Manual Operación y Mantenimiento BI652203-00-En

BI652203
April 2015
Operation and
Maintenance
Manual
MD6640 Blast Hole Drill
Serial Number DR612200 - Up
SAFETY.CAT.COM
BI652203
BI652203
BI652203
BI652203
MD6640 Blast Hole Drill

Operation and Maintenance Manual
SN: DR612202
–Table of Contents–
This manual is divided into major sections covering the various serviceable components and systems
of the MD6640Blast Hole Drill. These sections and their contents are organized as shown below.
Section 1 - INTRODUCTION
Section 2 - OPERATION
Section 3 - LUBRICATION
Section 4 - PREVENTIVE MAINTENANCE
Section 5 - SERVICE PROCEDURES
Section 6 - BRAKES AND COUPLINGS
Section 7 - COMPRESSED AIR SYSTEM
Section 8 - HEATING, VENTILATION AND AIR CONDITIONING
Section 9 - ENGINEERING DATA
Section 10- SCHEMATICS

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DANGER:
THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND
OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE
SERVICED BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO
WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES, AND/
OR WARD LEONARD LOOP DC DRIVES. FAILURE TO COMPLY COULD RESULT IN
PERSONAL INJURY OR DEATH.
DANGER:
DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE

WITHOUT A FULL UNDERSTANDING OF EACH COMPONENT’S OPERATION AND
FUNCTION. COMPONENTS UTILIZING ELECTRICAL POWER, AIR PRESSURE,
HYDRAULIC PRESSURE AND COMPRESSION OR TENSION SPRINGS FOR
OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY.
The FEEDER CABLE must contain a provision for a ground connection, especially whenever
2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on
ground circuits) to a suitable permanent ground. At the machine, the power line must securely
terminate through a bolted connection to the machine frame. This provides a constant ground for
the machine and its electrical equipment. Failure to provide this adequate ground endangers
employees and equipment.
THE NEED FOR A POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE
CANNOT BE OVEREMPHASIZED. Without a good grounding system, high voltages exist between
the machine and the ground. The portable trail cable and power lines supplying electric energy to
the machine must have a ground wire, ample in capacity, running parallel to the main wires over
the entire distance from the transformer to the machine. A suitable grounding system must be
used at the transformer. Consult your local electrical supplier for details.
DANGER:
DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE

ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM IS REQUIRED THAT
INCLUDES GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING
RESISTOR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY
CHECK SYSTEM IS ALSO RECOMMENDED.
BI652203
BI652203 1-1
Introduction Section
MD6640 Blasthole Drill
Section 1
Introduction
Always refer to the safety information in this section of this manual before
starting any maintenance procedure on this machine.
Table of Contents
GENERAL INFORMATION ............................................................................................................ 3

SAFETY .................................................................................................................................. 4
SAFETY PRECAUTIONS ........................................................................................................ 5
FIRE PREVENTION CONSIDERATIONS ..................................................................................... 8
STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS .............................. 9
WARNING SIGNS AND DECALS ................................................................................................ 12
Stored Energy Signs .................................................................................................................. 13
MACHINE OVERVIEW ................................................................................................................ 14
PROPEL MACHINERY .......................................................................................................... 15
MAIN FRAME AND DECKS ................................................................................................... 16
MACHINERY HOUSE ............................................................................................................ 17
MAIN AIR SYSTEMS .............................................................................................................. 18
Air Compressor .......................................................................................................................... 18
HYDRAULIC SYSTEM ........................................................................................................... 19
OPERATOR’S CAB .............................................................................................................. 20
MAST ..................................................................................................................................... 20
Mast/Machinery .......................................................................................................................... 21
ROTARY GEARCASE ........................................................................................................... 22
PULLDOWN GEARCASE ..................................................................................................... 23
DRILL TOOL STRING ASSEMBLY ........................................................................................ 24
BREAKOUT WRENCH ......................................................................................................... 25
CABLE REEL ........................................................................................................................ 25
65 OR 70 FOOT MAST - TYPICAL MACHINE SPECIFICATIONS .............................................. 26
GENERAL ESTIMATED COMPONENT WEIGHTS .................................................................... 28
DECK PLAN.......................................................................LOCATED AT THE END OF THE MANUAL

1-2 BI652203
BI652203 1-3
Section 1
Introduction
GENERAL INFORMATION
This manual is designed to assist the owner in the operation and maintenance of this machine. By
following easy to understand step-by-step procedures the operators and maintenance personnel
can perform all tasks in a safe manner. When a systematic and thorough maintenance/service
procedure is used for this machine, a minimum of unplanned downtime and more reliable operation
will result.
THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used as reference material to order
parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in
it. All parts are listed by group and/or product code numbers with the associated item/part numbers
for THIS SPECIFIC MACHINE. Order parts in the exact quantity needed. RIGHT and LEFT refer to
machine locations as viewed by the operator sitting in the operator’s seat in the cab. Please state
the correct machine SERIAL NUMBER when corresponding or contacting the factory service or
parts departments. Records on each machine are filed by serial number and when given this
number, your machine’s specific design and original equipment is accessed by the parts
representative. Periodic additions or revisions may be made to this manual. Should you require
additional information or factory service assistance contact your regional service representative or:
Caterpillar Global Mining, LLC

