selection to the other.

Right No function.

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Drill String Screen

Whenever a component of the drill string is replaced, use this screen to specify
the serial number of the new component. The screen contains a list of
components. The first item on the list is “Pipe.” The rest of the list is determined
during the PDA system setup.

To display the Drill String screen:

1. Press the Data Entry button to display the Data Entry Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to “Drill
String”. Then press the Enter button.

To return to the Data Entry Menu, press the Data Entry button.

Sample Screen
Operator ID

Screen Title
Selector

List of
components

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Using the Screen

1. Use the arrow buttons (Left, Up, Down, Right) to move the selector to the
item you want to select.

2. Press the Enter button to continue. The screen that appears depends on the
item you selected. Refer ahead to the next two subsections for examples.

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Button Usage

Enter Displays the screen appropriate to the component you

selected.

Left Moves the selector to the left column.

Up Moves the selector up one row.

Down Moves the selector down one row.

Right Moves the selector to the right column.

Drill String: Pipe Screen

Through this screen, you enter the serial numbers of the pipes in the order in
which they will be used for drilling. Pipe 1 is the first pipe used in the hole.
Pipe 2 is the second, and so on.

Screen
Operator ID

Screen Title

List of Pipes
(in order of
use in the
hole)

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Button Usage

Enter Selects the highlighted option, and displays the

appropriate screen.

Left Moves the highlight to the left column.

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Up Moves the highlight up one row.

Down Moves the highlight down one row.

Right Moves the highlight to the right column.

Using the Screen

1. Select the number of the pipe whose serial number you want to enter, for
example “Pipe 1.”

2. Press the Enter button to display the Pipe Serial Number screen for the
selected pipe. The most recently entered serial number appears in both boxes.

Pointer

3. Use the Left and Right arrow buttons to move the pointer to each position
you need to change in the New Serial Number.

4. At each position, use the Up and Down arrow keys to scroll through the
numbers and letters until you reach the correct one. Blanks appear between
“Z” and zero and between “9” and “A”.

5. Once the New Serial Number is correct, press the Enter button to return to
the Pipe Menu.

6. For each other pipe to be used in the hole, repeat steps 1 through 5. To return
to the Data Entry Menu, press the Data Entry button.

Button Usage

Enter Sets the serial number of the selected pipe to the value
in the New Serial Number box, displays the
acknowledgment screen for 3 seconds, and then returns
to the Pipe Menu.

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Left Moves the pointer left one digit.

Up Increases the value of the selected digit by one.

Down Decreases the value of the selected digit by one.

Right Moves the pointer right one digit.

Drill String: Hammer Entry Screen Example

Selecting any item on the Drill String screen, except “Pipe”, displays the serial
number screen for the item. For example, if your system is set up with
“Hammer” on the list, selecting Hammer displays the following screen.

Sample Screen

Pointer

To enter the serial number for the selected item:

1. Use the Left and Right arrow buttons to move the pointer to each position
you need to change in the New Serial Number.

2. At each position, use the Up and Down arrow keys to scroll through the
numbers and letters until you reach the correct one. Blanks appear between
“Z” and zero and between “9” and “A”.

3. Once the New Serial Number is correct, press the Enter button to return to
the Data Entry Menu.

Button Usage

Enter Sets the serial number of the selected item to the value
in the New Serial Number box, displays the
acknowledgment screen for 3 seconds, and then returns

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to the Data Entry Menu.

Left Moves the pointer left one digit.

Up Increases the value of the selected digit by one.

Down Decreases the value of the selected digit by one.

Right Moves the pointer right one digit.

Fluids
When you replenish fluids in the drill, use this screen to record the amount that
was added. The screen contains a list of fluids specified during the PDA system
setup.

Sample Screen
Operator ID

Screen Title
Selector

List of Fluids

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Using the Screen

1. Use the arrow buttons (Left, Up, Down, Right) to move the selector to the
item you want to select.

2. Press the Enter button to display a screen on which you enter the volume
added. (Refer ahead to the end of this subsection.)

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Button Usage

Enter Displays the Volume screen.

Left Moves the selector to the left column.

Up Moves the selector up one row.

Down Moves the selector down one row.

Right Moves the selector to the right column.

Fluid: Fluid Volume Screen

After you select the fluid that was replenished in the drill, use this screen to
record the amount that was added.

Sample Screen

Volume Entry
Area

Pointer

To enter the volume of the fluid added:

1. Use the Left and Right arrow buttons to move the pointer to each position
you need to change in the Volume box.

2. At each position, use the Up and Down arrow keys to scroll through the
numbers and letters until you reach the correct one. Blanks appear between
“9” and “0”.

3. Once the Volume is correct, press the Enter button to return to the Data Entry
Menu.

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Button Usage

Enter Records volume added as the value in the Volume box,

displays the acknowledgment screen for 3 seconds, and
then returns to the Data Entry Menu.

Left Moves the pointer left one digit.

Up Increases the value of the selected digit by one.

Down Decreases the value of the selected digit by one.

Right Moves the pointer right one digit.

Consumables
When you replace or replenish a consumable item on the drill, use this screen to
record the event. The screen contains a list of consumable items specified during
the PDA system setup.

Sample Screen
Operator ID

Screen Title
Selector

List of
Consumable
Items

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Using the Screen

1. Use the arrow buttons (Left, Up, Down, Right) to move the selector to the
item you want to select.

2. Press the Enter button.

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Button Usage

Enter Records the replacement item, time and date, displays

an acknowledgment screen for 3 seconds, and returns to
the Data Entry Menu.

Left Moves the selector to the left column.

Up Moves the selector up one row.

Down Moves the selector down one row.

Right Moves the selector to the right column.

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Reference to System Screens

System screens allow you to set up and manage your DEI + LOGGER system.
For example:

♦ Set up display parameters, such as the brightness and scaling for displayed
graphs.

♦ View the status of system elements, such as the external alarm’s state, the
condition of the memory, the DEI + LOGGER software version.

♦ Calibrate the DEI + LOGGER by following a sequence of interactive screens.

♦ Perform diagnostics, such as troubleshooting procedures and testing system

components.

When you press the System button on the DEI + LOGGER, the display shows
the System Menu screen, through which you access all other system screens.

This section explains each of the system screens and tells how to display and use
each one. Refer ahead to “Navigating Through System Screens” for a summary
diagram showing all system screens and how to navigate to each one.

System Menu
The System Menu provides an entry into the other system screens. Note that the
Configuration, Diagnostics, and General Info items display additional menus
from which you choose.