Mining Products Division
3501 S FM 1417
Denison, TX 75020
903-786-9621
The company reserves the right to make changes or add improvements to its machines at any
time. This will be without incurred obligations to install such changes on machines sold
previously. Due to this ongoing program of product research and development some
procedures, specifications and parts may be altered in a constant effort to improve our
machines.
1-4 BI652203
SAFETY
The safety alert symbols displayed here and throughout this manual, are used to call attention to
instructions concerning personal safety. Carefully read and follow these instructions and observe
all SAFETY, DANGER and CAUTION graphics mounted on various areas of the machine.
Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definitions.
If it is impossible to safely perform any of the enclosed maintenance and operational procedures,
contact your regional Caterpillar service representative or the factory.
The following defines distinctions between safety instructions. In all these definitions the safety
alert signal is used.
NOTE: This signal word denotes an item of required information pertaining to the equipment. A
loss of time, assets, or minor injury may result if the appropriate action is not taken.
CAUTION: This signal word serves as a reminder of safety practices or directs

attention to specific safety practices which could prevent possible
injury if precautions are not adhered to.
DANGER: This signal word denotes an imminently dangerous hazard which will
result in death, serious bodily injury, or serious damage to equipment
if not acknowledged and appropriate action taken.
DANGER: This signal word denotes an imminently dangerous electrical hazard

which will result in death, serious bodily injury, or serious damage to
equipment if not acknowledged and appropriate action taken.
Operating, maintaining or servicing this machine is dangerous unless performed properly. Each
person must satisfy himself and his employer that he is alert, has the necessary skills, knowledge,
proper tools and equipment for the task at hand. It is critical that all the methods used are safe and
correct. Factory service representatives and specialists are available to provide additional information
or technical assistance. The operator must be alert, physically fit and free from the influence of
alcohol, drugs, or any medications that might impair his eyesight, hearing or reactions.
CAUTION: STORED ENERGY! Components on machine are heavy and

removal of pins without proper preparation and precaution can cause
serious bodily injury and/or damage to the front-end of the machine.
Safety must always be paramount!
Consult your supervisor when safety is in doubt.

BI652203 1-5
SAFETY PRECAUTIONS
General Precautions:
• The employment of qualified maintenance personnel, through a scheduled maintenance
program, is the best way to minimize machine downtime and maximize productivity of
equipment.
• Keep hands, feet, and clothing away from rotating parts.
• Wear a hard hat, safety shoes and protective lenses at all times.
• Replace any and all safety and warning placards if they are defaced or removed from the
machine.
• Think before you act. Carelessness is one luxury the service man cannot afford.
• Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case
of skin contact refer to the Material Safety Data Sheet (MSDS) for that material and the suggested
method of cleanup.
• Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load could slip
off of the hook if they are not functioning properly.
• If a heavy item begins to fall, let it fall, don’t try to catch it.
• Keep your work area organized and clean. Wipe up oil or spills of any kind immediately. Keep
tools and parts off of the ground. Eliminate the possibility of a fall, slipping or tripping.
• Floors, walkways and stairways must be clean and dry. After fluid draining operations be sure
all spillage is cleaned up.
• Electrical cords and wet metal floors make a dangerous combination.
• Regularly inspect for any loose bolts or locking devices and properly secure them.
• Use extreme caution while working near any electrical lines or equipment whether it be high or
low voltage. Never attempt electrical repairs unless you are qualified.
• Check limit switches for proper operation.
• After servicing, be sure all tools, parts or servicing equipment are removed from the machine
and secured in an appropriate storage area.
• Mechanical Brakes are designed for use as static holding brakes only. Use as a motion (dynamic)
brake in emergency situations only.
• Use proper interior and exterior lighting.
• Install and maintain proper grounding and ground fault protection systems.
• Perform functional tests of all safety circuits.
• Allow electrical inspection and maintenance to be performed only by a qualified electrician.
• Use extreme caution when working around drilled holes.
1-6 BI652203
Maintenance Precautions:
• Do not wear rings, wristwatches or loose fitting clothing when working on machinery. They
could get caught on moving parts causing serious injury.
• Always wear a safety belt or harness when the danger of falling exists.
• Always have a second person to monitor the lifeline when working in confined spaces.
• Do not start an engine indoors unless adequate exhaust ventilators are provided and in operation.
• Never utilize the machine air or hydraulic systems for support when working on the machine.
Deactivate or isolate the entire system prior to performing maintenance.
• Equipment should be parked on level ground at all times during machine servicing and periods
of idleness.
• Cranes and hoists must be of sufficient capacity to lift the heavier components (gearcases,
pipe arms, etc.) Always work within the limitations of the equipment being utilized.
• Be sure heavy items are properly rigged and supported from cranes or hoists before removing
supporting members from the machine.
• Utilize guide lines or ropes to minimize the swing of suspended heavy components.
• Have sufficient service personnel available when removing or installing large heavy items to
maintain control at all times.
• Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on the jack
or hoist to carry the load, they could fail.
• When disassembling a machine, be sure to use safety stands and adequate cribbing to prevent
tipping or rollover of components.
• When using an oxy/acetylene torch, always wear welding goggles and gloves. Keep a charged
fire extinguisher within reach. Be sure the acetylene and oxygen tanks are separated by a
metal shield and are chained to the cart.
• Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable. Use
hammers, punches and chisels only when absolutely necessary. Always be sure to wear
safety glasses.
• Use extreme caution when using compressed air to dry parts. Use approved air blowguns, do
not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use proper shielding to
protect everyone in the work area.
• Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or servicing
the machine.
• Protective eye goggles should be worn at all times when working on the air conditioning system.
Work on the air conditioning system only in a well ventilated area.
• Wipe away excess lubricants around bearings and gears. Never lubricate parts in motion.
• Always wear approved rubber gloves, and use insulated hooks or tongs when handling trail
cable.
BI652203 1-7
Operating Precautions:
• Wear hearing protection when exposed to the following noise levels in excess of the period
indicated:
8 hours at 90 dBa
4 hours at 95 dBa
2 hours at 100 dBa
1 hour at 105 dBa
30 minutes at 110 dBa
15 minutes at 115 dBa
• When in doubt about the noise level, wear approved hearing protection.
• Do not attempt to get on or off the machine while it is in operation. Notify the operator prior to
any attempt to board/exit the machine.
• Do not move or operate the machine without first knowing the location and purpose of all
personnel, test or support equipment, on or near the machine.
• Do not allow unauthorized personnel on board the machine while in operation.
• Use audible signals to warn of machine movements. A signal horn button is provided for this
purpose.
• Do not propel until the travel route has been cleared of obstructions.
• Do not propel the machine on a slope greater than specified in the stability limits shown on the
STABILITY CHART at the end of this section.
• Do not leave the rotary gearbox suspended in the air when leaving the machine unattended.
• Prevent trail cable from being dragged on the ground for long distances or at high speeds.
• Limit the amount of cable being dragged by the machine. Pulling too much cable will damage
both the cable and the machine.
1-8 BI652203
FIRE PREVENTION CONSIDERATIONS
Always have a “charged” fire extinguisher on hand and know how to use it. Inspect and service the
extinguisher as indicated on its instruction plate.
DO NOT smoke while handling flammables or when near batteries.
Inspect all lines, tubes, and hoses carefully. Tighten all connections to their recommended torque
specification. See Section 4 of this manual for the Scheduled Maintenance recommendations and
the Walk Around Inspection procedure.
Repair or replace loose or damaged lines, tubes, and hoses as soon as possible.
Make certain that all clamps, guards, and shields are replaced correctly so as to prevent vibration
and the chafing of parts during operation.
DO NOT carry flammable fluids such as gasoline or solvents on board themachine.
DO NOT over-bend or strike pressurized lines or hoses. DO NOT install bent or damaged lines,
tubes, or hoses. Replace them immediately.
DO NOT start the machine or move any of the controls if a warning tag is attached to the controls
or the start panel.
Keep all cleaning rags properly stored. DO NOT discard them into a pile on board.
Keep all structural frame compartments, walkways, and work areas clean and free of lubricant
residue.
NEVER weld, burn, or perform service on the machine alone.