From any screen, press the System button to display this screen. The most
recently used option is highlighted when the menu appears.

IMPORTANT: The drill must be idle or not drilling before you use many of the
system screens. In general, use the system screens only when you are not drilling.

The menu is shown and explained below.

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Operator ID

Screen Title

Options to
Display
System
Screens

Current Hole Current Drill Current Time

Number Status (24-hour clock)

To select an item on the menu:

1. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to the
item you want to select.

2. Press the Enter button.

Button Usage

Enter Selects the highlighted option, and displays the

appropriate screen.

Left Moves the highlight to the left column.

Up Moves the highlight up one row.

Down Moves the highlight down one row.

Right Moves the highlight to the right column.

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Navigating Through System Screens

The following diagram shows all the available system screens and how to get to
each of them from the System Menu. Note that the screens containing additional
menus are highlighted with black title bars.

On the diagram, the arrows between screens indicate the item to highlight on the
menu before you press the Enter button to display the corresponding screen. For
example, on the System Menu, highlight “Brightness” and press the Enter button
to display the Brightness Screen.

The following subsections explain each menu and screen shown in the diagram.

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Mast Level Screen

This screen shows the current mast angle and mast level in 0.1° increments as
measured by the optional dual axis inclinometer. Note that this screen is
available only if the inclinometer is installed on your system and enabled.

To display the Mast Level screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Mast Level”. Then press the Enter button.

To return to the System Menu, press the System button.

Sample Screen

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Brightness Screen
You may need to adjust the brightness of the DEI + LOGGER display area to
optimize your view of the screens as the level of light in the environment
changes. Use the Brightness screen to adjust the brightness level of the display.

To display this screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Brightness”. Then press the Enter button.

Sample Screen
Operator ID

Screen Title

Current
Brightness
Level

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Using the Screen

To change the brightness of the display:

1. Press the Up arrow button to increase the brightness - up to 100%. Or, press
the Down arrow to decrease the brightness. As the percentage value on the
screen changes, the brightness level of the display changes accordingly. 15% is
the lowest brightness level and 100% is the brightest.

2. When the display is the brightness you want, press the Enter button.

A confirmation screen appears for 3 seconds, then the System Menu reappears.

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Button Usage

Enter Applies the selected brightness level.

Left No function.

Up Increases the brightness level setting. Maximum is 100%.

Down Decreases the brightness level setting. Minimum is 15%.

Right No function.

Shift Times Screens

Statistics are tracked by shifts and displayed on the shift statistics screens. Use
this screen to view the start and end times for three shifts (Shifts 1, 2, and 3).
Note: The shift times are set at the office, and you cannot change them on the
DEI + LOGGER.

To display this screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to “Shift
Times”. Then press the Enter button.

To return to the System Menu, press the Enter button, or press the System
button again.

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Sample Screen
Operator ID

Screen Title

Start and end

times for the
shift indicated
in the title
(hour: minute)

Current Hole Current Drill Current Time

Number Status (24-hour clock)

The screen shows the start and end times for each of the three shifts. Note that
time is always presented as on a 24-hour clock (hour:minute).

Alarms Screen
The DEI + LOGGER provides two automatic alarms to notify you of problem
conditions. You specify the criteria for each alarm, and whether or not you want
to use the alarm. If you enable an alarm and the alarm condition occurs, the DEI
+ LOGGER flashes the appropriate alarm screen on the display until the alarm
condition is corrected. Since these alarm conditions are detected during drilling,
it is the Statistics: Current Hole screen that is interrupted.

You can also connect an external alarm to the back of the DEI + LOGGER
(rightmost connector on the top row). The external alarm, too, is triggered when
the conditions specified on this screen occur.

The two alarms are:

♦ ROP alarm. You specify the maximum rate of penetration. Then, if the ROP
exceeds that rate, the DEI + LOGGER flashes a warning screen on the
display, telling you the ROP has reached or exceeded your specified
maximum.

♦ Depth alarm. You specify the maximum depth for the hole. Then, if the
drilling reaches that depth, the DEI + LOGGER flashes a warning screen
telling you the depth has reached or exceeded your specified distance.

Use the Alarms screen to view or change the criteria for the ROP and Depth
alarms and to enable or disable either alarm.

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To display the Alarms screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Alarms”. Then press the Enter button.

Sample Screen
Operator ID

Screen Title

Alarm criteria
and current
status

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Using the Screen

When the screen first appears, the current criteria and state is displayed for both
alarms.

To change the alarm criteria or the state:

1. Use the Left and Right arrow buttons to move the pointer to the element you
want to change — either the maximum ROP rate or hole depth or the on/off
state of one of the alarms.

2. Use the Up or Down arrow buttons to increase or decrease (respectively) the

value of the selected digit or to alternate the state between “ON” and “OFF”.

3. Repeat steps 1 and 2 until both the values and states on the screen are as you
currently require.

4. Press Enter to apply the new settings.

A confirmation screen appears for 3 seconds, then the System Menu reappears.

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Button Usage

Enter Apply the new settings and return to the System Menu.

Left Moves the pointer left one element—digit or state

setting.

Up For values, increases the value of the selected digit by

one. For on/off states, alternates between “ON” and
“OFF”.

Down For values, decreases the value of the selected digit by

one. For on/off states, alternates between “ON” and
“OFF”.

Right Moves the pointer right one element—digit or state

setting.

Graphic Scaling Screen

The Statistics: Current Hole screen displays a graph of the hole depth and target
depth (see page 61) . The ROP Graphic screen (see page 68) and the statistics
screens for previous holes display a graph of the ROP at each depth, for the
relevant hole.

Use the Graphic Scaling screen to define the scale for those graphs by adjusting
the minimum and maximum Depth and ROP values to use on the scales.

Note: You can adjust the graphic scaling only at the start of a new hole.

To display this screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Graphic Scaling”. Then press the Enter button.

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Sample Screen
NOTE: The values on this sample define the axes to be as they are shown in the
sample illustrations of the Statistics: Current Hole screen and the ROP Graphic
screen in earlier sections of the manual.

Operator ID

Screen Title

Scale Settings

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Using the Screen

When the screen first appears, the current scale settings are displayed for both
graph axes.

To change the scale settings:

1. Use the Left and Right arrow buttons to move the pointer to the digit you
want to change or to a different scaling parameter.

2. For each digit you want to change, use the Up or Down arrow buttons to
increase or decrease (respectively) the value of the selected digit.

3. Repeat steps 1 and 2 until all the values on the screen are as you want.

4. Press Enter to apply the new settings.

A confirmation screen appears for 3 seconds, then the System Menu reappears.