BI652203 1-9
STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS
These signals are derived from ANSI-B30.5-1868 and are intended to provide standardization to
the signaling used in communication between maintenance personnel and crane operators during
the maintenance cycle.
HOIST Extend forearm upward, keeping forefinger extended and pointing

up, make small circular movements with hand.
LOWER Extended arm downward, keeping forefinger extended and pointed

down, make small circular movements with hand.
MAIN HOIST Tap fist on head until signal received by operator, then use
standard signals.
USE WHIP LINE (Auxiliary Hoist) Tap elbow with open hand until signal
received by operator, then use standard signals.
1-10 BI652203
RAISE BOOM Extend arm fully with fingers closed and thumb pointing
upward.
STOP Extend arm fully with fingers extended and palm facing down.
EMERGENCY STOP With arm fully extended, fingers fully extended and
palm facing down, move arm rapidly along a horizontal plane.
TRAVEL With arm extended forward, hand open and raised at wrist, make a
pushing motion in the desired direction of movement.
DOG EVERYTHING Clasp hands together in front of body.
TRAVEL (both tracks) With both fists clenched in front of body, make a
circular motion with the desired direction of motion (forward or reverse)
duplicated with fists.
LOWER BOOM Extend arm fully with fingers closed and thumb pointing
down.
MOVE SLOWLY While giving any motion signal, hold other hand motionless
in front of desired signal hand. (Hoist slowly is example provided.)
BI6522031-11
RAISE BOOM AND LOWER LOAD Extend arm horizontally with fingers
extended and thumb pointing upward, alternately open and close fingers for
the duration of the desired movement.
LOWER BOOM AND RAISE LOAD Extend arm horizontally with fingers
extended and thumb pointing downward, alternately open and close fingers
for the duration of the desired movement.
SWING Extend arm horizontally with index finger extended in desired

direction of swing.
TRAVEL (Single Track) Use a raised fist on the side that remains locked and
make a vertical circular motion in front of chest for the direction and side of
desired movement.
EXTEND BOOM (Telescoping Booms) Place both hands in front of body

with palms upward, fingers clenched, and thumbs extending outward.
RETRACT BOOM (Telescoping Booms) Place both hands in front of body

with palms upward, fingers clenched, and thumbs extending inward.
EXTEND BOOM (Telescoping Booms) With fingers clenched and thumb

extended toward body, use a single hand motion to tap on chest with thumb
of hand.
RETRACT BOOM (Telescoping Booms) With fingers clenched and thumb

extended away from body, use a single hand motion to tap on chest with
heel of hand.
1-12 BI652203
WARNING SIGNS AND DECALS
The placards depicted below are mounted on the machine as delivered. These hazard warning
placards convey information to operators, maintenance personnel, or anyone who will be on or
near the machine. The information is designed to help prevent situations which may result in injury
to personnel or damage to the machine.
BI6522031-13
Stored Energy Signs

1-14 BI652203
MACHINE OVERVIEW
This machine is designed and constructed to provide efficient service under the most severe
conditions. It is built to the highest possible standards and will provide trouble free operation if
properly maintained.
Winch, Auxiliary
Mast Ladder
Mast
Assembly
Mast Rack
Mast
Safety
Restraint
Device
Pipe Rack Front

of
Machine
Mast Machinery
Guide Frame
Pulldown Mast Brace
Gearcase
Mast
Machinery Main Machinery House
Breakout
Wrench Air Hose
Air House Filter
Conditioner Hydraulic Cylinder, Assembly
Rear
Mast Hoist
Leveling
Jack Operator’s
Mast Hinge
Cab
A-Frame
Water
Tank
Rotary
Gearcase
Shock
Coupling
nm view
Front
Main Frame Pad, Leveling
Leveling Jack Crawler Assembly Jack
Pad, Leveling Jack Boarding Stairs
Walkways, House Crawler
Drive Sprocket
BI6522031-15
PROPEL MACHINERY
The propel system of this machine is a chainless hydraulic drive system which will allow the separate
tracks to counter-rotate. This capability provides the machine with the capacity to turn completely
around within its own length. Each track is driven by a hydraulic motor and a planetary gearbox
equipped with a hydraulically released, spring activated brake. The machine is capable of 2 different
propel speed ranges. The lower speed range is used for maneuvering in close spaces while the
high speed range is used for tramming in open areas, over long distances.
Equalizer Axle
Rear Axle
Upper
Roller
Lower Track
Idler Roller Final Drive

1-16 BI652203
MAIN FRAME AND DECKS
The main frame is of welded box type construction with integrally placed mast supports and jack
towers.
BI6522031-17
MACHINERY HOUSE
1-18 BI652203
MAIN AIR SYSTEMS
The screw compressor is located within the machinery house just forward of the hydraulic pump
gearbox. The rotary screw compressor is an oil flooded, single stage twin screw type compressor
which has a nominal rating of 3,000 cfm (84.9m3/min), @ 65 psi and a maximum operating pressure
of 65 psi.
Air Compressor
BI6522031-19
HYDRAULIC SYSTEM
Hydraulic pressure for operation of this machine is provided by four separate pumps. These pumps
are driven by the electric motor located in main machinery house, forward of the hydraulic filters
and reservoir.
The machine has 2 separate, though not completely independent hydraulic systems, the OPEN
and CLOSED circuits. Both draw fluid from a common reservoir.
1-20 BI652203
OPERATOR’S CAB
The sound insulated operator’s cab of the MD6640 provides a sealed, comfortable enclosure from
which the operator can perform the tasks involved with the operation of the machine. The location
and design of this compartment have been structured to provide the optimum viewing angles with
immediate accessibility. The operator’s seat is a self-contained unit that includes the seat, seat
suspension and swivel base assembly, the primary operator’s controls and the JLT display monitor.
The auxiliary control console is within reach to provide access to additional functions of the machine.
The cab is provided with dual doorways to the main deck.
MAST
The mast is a fabricated structure of steel tubes and formed plates. The major structure is composed
of vertical tubes welded together with back bracing. The mast functions to provide the mounting and
guide for the equipment required to operate the drilling function of the machine. The mast is capable of
being positioned at any 5o increment within it’s operating range from 65 degrees through 90 degrees
(vertical). The mast can be raised and lowered by 2 (two) 9.00 inch (228mm) hydraulic cylinders.
BI6522031-21
Mast/Machinery
1-22 BI652203
ROTARY GEARCASE
BI6522031-23
PULLDOWN GEARCASE
1-24 BI652203
DRILL TOOL STRING ASSEMBLY

BI6522031-25
BREAKOUT WRENCH
CABLE REEL
1-26 BI652203
65 OR 70 FOOT MAST - TYPICAL MACHINE SPECIFICATIONS
Refer to the images on the following page.

Hole Diameter to 16” 406mm
Hole Depth (single pass - 65 Ft. mast) 65 Ft. 19.81m
Hole Depth (single pass - 70 Ft. mast) 70 Ft. 21.34m
A Overall Height with 65 Ft. (19.81m) mast 102' 5” 31.22m
A Overall Height with 70 Ft. (21.34m) mast 104' 5” 31.85m
B Height to Top of handrails on Operator’s Cab 18' 6" 5.64m
C Ground to Top of Deck 6' 4" 1.93m
D Ground to Bottom of Rear Jack 2' 0" 0.61m
E Ground to Top of Machinery House Roof 14’ 10” 4.52m
F Overall Width of machine 23' 9" 7.24m
F1 Machine C/L to Left side 11' 10" 3.61m
F2 Machine C/L to Right side 11' 11" 3.63m
G Machine C/L to Left Outside Edge of Tracks (36 inch/914mm) 10' 5" 3.17m
G1 Machine C/L to Right Outside Edge of Tracks (36 inch/914mm) 9' 7" 2.92m
H Machine C/L to Left Rear Leveling Jack C/L 7' 6" 2.29m
H1 Machine C/L to Right Rear Leveling Jack C/L 7' 3” 2.21m
I Centerline of Hole to Centerline of Equalizer Axle 0’ 5” 0.12m
J Height to Top of Machinery House Pressurization Unit 16’ 6” 5.03m
K Height to Top of Cable Reel 10’ 1” 3.07m
L Ground to Bottom of Front Jack 2’ 1” 0.63m
M Diameter of Jack Pads 3' 8" 1.12m
N Centerline of Hole to Centerline of Rear Jacks 15 3/4” 4.59m
O Overall Crawler Length 23' 9” 7.24m
P Hole C/L to Rear of Operator’s Cab 10' 2” 3.1m
Q Distance between Front and Rear Jack Centerlines 36' 2” 11.02m
R Overall Machine Length 48' 4" 14.73m
S Overall Machine Length with Cable Reel 55’ 8" 16.97m
T Overall Machine Length with 65’ Mast at Rest (19.81m) 121’3" 36.95m
T Overall Machine Length with70’ Mast at Rest (21.34m) 123’ 4" 37.64m
U Overall Machine Height with 65’ Mast at Rest (19.81m) 32’ 3" 9.52m
BI6522031-27
B
J
C N K
D
I O M L
1 Q
H H
1 R
G G
S
F1 F2
F T
mdim49HR
1-28 BI652203
GENERAL ESTIMATED COMPONENT WEIGHTS
CAUTION: These are estimated weights only. Contact your Caterpillar service
representative for the exact weight of components on your specific
machine before rigging and lifting.
Quantity Weight Each