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Button Usage

Enter Apply the new settings and return to the System Menu.

Left Moves the pointer left one digit or box.

Up Increases the value of the selected digit by one.

Down Decreases the value of the selected digit by one.

Right Moves the pointer right one digit or box.

Configuration Menu
This screen provides three options for viewing and changing the system setup.

To display the Configuration Menu:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Configuration”. Then press the Enter button.

Screen
Operator ID

Screen Title

Configuration
Options

Current Hole Current Drill Current Time

Number Status (24-hour clock)

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Button Usage

Enter Selects the highlighted option, and displays the

appropriate screen.

Left No function.

Up Moves the highlight up one row.

Down Moves the highlight down one row.

Right No function.

Calibration Screens
For illustrations of the screens and complete instructions for displaying and using
them, refer to “Calibrating the DEI + LOGGER” in Chapter 2.

Mast Adjustment Screen

The completed Inclinometer installation may be electronically shimmed when the mast
is vertical. On the mast adjustment screen – observe the instruction at the bottom of the
screen “PRESS ENTER TO ZERO VALUES”. By pressing the Enter key, both of the dual-
axis inclinometers will be re-set to zero. This procedure will not be required again
unless the inclinometer or the drill mast has been modified, removed or adjusted. This
screen is only available from the password protected Calibration mode.

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System Parameters Screen

This screen shows the system parameters set by the office.

To return to the Configuration Menu, press the Enter button.

Operator ID

Screen Title

Current
System
Parameters

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Diagnostics Menu
This screen provides two options for viewing and entering diagnostics
information. Use the diagnostics screens in conjunction with the troubleshooting
instructions in the manual.

To display the Diagnostics Menu:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Diagnostics”. Then press the Enter button.

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Screen
Operator ID

Screen Title

Diagnostics
Options

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Using the Screen

Use the Up or Down arrow buttons to highlight the option you want. Then press
the Enter button. The two options are:

♦ Detailed System Status. When you select this option, the Detailed System
Status submenu appears, allowing you to display any of nine types of status
information.

♦ Troubleshooting. When you select this option, the DEI + LOGGER displays
a series of three screens on which you locate the symptom you are having.
The most likely problem area is noted beside each symptom. For complete
troubleshooting instructions, refer to Chapter 4.

Button Usage

Enter Selects the highlighted option, and displays the

appropriate screen.

Left No function.

Up Moves the highlight up one row.

Down Moves the highlight down one row.

Right No function.

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Detailed System Status Menu

This submenu provides nine options for viewing status information about the
DEI + LOGGER components:

♦ Results of a memory test.

♦ Results of a display test.
♦ Status of the bit air switch.
♦ Status of the tram switch.
♦ Operation of the Zero Hole Depth button.
♦ Status of the external alarm.
♦ Status of the encoder.
♦ Status of communications with external device
♦ Mast angle and level

To display the Detailed System Status Menu:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Detailed System Status”. Then press the Enter button.

Screen
Operator ID

Screen Title

Status
Options

Current Hole Current Drill Current Time

Number Status (24-hour clock)

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Button Usage

Enter Selects the highlighted option, and displays the

appropriate screen.

Left Moves the highlight to the left column.

Up Moves the highlight up one row.

Down Moves the highlight down one row.

Right Moves the highlight to the right column.

System Status: Memory Test Screens

The DEI + LOGGER contains 1 MB of SRAM in which system settings and
historical production information are stored. Since the power required for the
memory (SRAM) is backed up by a lithium battery, your data and settings are
safe as long as the battery is operating. However, the memory could fail if the
battery needs to be replaced.

Test the memory under any of the following conditions:

♦ The calibration fails, and re-calibrating does not correct the failure.

♦ Data displayed on the screen is incorrect.

If the memory test fails, return the DEI + LOGGER to Thunderbird Mining
Systems for repair.

To display the Memory Test screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Diagnostics”. Then press the Enter button to display the Diagnostics menu.

3. Use the Up and Down arrow buttons to move the highlight to “Detailed
System Status”. Then press the Enter button to display the Detailed System
Status menu.
4. Use the arrow buttons to move the highlight to “Memory”. Then press the
Enter button.

To return to the Detailed System Status menu, highlight “No” and press the
Enter button. To return to the System Menu, press the System button.

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Initial Screen
Operator ID

Screen Title

Options

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Using the Screen

To run the memory test:

1. If necessary, on the Memory Test screen, use the Left arrow to highlight
“Yes”.

2. Press Enter to begin the test. While the test is in progress, a new screen
appears asking you to “Please Wait.” While this screen is displayed, no
control buttons are functional.

3. After the test is complete, a different screen appears, indicating the results of
the test. For example, if the test is successful, the screen looks like this:

4. To return to the Detailed System Status menu, press the Enter button. Or, to
return to the System Menu, press the System button.

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System Status: Display Test Screens

If segments are missing in the display, or if the display appears wrong in some
other way, run the display test.

To display the Display Test screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Diagnostics”. Then press the Enter button to display the Diagnostics menu.

3. Use the Up and Down arrow buttons to move the highlight to “Detailed
System Status”. Then press the Enter button to display the Detailed System
Status menu.
4. Use the arrow buttons to move the highlight to “Display”. Then press the
Enter button.

To return to the Detailed System Status menu, highlight “No” and press the
Enter button. To return to the System Menu, press the System button.

Initial Screen
Operator ID

Screen Title

Options

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Using the Screen

To run the display test:

1. If necessary, on the Display Test screen, use the Left arrow to highlight “Yes”.

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2. Press Enter to display a test pattern screen, which consists of alternating light
and dark pixels in a “checkerboard” pattern. Any display anomalies should
be easily visible on this screen. After 7 seconds, the test pattern screen is
removed and the Detailed System Status menu reappears.

While this screen is displayed, no control buttons are functional.

The following two illustrations show test pattern screens.

♦ The first shows what the screen looks like when the display is working
properly.

♦ The second sample indicates a problem with the display. If your display
shows a problem, contact Thunderbird Mining Systems for information on
how to return the unit for repair.

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System Status: Bit Air Switch Status Screen

This screen shows the state of the bit air—on or off. You use it in conjunction with
the troubleshooting procedures. For details refer to “Air Circuit Tests” in Chapter
4.

To display the Bit Air Switch status screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Diagnostics”. Then press the Enter button to display the Diagnostics menu.

3. Use the Up and Down arrow buttons to move the highlight to “Detailed
System Status”. Then press the Enter button to display the Detailed System
Status menu.
4. Use the arrow buttons to move the highlight to “Bit Air Switch”. Then press
the Enter button.

To return to the Detailed System Status menu, press the Enter button. To return
to the System Menu, press the System button.

Sample Screen
Operator ID

Screen Title

Status
Indicators

Current Hole Current Drill Current Time

Number Status (24-hour clock)

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System Status: Tram Switch

This screen shows the state of the tram switch —on or off. “On” indicates the drill
is tramming.

To display the Tram Switch status screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Diagnostics”. Then press the Enter button to display the Diagnostics menu.

3. Use the Up and Down arrow buttons to move the highlight to “Detailed
System Status”. Then press the Enter button to display the Detailed System
Status menu.
4. Use the arrow buttons to move the highlight to “Tram Switch”. Then press the
Enter button.

To return to the Detailed System Status menu, press the Enter button. To return
to the System Menu, press the System button.

Sample Screen
Operator ID

Screen Title

Status
Indicators

Current Hole Current Drill Current Time

Number Status (24-hour clock)

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System Status: Zero Hole Button Status Screen

When you first install the DEI + LOGGER, use this screen to check that the Zero
Hole Depth button is operating. If, during your operations, the total hole count is
not incremented correctly, use this screen to check the operation of the button.

To display the Zero Hole Depth button status screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Diagnostics”. Then press the Enter button to display the Diagnostics menu.

3. Use the Up and Down arrow buttons to move the highlight to “Detailed
System Status”. Then press the Enter button to display the Detailed System
Status menu.
4. Use the arrow buttons to move the highlight to “Zero Hole Button”. Then
press the Enter button.

To return to the Detailed System Status menu, press the Enter button. To return
to the System Menu, press the System button.

Sample Screen
Operator ID

Screen Title

Status
Indicators

Current Hole Current Drill Current Time

Number Status (24-hour clock)

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Using the Screen

To check the operation of the Zero Hole Depth button on the front of the DEI +
LOGGER:

1. When the screen first appears, make sure the Zero Hole Button “OFF” box is
highlighted.

2. Press the Zero Hole Depth control button on the front of the DEI + LOGGER.
Make sure the Zero Hole Button “ON” box is highlighted while you are
pressing the button.

3. Release the button. Make sure the Zero Hole Button “OFF” box becomes
highlighted again.

4. If the boxes do not become highlighted as expected, contact Thunderbird

Mining Systems.

To check the operation of the remote Zero Hole switch (if you have connected a
remote switch to the back of the DEI + LOGGER):

1. When the screen first appears, make sure the Zero Hole Switch “OFF” box is
highlighted.

2. Press the remote Zero Hole control switch. Make sure the Zero Hole Switch
“ON” box is highlighted while you are pressing the switch.

3. Release the switch. Make sure the Zero Hole Switch “OFF” box becomes
highlighted again.

4. If the boxes do not become highlighted as expected, check your remote switch
connections and repeat the test. If the result of the test remains the same,
contact Thunderbird Mining Systems to order a switch replacement.

System Status: External Alarm Status Screen

You can connect your own external alarm to the appropriate connector on the
back of the DEI + LOGGER (the rightmost connector on the top row). Use this
screen to check whether the alarm is enabled or disabled.

To display the External Alarm status screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Diagnostics”. Then press the Enter button to display the Diagnostics menu.

3. Use the Up and Down arrow buttons to move the highlight to “Detailed
System Status”. Then press the Enter button to display the Detailed System
Status menu.
4. Use the arrow buttons to move the highlight to “External Alarm”. Then press
the Enter button.

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To return to the Detailed System Status menu, press the Enter button. To return
to the System Menu, press the System button.

Sample Screen
Operator ID

Screen Title

Status
Indicators

Current Hole Current Drill Current Time

Number Status (24-hour clock)

If the “ON” box is highlighted, the external alarm is activated (the alarm
condition exists).

If the “OFF” box is highlighted, the alarm is not activated.

System Status: Encoder Status Screen

This screen indicates the various states of the quadrature encoder. You use it in
conjunction with the troubleshooting procedures. For details refer to “Encoder
Circuit Tests” in Chapter 4.

To display the Encoder status screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Diagnostics”. Then press the Enter button to display the Diagnostics menu.

3. Use the Up and Down arrow buttons to move the highlight to “Detailed
System Status”. Then press the Enter button to display the Detailed System
Status menu.
4. Use the arrow buttons to move the highlight to “Encoder”. Then press the
Enter button.

To return to the Detailed System Status menu, press the Enter button. To return
to the System Menu, press the System button.

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Sample Screen
Operator ID

Screen Title

Status
Indicators

Current Hole Current Drill Current Time

Number Status (24-hour clock)

System Status: Data Port Screen

This screen indicates whether or not the DEI + LOGGER is communicating with
an outside device such as a PDA or computer.

To display the Data Port screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Diagnostics”. Then press the Enter button to display the Diagnostics menu.

3. Use the Up and Down arrow buttons to move the highlight to “Detailed
System Status”. Then press the Enter button to display the Detailed System
Status menu.
4. Use the arrow buttons to move the highlight to “Data Port”. Then press the
Enter button.

To return to the Detailed System Status menu, press the Enter button. To return
to the System Menu, press the System button.

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Sample Screen
Operator ID

Screen Title

Status
Indicators

Current Hole Current Drill Current Time

Number Status (24-hour clock)

System Status: Mast Level Screen

This screen shows the current mast angle and mast level in 0.1° increments as
measured by the optional dual axis inclinometer. Note that this screen is
available only if the inclinometer is installed on your system and enabled.

To display the Mast Level screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Diagnostics”. Then press the Enter button to display the Diagnostics menu.

3. Use the Up and Down arrow buttons to move the highlight to “Detailed
System Status”. Then press the Enter button to display the Detailed System
Status menu.
4. Use the arrow buttons to move the highlight to “Mast Level”. Then press the
Enter button.

To return to the Detailed System Status menu, press the Enter button. To return
to the System Menu, press the System button.

Note: You can view this screen directly from the System Menu by selecting
“Mast Level” on the menu and pressing the Enter button.

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Sample Screen
Operator ID

Screen Title

Status
Indicators

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Troubleshooting Screens
The troubleshooting screens list possible symptoms of problems, and they
indicate the area where the problem is. Use these screens in conjunction with the
troubleshooting procedures in the next section.

To display the Troubleshooting screens:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“Diagnostics”. Then press the Enter button to display the Diagnostics menu.