(U.S. Pounds)
Lower Works
Frame, R.H. Crawler ................................................................ 1 ................ 8,480
Frame, L.H. Crawler ................................................................. 1 ................ 8,480
Axle, Crawler Front Equalizer ................................................... 1 ................ 3,370
Axle, Crawler Rear ................................................................... 1 ................ 6,480
Tumbler, Crawler Drive ............................................................ 2 ................ 1,160
Propel Gearcase ...................................................................... 2 ................ 2,750
Link, Crawler .......................................................................... 110 ................. 240
Propel Motor ............................................................................. 2 ................... 198
A-Frame
Leg, Front A-Frame .................................................................. 2 ................... 800
Leg, Rear A-Frame ................................................................... 1 ................ 2,900
Cylinder, Mast Latch ................................................................. 2 ..................... 15
Pin, A-Frame Lock .................................................................... 2 ..................... 15
Pin, Mast Latch Lock ................................................................ 2 ..................... 15
Pin, A-Frame ............................................................................ 2 ..................... 40
Ladder, A-Frame ....................................................................... 1 ..................... 80
Main Frame
Main frame ................................................................................ 1 ...............45,130
Casing Assembly, Left Rear Jack ............................................ 1 ................ 2,260
Casing Assembly, Right Rear Jack .......................................... 1 ................ 5,680
Cylinder, Leveling Jack Hydraulic ......................................... 4 ................... 845
Spud, Jack ............................................................................ 4 ................... 660
Shoe, Spud ........................................................................... 4 ................... 505
Power Module ........................................................................... 1 ...............13,600

Base, Power Module ................................................................ 1 ................ 1,550
Motor ..................................................................................... 1 ................ 6,100
Pump Drive Assembly .......................................................... 1 ................... 805
Bracket, RH, Hydraulic Pump Drive ................................. 1 ................... 155
Bracket, LH, Hydraulic Pump Drive .................................. 1 ................... 150
Pump, Gear, Tandem, ...................................................... 1 ..................... 45
Pump Drive ...................................................................... 1 ................... 175
Filter, Assembly, Air Inlet ....................................................... 1 ................... 605
Air End Assembly ................................................................. 1 ................ 4,070
Separator Assembly ............................................................. 1 ................ 4,275
Reservoir, Hydraulic ................................................................. 1 ................... 705
Reservoir, Lube ........................................................................ 1 ................... 460
BI6522031-29

(U.S. Pounds)
Oil Cooler, Air Cooled ............................................................... 1 ................... 570

Guard, Oil Cooler ................................................................. 1 ................... 185
Cooler, Compressor Assembly ................................................ 1 ................ 4,200
Cooler, Compressor ................................................................. 1 ................ 3,000
MCC. Low Voltage .................................................................... 1 ................... 900

MCC, Main Compressor........................................................... 1 ................ 1,080
Cabinet, ZHC ............................................................................ 1 ................ 1,030
Control Panel, Static DC Drive ................................................. 1 ................... 210
Cabinet ..................................................................................... 1 ................... 600
Cabinet, PLC ............................................................................ 1 ................... 800
Cabinet, Rotary-ZROC ............................................................. 1 ................ 1,035
Leveling Jack Stand .................................................................. 1 ................... 470

Control Valve ............................................................................ 1 ................... 160
Operator Cab Assembly ........................................................... 1 ................ 8,400

Air Conditioner .......................................................................... 1 ................... 930
Hatch, Bit View ......................................................................... 1 ................... 225