3. Use the Up and Down arrow buttons to move the highlight to

“Troubleshooting”. Then press the Enter button.
NOTE: To return to the Detailed System Status menu, press the Enter button. To
return to the System Menu, press the System button.

For your convenience the screens are reproduced in the section “Typical
Symptoms” in Chapter 4.

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General Info Menu

This screen provides two options for viewing information about the DEI +
LOGGER hardware and software.

To display the General Info Menu:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“General Info”. Then press the Enter button to display the General Info menu.

Screen
Operator ID

Screen Title

Information
Options

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Using the Screen

Use the Up or Down arrow buttons to highlight the option you want. Then press
the Enter button. The two options are:

♦ Hardware. A series of screens listing hardware-related information for the

DEI + LOGGER, such as current hardware version number, DEI + LOGGER
connector configuration, DEI + LOGGER and drill system part numbers, and
descriptions as setup through the PDA.

♦ Software. A screen showing the software version currently in use on the DEI
+ LOGGER.

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General Info: Hardware

This screen provides a menu of options for viewing information about the
hardware components related to the DEI + LOGGER.

To display the Hardware screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“General Info”. Then press the Enter button to display the General Info menu.

3. Use the Up and Down arrow buttons to move the highlight to “Hardware”.
Then press the Enter button to display the hardware menu.

Screen
Operator ID

Screen Title

Hardware
Information
Options

Current Hole Current Drill Current Time

Number Status (24-hour clock)

Using the Screen

Use the Up or Down arrow buttons to highlight the option you want. Then press
the Enter button. The options are:

♦ Version Number. A screen showing the hardware version of the DEI +

LOGGER system you are using.

♦ Profile. A screen showing the connector configuration as viewed from the

back of the DEI + LOGGER module.

♦ Part Numbers. A series of screens listing DEI + LOGGER and drill system
part numbers and descriptions as setup through the PDA.

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General Info: Hardware: Version Number

This screen displays the hardware version number of the DEI + LOGGER you
are using. This information may be valuable to technical support personnel if
they need to troubleshoot your system.

To display the Version Number screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“General Info”. Then press the Enter button to display the General Info menu.

3. Use the Up and Down arrow buttons to move the highlight to “Hardware”.
Then press the Enter button to display the hardware menu.

4. Use the Up and Down arrow buttons to move the highlight to “Version
Number”. Then press the Enter button to display the Version Number screen.

Screen
Operator ID

Screen Title

Version
Number
Information

Current Hole Current Drill Current Time

Number Status (24-hour clock)

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General Info: Hardware: Profile

This screen graphically displays the connector configuration on the back of the
DEI + LOGGER module.

To display the Profile screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“General Info”. Then press the Enter button to display the General Info menu.

3. Use the Up and Down arrow buttons to move the highlight to “Hardware”.
Then press the Enter button to display the hardware menu.

4. Use the Up and Down arrow buttons to move the highlight to “Profile”. Then
press the Enter button to display the Profile screen.

Screen

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General Info: Hardware: Part Numbers

These screens list the hardware components related to the DEI + LOGGER and
drill system and give the part number and description of each as set up through
the PDA system.

To display the Part Number screens:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“General Info”. Then press the Enter button to display the General Info menu.

3. Use the Up and Down arrow buttons to move the highlight to “Hardware”.
Then press the Enter button to display the hardware menu.

4. Use the Up and Down arrow buttons to move the highlight to “Part
Numbers”. Then press the Enter button to display the first screen.

On each screen except the last one, use the Down arrow button to move to the
next screen in sequence. On each screen except the first one, use the Up arrow
button to return to the previous screen in sequence.

NOTE: To return to the General Info menu, press the Enter button. To return to
the System Menu, press the System button.

Sample Screen
Operator ID

Screen Title

Part Number
Information

Current Hole Current Drill Current Time

Number Status (24-hour clock)

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General Info: Software

This screen shows the software version currently operating on your DEI +
LOGGER. Use this screen if a Thunderbird Mining Systems technician asks you
for the version of software you are using.

To display the Software Info screen:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to
“General Info”. Then press the Enter button to display the General Info menu.

3. Use the Up and Down arrow buttons to move the highlight to “Software”.
Then press the Enter button.

NOTE: To return to the General Info menu, press the Enter button. To return to
the System Menu, press the System button.

Sample Screen
Operator ID

Screen Title

Part Number
Information

Current Hole Current Drill Current Time

Number Status (24-hour clock)

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Chapter 4
Troubleshooting

Prerequisite Troubleshooting Information

By design, the DEI + LOGGER system is composed of various modules that may
be disconnected and re-connected very easily. A thorough knowledge of basic
system operation and "what parts do what" will help you make a quick and
accurate diagnosis of your problem, thus saving you time and frustration.

Before you begin any troubleshooting activities, read this section carefully to gain
a clear understanding of the system’s general operation and its various
components. Use the diagram in Figure 35 as a reference as you read the
information and follow the procedures.

Then proceed to the next section, “Troubleshooting Procedures,” and attempt to

isolate the problem.

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Figure 35. Typical Installation on Electric Machine

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The DEI + LOGGER

How it maintains drilling information

During drilling, the DEI + LOGGER receives a set of complex pulses from the
optical shaft encoder. During calibration X number of pulses were specified as
equal to Y (feet or meters) in depth. Based on this equality, the DEI + LOGGER
uses the pulses it receives to determine the hole depth information. It uses the
depth information along with an internal timer to determine the rate-of-
penetration.

In general operation, the DEI + LOGGER tracks the number of pulses and their
direction in order to determine where the bit is at any given moment. In addition,
it uses information from an air pressure switch to determine whether the bit air is
on or off. This information, along with the pulses and some internal algorithms,
allows the DEI + LOGGER to determine if an additional stem (pipe) is being
added or removed. In this way, it accurately maintains the hole depth.

The encoder pulses, along with a signal from the air pressure switch, allow the
DEI + LOGGER to track the bit position and speed. For all of this to work
correctly it is imperative that the DEI + LOGGER is accurately calibrated, the air
pressure switch properly functioning and the encoder properly driven.

Its power requirements and usage

In normal operation, the DEI + LOGGER is supplied with 21-30 VDC. Power is
typically supplied through either the drill’s 21-30 VDC batteries or a DC power
supply. This voltage is used to power the internal electronics as well as external
modules:

♦ It supplies the optical shaft encoder with 5 VDC and receives a set of four
pulses in return.

♦ It sends a signal of approximately 4.5 VDC to the air pressure switch.