Cylinder, Bit Viewing Hatch ................................................... 1 .................... 115
Retainer, Plate .......................................................................... 1 ..................... 40
Cylinder, Dust Seal ................................................................... 1 ..................... 90
Carrier, Dust Seal ..................................................................... 1 ................... 300
Gate, Front ............................................................................... 1 ................... 380
Gate, Rear ................................................................................ 1 ................... 630
Frame, Dust Enclosure ............................................................ 1 ................... 700
Stairway, Boarding .................................................................... 1 ................... 210
Cable Reel ................................................................................ 1 ................ 8,000
Machinery House
Wall, Machinery House R.H. ..................................................... 1 ................ 1,745
Wall, Machinery House Front ................................................... 1 ................ 1,040
Wall, Machinery House L.H. ..................................................... 1 ................ 1,180
Door Cove, L.H. ........................................................................ 1 ................... 135
Cove, Hydraulic ........................................................................ 1 ................ 1,250
Panel, Center Roof ................................................................... 1 ................... 575
Panel, Rear Roof ...................................................................... 1 ................... 600
Extension, Left Hand ................................................................ 1 ................ 8,925
Panel, Roof, L.H. Extension ..................................................... 1 ................... 430
Roof Section, Machinery House ............................................... 1 ................ 2,030
Hatch, Pressurization Unit Roof ............................................... 1 ................... 345
Enclosure, Dynavane Bleed Fan .............................................. 1 ................... 375
1-30 BI652203

(U.S. Pounds)
Duct, Pressurization Unit Transition ......................................... 1 ................... 275

Duct, Upper Bleed Fan Discharge ........................................... 1 ..................... 90
Duct, Lower Bleed Fan Discharge ........................................... 1 ................... 100
Shroud, Pressurization Unit Rain ............................................. 1 ................... 120
Filter, Air/Bleed Air Duct ............................................................ 1 ................ 1,000
Support, Blower Fan ................................................................ 2 ................... 145
Hatch, Roof .............................................................................. 1 ................... 350
Oil Cooler Blower and Blower Motor ........................................ 1 ................... 220
Mast Braces
Brace, Mast .............................................................................. 2 ................ 1,555
Sleeve, L.H. Brace ................................................................... 1 ................... 705
Sleeve, R.H. Brace ................................................................... 1 ................... 710
Support, R.H. Mast Brace ........................................................ 1 ................... 865
Support, L.H. Mast Brace ......................................................... 1 ................... 860
Support Arm, R.H. Safety Sling (lower) .................................... 1 ................... 105
Eyebolt ...................................................................................... 2 ................... 145
Pin, Lock ................................................................................... 2 ..................... 20
Cylinder, Brace Lock ................................................................ 2 ..................... 20
Pin, Pivot .................................................................................. 8 ..................... 40
Cylinder, Mast Hoist Hydraulic .................................................. 2 ................ 1,350
Mast Assembly
Mast Structure .......................................................................... 1 ...............26,000
Rack, Pulldown Pinion ............................................................ 42 .................. 100
Plate, Mast Bottom ................................................................... 1 ................ 1,995
Gearcase, Pulldown ................................................................. 1 ................ 1,170

Shaft, Input ........................................................................... 1 ..................... 72
Coupling, Pulldown Input ...................................................... 1 ..................... 50
Shaft, 2nd Intermediate Pulldown ......................................... 1 ................... 145
Gear, 2nd Intermediate Pulldown ......................................... 1 ................... 390
Housing, Encoder ................................................................. 1 ..................... 30
Pinion, First Intermediate ...................................................... 1 ................... 155
Gear, First Intermediate ........................................................ 1 ................... 465
Gear, Output ......................................................................... 1 ................... 690
Shaft, 1st Intermediate & Shipper, Pulldown ........................ 1 ................... 710
Brake, Pulldown ................................................................... 1 ................... 100
Motor, Hoist and Pulldown .................................................... 1 ................ 1,900
Support, Pulldown Gearcase ............................................... 1 ................ 1,015
BI6522031-31

(U.S. Pounds)
Gearcase, Rotary ..................................................................... 1 ................ 2,950

Shaft, Intermediate Rotary .................................................... 1 ..................... 75
Gear, Intermediate Rotary .................................................... 1 ................... 100
Gear, Rotary Drive ................................................................ 1 ................... 590
Shaft, Rotary Drive ............................................................... 1 ................... 355
Bearing, Shaft Center ........................................................... 1 ................... 130
Carrier, Lower Bearing ......................................................... 1 ................... 215
Retainer, Bearing .................................................................. 1 ................... 210
Housing, Upper Seal ............................................................ 1 ..................... 35
Carrier, Upper Bearing .......................................................... 1 ..................... 30
Bearing, Shaft Lower ............................................................ 1 ..................... 35
Pinion, Rotary Motor ............................................................. 1 ..................... 55
Motor, Rotary ........................................................................ 1 ................ 2,550
Coupling, Shock ....................................................................... 1 ................ 2,500
Guide Frame (LH) .................................................................... 1 ................ 1,130

Guide Frame (RH) .................................................................... 1 ................ 1,130
Housing, L.H. Mast Guide Roller .......................................... 1 ................... 415
Guide Roller Assembly, Upper .................................................. 2 ................... 150
Guide Roller, Upper .............................................................. 4 ..................... 40
Guide Roller, Lower (Front) .................................................. 2 ..................... 45
Extender, Drill Pipe ................................................................... 1 ................... 620

Bushing, Drill Pipe Guide .......................................................... 1 ................... 310
Wrench, Bit, 12.25 ................................................................... 1 ................... 125
Wrench, Bit, 10.625 ................................................................. 1 ................... 140
Tool Wrench Assembly ............................................................ 2 ................ 2,100
Winch, Hydraulic Driven ........................................................... 1 ................... 415
Hydraulic Cylinder, Rack Position ............................................ 2 ..................... 90
Ladder, Mast ............................................................................. 5 ................... 100
Ladder, Mast Lower .................................................................. 1 ..................... 85
1-32 BI652203
BI652203 2-1
Operation Section
Section 2
Operation
Always refer to the safety information in Section 1 of this manual before
Table of Contents
GENERAL INFORMATION ............................................................................................................ 5