It is important to mount the DEI + LOGGER in a location where it does not get
too hot to touch. Since the unit uses only 15 VDC of the power it receives, the
more input power, the more heat that must be dissipated. The DEI + LOGGER
will get quite warm if 30 VDC is supplied and the DEI + LOGGER is mounted
with the sun shining on it.

If the power supplied to the DEI + LOGGER is greater than 30 VDC, it may be
damaged and must be returned to Thunderbird Mining Systems for repair.

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Air Pressure Switch

The air pressure switch is connected to the bailing air line or the working air
gauge on the panel with a “T”. It should be adjusted to go on and off quickly. The
DEI + LOGGER uses the information from this switch to aid in deciding if a
length of drill pipe is being added or removed.

The switch is provided with a signal of approximately 4.5 VDC from the DEI +
LOGGER. When the switch is open (air is detected) the DEI + LOGGER keeps
the line at a 4.5 VDC potential. When the switch is closed (air pressure is lost), the
DEI + LOGGER sets the line to ground or earth potential.

The state of the switch indicates to the DEI + LOGGER the state of the drilling:

♦ Open. Informs the DEI + LOGGER that drilling is in process or about to

begin. The DEI + LOGGER uses this information, along with information
from the encoder, to make internal decisions regarding the hole depth and
ROP.

♦ Closed. Informs the DEI + LOGGER that drilling has ceased and perhaps
steel is being added or removed. If the drill feed direction is then reversed
relative to normal drilling mode (as indicated by the encoder data) “Distance
From Bottom” data is calculated and displayed on the DEI + LOGGER
screen. When the “Distance From Bottom” value is greater than 85% of the
hole depth, the “PIPE” message flashes on the screen and “Distance From
Bottom” is blanked out. Based on what happens next, it determines whether
steel is being added or removed and adjusts its calculations accordingly.

If an incorrect value is entered for PIPE length and the drill is being used for
multi-pass drilling, then you can expect the hole depths to be inaccurate, since
each time steel is added the DEI + LOGGER will add too much depth.

Optical Shaft Encoder

The encoder is connected somewhere within the pulldown mechanism. It is
provided with a 5VDC signal from the DEI + LOGGER.

Its purpose is to monitor the movement of the drill power head. When the drill
power head is moved, the encoder shaft is rotated causing the encoder to
produce some combination of 4 signals (quadrature with complements) relative
to the linear movement of the power head. It sends these signals to the DEI +
LOGGER.

These signals may be thought of as two signal pairs: A and A, B and B. At any
given moment the DEI + LOGGER is receiving two signals, one from each pair.
You can observe the signals change on the Encoder system status screen. (Refer
back to “System Status: Encoder Status Screen”.)

The DEI + LOGGER uses the information it receives from these signals to help it
determine the distance, direction, and speed of the power head. This is translated
into hole depth, distance from bottom, and ROP.

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Chain and Sprocket Encoder Drives

Various combinations of chains and sprockets are used to drive the optical shaft
encoder. Their purpose is to translate the linear motion of the power head into
the rotary motion of the encoder shaft.

Most problems with chains and sprockets are due to poor alignment of the chain
and sprockets or incorrect tension on the chain. It is critical that the chain be
aligned properly with the sprockets. If it is not, the chain might come off or
break, or the encoder might be damaged. If the chain is too loose, it will keep
jumping off. If it is too tight, it will damage the bearings in the encoder, and you
will have to replace the encoder.

It is recommended that you use stainless steel chain (which is the type provided
by Thunderbird Mining Systems). Although it is more expensive than other types
of chains, it is stronger, has much less stretch, and does not seize from rust.

Torque Reel Encoder Drive

Torque reels (spring tension take-up) are typically used on machines that have
cylinder and/or cable pulldown systems. The torque reel is mounted inside an
enclosure with the wire rope wrapping a sheave that is mounted to the encoder
shaft. The wire rope exits the housing through a quad bi-lateral bearing set. The
bearing is machined aluminum with stainless steel pins and Teflon rollers.

The main enclosure is mounted to the top of the mast and the end of the wire
rope is attached to a wire rope leader, which drops down and attaches to the
carriage, or perhaps the power head. Typically the carriage has a 1:2 ratio with
the power head. So, attaching the leader to the carriage instead of the power
head means less rope will be pulled from the reel as the head moves, thereby
reducing wear and tear.

It is critical for the wire rope to be perpendicular to the torque reel housing and
for the tension and the extraction length of the rope to be set correctly before
drilling begins. If you do not allow enough rope for the movement of the drill
head or carriage, the unit will be damaged.

Interconnecting Cables
Military-grade connectors are used for connecting all the cables in the system
except the connection made to the power source on the drill. All the Teflon-type
(red) cables have their connectors filled with a semi-rigid sealing epoxy, while
the connectors of other cables are sealed with an RTV type electronic grade
silicon or the semi-rigid sealing epoxy.

Due to this construction, if the cables operate properly when installed, they can
be expected to continue working indefinitely, assuming no physical damage
occurs.

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Troubleshooting Procedures
1. Make sure that all DEI + LOGGER cable connections are tight.

2. Make sure there is a good connection to the drill’s power source.

3. Review the Troubleshooting system screens to see if your symptom is listed in

one of them (refer ahead to “Typical Symptoms”). If your symptom is listed,
follow the procedure in the troubleshooting section for the circuit indicated on
the screen.

Typical Symptoms
Troubleshooting system screens on the DEI + LOGGER list symptoms of
possible problems, and they indicate the circuit where the problem may likely be
corrected. For your convenience, the screens are reproduced in this section.

To display the screens:

1. Press the System button to display the System Menu.

2. Use the arrow buttons (Left, Up, Down, and Right)to highlight
“Diagnostics”. Then press the Enter button to display the Diagnostics menu.

3. Use the arrow buttons to highlight “Troubleshooting”. Then press the Enter
button.

NOTE: To return to the Detailed System Status menu, press the Enter button. To
return to the System Menu, press the System button.

Screens
Press the Down arrow
button on the DEI +
LOGGER to move to
the next
troubleshooting
screen.

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Press the Down arrow

button on the DEI +
LOGGER to move to
the next
troubleshooting
screen, or press the Up
button to return to the
previous one.

Press the Up arrow

button on the DEI +
LOGGER to return to
the previous
troubleshooting
screen.

Power Circuit Tests

Components
This circuit consists of:

♦ The DC power cable (7070-191-xxx) connecting the drill’s 21-30 VDC power
source to the POWER connector on the rear panel of the DEI + LOGGER.

Diagnostic Information and Procedure

If your symptom is “Graphical display does not illuminate”, make sure that you
have pressed the Power button on the front panel of the DEI + LOGGER. The
button remains pushed in when the system is on. If the display still does not
illuminate, follow the procedure below.

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Before you begin the following checklist:

1. Disconnect the air pressure switch cable from the DEI + LOGGER. If the
problem changes, go to “Air Circuit Tests.”

2. Disconnect the encoder cable from the DEI + LOGGER. If the problem
changes, go to “Encoder Circuit Tests.”

Problems with the DEI + LOGGER are normally in the power circuit and are
generally due to one of the following. Go through this checklist in order.

1. Check the wiring.

There may be loose or improper wiring, either in the positive or the ground
(earth). Most often it is a poor ground that does not allow proper current
draw or injects a large amount of noise. The greater distance any electronic
equipment is from the original source, the greater the differential in ground
potential and the greater the chance of generated noise interfering with
electronic equipment.
When in doubt, move the DEI + LOGGER’s input ground (where the DEI +
LOGGER power cable connects to the power source) as close to the original
power source as possible. Do not assume that since the operator console lights
work, the electronics will.
2. Check the power source.
♦ If you suspect that power input is inadequate, begin checking voltages at
the power source, working your way toward the DEI + LOGGER. All
voltage readings should be 21 – 30 VDC.
♦ If you suspect that power input is excessive, check the voltage levels to the
DEI + LOGGER, starting at the DEI + LOGGER’s power cable and
working backward toward the source. All voltage readings should be 21 –
30 VDC.
♦ If the DEI + LOGGER display is blank, but the Power button is pushed in
(to the “ON” position),the DEI + LOGGER may be receiving excessive
power. The drill’s batteries may be low or damaged, causing the alternator
to overcompensate and output too much power.
♦ If the display flashes on and off, the drill’s alternator diodes may have
failed, allowing half-wave rectified voltage into the electrical system. This
may not yet have caused damage, but it will eventually damage the DEI +
LOGGER.

3. If the DEI + LOGGER is too hot to touch and it is mounted where the sun
shines on it, you may need to move it out of direct sunlight.
4. There may be a case short in the DEI + LOGGER. Unbolt the unit from its
mounting bracket, isolate it from ground (earth). If it cools off, there is a case
short. Return it to Thunderbird for repair.
If none of these suggestions solves your problem, contact Thunderbird Mining
Systems for service.

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DEI + LOGGER Installation and Operations Guide

Air Circuit Tests

Components
This circuit consists of:

♦ An air pressure switch (3700-03x-001), which is pre-adjusted at the factory.

♦ An electrical cable (7070-189-xxx) connecting the air pressure switch to the

DEI + LOGGER.

♦ An air pressure connection to the working or bit air, typically a “T” joint from
the panel gauge to the air pressure switch.

Note: Instead of the air pressure switch, some installations use a mechanical
switch on the console, or a set of contacts on the drill’s AIR ON/OFF switch.

Diagnostic Information
Failures in the air circuit are generally due to one of the following, listed in order
of probability:

a. Incorrect value entered for the standard pipe length in Step 9 of the
calibration procedure.

b. Lack of pressure to the air pressure switch due to a clogged or frozen air feed
line.

c. Disconnected or loose cable connections, perhaps occurring during recent

repairs to machinery.

d. Incorrect air pressure connection.

If the air pressure switch is connected to the main (compressor) air rather than
the working (bit) air, there will be incorrect pressure to the switch.

e. Incorrect adjustment of the switch. The air pressure switch is preset at the
factory, but adjustment may be necessary. Refer to “Air Circuit Tests, Switch
Adjustment.” for adjustment instructions.

Diagnostic Procedure
Before you begin this procedure:

1. Make sure the power circuit is working properly. Most problems occur in the
power circuit.

2. Disconnect the encoder cable from the DEI + LOGGER. If the problem
changes, go to “Encoder Circuit Tests.”

3. Display the Bit Air Switch system screen (for instructions, refer back to
“System Status: Bit Air Switch Status Screen” in Chapter 3.)

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Then begin with Initial Check and follow all steps of the procedure in order,
observing the status indicated on the Bit Air Switch status screen.

Figure 36. DEI +

LOGGER Air Switch
Cable Connector

Initial Check
Action to take If result is this, go to next step If not, do this...

1. Turn the air pressure off. Status is OFF. Go to Bit Air Switch Cable Check.

2. Turn the air pressure on. Status is ON. Go to Bit Air Switch Cable Check.

3. Turn the air pressure quickly on Status changes between ON and Go to Switch and Line Check.
and off several times. OFF appropriately.

4. Go to “Re-Calibrate.”

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Bit Air Switch Cable Check

Action to take If result is this, go to next step If not, do this...

1. Disconnect the air switch cable Status is ON. Verify the power circuit again.
from the back of the DEI +
LOGGER. If the problem continues, replace
the DEI + LOGGER.

2. Use a piece of wire or a paper Status is OFF. Verify the power circuit again.
clip to jumper Pin A to Pin B of
the AIR connector on the back If the problem continues, replace
of the DEI + LOGGER. the DEI + LOGGER.

3. Re-connect the air switch cable Status is ON. Replace the air switch cable.
to the DEI + LOGGER, and
disconnect it at the air pressure
switch.

4. Use a piece of wire or a paper Status is ON. Replace the air switch cable.
clip to jumper the pins on the
cable connector.

5. Re-connect the cable to the air pressure switch. Then go to Switch and Line Check.

Switch and Line Check

Action to take If result is this, go to next step If not, do this...

1. Disconnect the pressure line at Line is not clogged. Clear the line, or replace it. Then
the air pressure switch. Check connect the line at the air pressure
the line to see if it is clogged. switch and continue.

2. Turn the air pressure quickly on Switch quickly activates and de- Clean the switch and recheck.
and off several times. activates.
If the problem continues, do the
“Switch Adjustment,” then recheck.

If the problem continues, replace

the switch.

3. Remove the four cover screws The connections are secure, un- Repair or replace the wires.
on the air pressure switch and frayed, and unbroken.
check the internal connections. If the problem continues, replace
the switch.

4. Re-connect the encoder cable to the DEI + LOGGER.

Repeat Initial Check. If the problem continues, go to “Re-Calibrate.”

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Switch Adjustment
The air pressure switch is adjusted at the factory and normally does not need to
be re-adjusted. Use this procedure only if, when you perform the “Air Circuit
Tests, Diagnostic Procedures,” the air switch does not activate and de-activate as
the bailing air is turned on and off (Switch and Line Check, step 2).