OPERATION NEAR ELECTRICAL TRANSMISSION LINES ................................................... 5
CONTROLS - LOCATION AND FUNCTION ................................................................................ 6
OPERATOR’S CONTROL CONSOLES ...................................................................................... 7
OPERATOR’S CONTROL CONSOLE - OVERVIEW ................................................................... 7
LEFT CONTROL CONSOLE .................................................................................................. 8
LEFT CONTROL CONSOLE - OVERVIEW ................................................................................ 8
PROGRAMMED DRILL CONTROL PUSHBUTTON — OPTION ...................................... 9
OPERATING MODE SELECTOR SWITCH ...................................................................... 9
PULLDOWN / HOIST SPEED RANGE SELECTOR SWITCH ......................................... 9
HOIST BRAKE SWITCH ................................................................................................. 10
MAIN AIR VALVE SWITCH ............................................................................................... 10
DEPTH INDICATOR RESET PUSH-BUTTON ................................................................ 10
EMERGENCY STOP PUSH-BUTTON ............................................................................ 11
BIT VIEW HATCH SWITCH ............................................................................................. 11
LEFT JOYSTICK (DUAL FUNCTION) - PROPEL TRACK / WINCH ............................... 11
ROTARY DRIVE SPEED SELECTOR SWITCH ............................................................ 12
HOIST/PULLDOWN RHEOSTAT .................................................................................... 12
DUST CONTROL ON/OFF SWITCH — OPTION .......................................................... 12
DUST CURTAIN SWITCH — OPTION ............................................................................ 12
DUST CONTROL FLOW CONTROL — OPTION .......................................................... 13
UNDER DECK SPRAYERS — OPTION ........................................................................ 13
RIGHT CONTROL CONSOLE .............................................................................................. 14
RIGHT CONTROL CONSOLE - OVERVIEW ............................................................................. 14
PIPE POSITIONER SWITCH .......................................................................................... 15
RIGHT JOYSTICK (TRIPLE FUNCTION) - PROPEL TRACK / PIPE RACK / MAST ...... 15
ROTARY SPEED POTENTIOMETER ............................................................................ 16
DUST SEAL SLIDER SWITCH ....................................................................................... 16
PROPEL SPEED RANGE SELECTOR SWITCH .......................................................... 16
HORN PUSH-BUTTON ................................................................................................... 16
TOOL WRENCH SWITCH .............................................................................................. 17
BREAKOUT WRENCH SWITCH .................................................................................... 17
PIPE RACK SELECTOR SWITCH ................................................................................. 17
BIT CAROUSEL SWITCH ............................................................................................... 17
LEVELING JACK CONTROL SWITCHES ...................................................................... 18
2-2 BI652203
Operation Section
AUTO LEVEL SWITCH ................................................................................................... 18

AUXILIARY CONTROL CONSOLE ....................................................................................... 19
AUXILIARY CONTROL CONSOLE ............................................................................................ 19
EXTERIOR LIGHTS ........................................................................................................ 19
TRAIL CABLE TRIP PUSH-BUTTON .............................................................................. 19
FLOOR DEFROST SWITCH .......................................................................................... 20
HEATER / VENT / AIR CONDITIONER CONTROLS ...................................................... 20
BOARDING STAIRS SWITCH ......................................................................................... 20
RADIO / CASSETTE PLAYER ........................................................................................ 20
OPERATOR’S DISPLAY ............................................................................................................. 21
OPERATOR’S DISPLAY MONITOR ........................................................................................... 21
DISPLAY AREA & INDICATORS ............................................................................................ 21
DISPLAY SCREENS ............................................................................................................. 22
TITLE SCREEN ......................................................................................................................... 22
LEVELING SCREEN ................................................................................................................. 23
STATUS SCREEN ..................................................................................................................... 23
ACTIVE ALARM ........................................................................................................................ 24
STATUS SCREEN with Pop-up Ribbon ...................................................................................... 24
ALARM HISTORY ...................................................................................................................... 25
HELP NAVIGATION ................................................................................................................... 25
PLC DIAGNOSTICS .................................................................................................................. 26
CALIBRATION and LIMITS ....................................................................................................... 26
OPERATING HOURS ................................................................................................................ 27
FIELD TESTS ............................................................................................................................ 27
MACHINERY HOUSE CONTROLS ...................................................................................... 28
LIGHTING LOAD CENTER .............................................................................................. 28
LIGHTING LOAD CENTER ........................................................................................................ 28
CONTROLS LOCATED ON LOW VOLTAGE START CABINET .................................... 29
CONTROLS LOCATED ON LOW VOLTAGE CABINET ................................................. 29
CONTROL LOCATED ON PROGRAMMABLE CONTROLLER CABINET ..................... 30
TYPICAL PROGRAMMABLE CONTROL CABINET ................................................................... 30
HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS ............................... 30
TYPICAL HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS ........................... 30
MISCELLANEOUS CONTROLS ..................................................................................... 31
HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL ...................................... 31
Hydraulic Reservoir Remote Fill Control Panel ............................................................................ 31
PORTABLE REMOTE PROPEL STATION (OPTIONAL) ................................................ 31
PORTABLE REMOTE PROPEL STATION ................................................................................. 31
RADIO REMOTE PROPEL STATION (OPTIONAL) ........................................................ 32
PRESTART CHECKS ................................................................................................................. 34
EXTERNAL INSPECTION ..................................................................................................... 34
ONBOARD INSPECTION ..................................................................................................... 36
PRESTART LUBRICATION ......................................................................................................... 38
START-UP ................................................................................................................................... 39
MACHINE START UP ............................................................................................................ 39
MACHINERY CHECK ...................................................................................................... 40
BREAK-IN OF NEW COMPONENTS ............................................................................. 40
ROTARY DRIVE UNIT BREAK-IN ............................................................................. 40
BI652203 2-3
Operation Section
HOIST/PULLDOWN GEARCASE BREAK-IN ........................................................... 40