1. Make sure the air pressure switch is installed correctly and connected to the
DEI + LOGGER.

2. Make sure the drill compressor is running.

3. Turn off the bailing air.

4. Loosen the locknut on the top of the air pressure switch.

5. Turn the adjustment screw until the front panel display on the air pressure
switch reads 30% to 40% of working air pressure. For example, if the bit air
pressure is 60 psi, the front panel display should be 20.

Figure 37. Air Pressure Switch Front Panel

Note: The Operation Indicator can only be adjusted at the factory.

6. Watch the status boxes on the Bit Air Switch status screen of the DEI +
LOGGER as you cycle the bailing air on and off. Make sure the status
changes between on and off quickly and corresponds to the on/off state of the
bailing air. You should also hear and see the air pressure switch open and
close as you cycle the bailing air.

7. If necessary, repeat steps 3 through 6 until step 6 is satisfied.

8. Tighten the locknut on the top of the air pressure switch.

9. Verify step 6.

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DEI + LOGGER Installation and Operations Guide

Encoder Circuit Tests

Components
This circuit consists of:

♦ An optical shaft encoder (4500630)

♦ An electrical cable (7060-190-xxx) connecting the DEI + LOGGER to the

encoder.

♦ In some instances there is an electrical extension cable (7060-195-xx) that

extends the length of the 7060-190-xxx cable. It is typically installed from the
DEI + LOGGER to a position near the drill mast hinge pin.

♦ An encoder drive mechanism that is connected between the drill’s pulldown

system and the encoder shaft.

Diagnostic Information
Failures in the encoder circuit are generally due to one of the following, listed in
order of probability:

a. Calibration was incorrect.

If an incorrect value is entered at any point in calibration, or the power head

drifts during the calibration, you can expect all displayed measurements to be
incorrect.

b. Smashed, cut, or otherwise damaged cabling causing complete or intermittent

shorts and opens.

Note: If two of either pair ( or ) of the status boxes on the Encoder

Status screen are highlighted at any time, it is likely that there is a short in
either the cable or the encoder itself. If none of the boxes are highlighted, it is
likely that there is an open in the cable or the encoder.

c. Encoder drive chain comes off, slips, or misses because there is too much or
little tension on the chain.

d. On a direct drive installation, the hose connecting the encoder to the hub may
be broken or disconnected, or the cable clamps on the hose may be loose,
allowing the hose to slip.

e. Damaged encoder, either mechanically or electrically.

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Diagnostic Procedure
Before you begin this procedure:

1. Make sure the power circuit is working properly. Most problems occur in the
power circuit.

2. Disconnect the air switch cable from the DEI + LOGGER. If the problem
changes, go to “Air Circuit Tests.”

3. Display the Encoder system screen (for instructions, refer back to “System
Status: Encoder Status Screen” in Chapter 3.)

Then begin with Initial Check and follow all steps of the procedure in order,
observing the status indicated on the Encoder status screen.

Figure 38.
DEI + LOGGER
Encoder Cable
Connector

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DEI + LOGGER Installation and Operations Guide

Initial Check
Action to take If result is this, go to next step If not, do this...

1. Disconnect the encoder cable No status lights are highlighted Verify the power circuit. If it is
from the back of the DEI + on the Encoder status screen. working properly, replace the DEI
LOGGER. + LOGGER.

2. Using a piece of wire or a paper Box is highlighted. Same: verify the power circuit. If it
clip, jumper the encoder is working properly, replace the
connector socket D to socket A. DEI + LOGGER.

3. Jumper socket D to socket B. Box is highlighted. Same: verify the power circuit. If it
is working properly, replace the
DEI + LOGGER.

4. Jumper socket D to socket C. Box is highlighted. Same: verify the power circuit. If it
is working properly, replace the
DEI + LOGGER.

5. Jumper socket D to socket E. Box is highlighted. Same: verify the power circuit. If it
is working properly, replace the
DEI + LOGGER.

6. Re-connect the encoder cable to

the back of the DEI + LOGGER,
and go to Encoder Cable Check.

Figure 39. Cable to

Optical Shaft Encoder

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 Chapter 4 Troubleshooting

Encoder Cable Check

Action to take If result is this, go to next step If not, do this...

1. Disconnect the encoder cable No status lights are highlighted Replace the cable.
from the encoder. on the Encoder status screen.

2. Using a piece of wire or a paper Box is highlighted. Replace the cable.

clip, jumper the cable connector
socket D to socket A.

3. Jumper socket D to socket B. Box is highlighted. Replace the cable.

4. Jumper socket D to socket C. Box is highlighted. Replace the cable.

5. Jumper socket D to socket E. Box is highlighted. Replace the cable.

6. Go to Encoder Check.

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DEI + LOGGER Installation and Operations Guide

Encoder Check
Action to take If result is this, go to next step If not, do this...

1. Re-connect the encoder cable to Exactly one box from each pair Replace the encoder.
the encoder. ( or )is highlighted
on the Encoder status screen.

2. Rotate the encoder shaft by hand. The shaft turns smoothly and Replace the encoder.
quietly.
Make sure the tension on the chain
is not too tight.

3. Continue rotating the encoder The highlighted boxes on the Replace the encoder.
shaft by hand. screen alternate — exactly one
box per pair being highlighted
at any one time.

4. Press the Statistics button on the The ROP/DISTANCE FROM Replace the encoder.
DEI + LOGGER. Then continue BOTTOM display on the
rotating the encoder shaft by statistics screen is updated in
hand. units of one-tenth.

5. Go to “Re-Calibrate.”

Re-Calibrate
1. Most problems occur in the power circuit. Verify that it is working properly.

2. If the problem continues, re-calibrate the DEI + LOGGER, making sure that
you enter the correct pipe length in Step 9 and all other calibration values
accurately.

If you are unable to calibrate successfully, go to “Encoder Circuit Tests.”

3. If the problem continues, replace the DEI + LOGGER.

If the following occurs twice in succession, return the digital DEI + LOGGER to
Thunderbird Mining Systems for repair: When the DEI + LOGGER is first
turned on, the Calibration Failed warning screen flashes on the display.

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 Appendix A
Cable Pinouts

Figure 40.
7070-189-xxx
Cable Assembly —
DEI + LOGGER to Air
Pressure Switch

Figure 41.
7060-190-xxx
Cable Assembly —
DEI + LOGGER to
Optical Shaft Encoder

Figure 42.
7070-191-xxx
Cable Assembly —
DC Power to DEI +
LOGGER

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