ELECTRIC MOTOR BREAK-IN ................................................................................ 40
OPERATION ............................................................................................................................... 41
PROPELLING ....................................................................................................................... 41
DEFINITIONS .................................................................................................................. 41
PROPEL PROCEDURE ................................................................................................. 42
STRAIGHT PROPEL - FORWARD OR REVERSE .................................................................... 43
GRADUAL RIGHT HAND TURN ................................................................................................. 44
GRADUAL LEFT HAND TURN ................................................................................................... 44
COUNTER-ROTATION LEFT HAND TURN ................................................................................ 45
ENSURE GRADUAL TURNS ARE MADE - 15° INCREMENTS ................................................. 45
TOWING PROCEDURE ................................................................................................. 47
TOWING PROCEDURE ............................................................................................................. 47
CABLE REEL OPERATION .................................................................................................. 49
LEVELING ............................................................................................................................. 50
MAST RAISING AND LOWERING ......................................................................................... 51
MAST RAISING ................................................................................................................ 52
MAST STATUS SCREEN .......................................................................................................... 53
MAST LOWERING .......................................................................................................... 54
PULLDOWN MACHINERY OPERATION .............................................................................. 55
AUXILIARY WINCH OPERATION .......................................................................................... 56
PIPE RACK OPERATION ............................................................................................... 57
PIPE RACK OPERATION .......................................................................................................... 58
TOOL HANDLING .................................................................................................................. 60
PIPE LOADING AND UNLOADING .................................................................................. 60
DRILL TOOL STRING ASSEMBLY .................................................................................. 62
TOOL STRING .......................................................................................................................... 62
STABILIZER INSTALLATION ..................................................................................................... 63
BREAKOUT WRENCH OPERATION ................................................................................... 67
DRILL TOOL STRING DISASSEMBLY .................................................................................. 68
ADDING ADDITIONAL DRILL PIPE .................................................................................. 70
REMOVAL OF MULTIPLE SECTION DRILL PIPE ........................................................... 71
ANGLE DRILLING ................................................................................................................. 72
ANGLE DRILLING EQUIPMENT ................................................................................................ 72
PIPE POSITIONER ................................................................................................................... 73
JIB CRANE ................................................................................................................................ 74
DUST SUPPRESSION SYSTEM OPERATION .................................................................... 75
WATER INJECTION SYSTEM .................................................................................................. 76
DRILLING .............................................................................................................................. 77
VERTICAL DRILLING ...................................................................................................... 77
STARTING THE HOLE (COLLARING) ...................................................................... 78
NORMAL DRILLING ................................................................................................... 79
ENDING THE HOLE .................................................................................................. 81
ENDING THE HOLE (MULTIPLE PIPE SECTIONS) ................................................. 82
DRILLING DIFFICULT FORMATIONS ............................................................................. 82
UNCONSOLIDATED MATERIALS ................................................................................... 83
WET OR STICKY FORMATIONS ......................................................................................... 85
ANGLE DRILLING ................................................................................................................. 86
2-4 BI652203
Operation Section
PROGRAMMED DRILL CONTROL DRILLING ..................................................................... 87

PREPARING TO MOVE .................................................................................................. 88
MACHINE SHUTDOWN ........................................................................................................ 89
SHUT DOWN PROCEDURE ................................................................................... 89
SHORT TERM STORAGE ........................................................................................ 90
LONG TERM STORAGE ........................................................................................... 91
ATTENDED LONG TERM STORAGE ...................................................................... 92
UNATTENDED LONG TERM STORAGE .................................................................. 92
TOOL RECOVERY ..................................................................................................................... 93
DRILL STABILITY CHARTS ................................................................................................... 95
Drill Stability Chart - Special Propel Conditions .......................................................................... 95
Drill Stability Chart - Typical Propel Conditions ........................................................................... 96
BI652203 2-5
Operation Section
Section 2
Operation
GENERAL INFORMATION
This section of the manual will assist in the operation of this machine. It provides the operator with
the location and explanation of the controls, instructions for machine operation and certain
maneuvering techniques. Throughout this section and the remainder of the manual, the use of the
terms “LEFT, RIGHT, FRONT and REAR” refer to machine locations as viewed by the operator
sitting in the operator’s seat in the cab.
Safe operation of the machine minimizes production delays and costly damage to equipment.
Carefully study and follow all recommended procedures in this manual. Safety guidelines are
intended to prevent accidents from occurring and are provided in the interest of all mine personnel.
Overall safety depends upon the use of good judgment and the alertness of the entire mining
crew. Refer to Section 1 in this manual for specific safety precautions.
OPERATION NEAR ELECTRICAL TRANSMISSION LINES
DANGER: HIGH VOLTAGE! The following precautions shall be complied with

whenever operating around or near electrical distribution and
transmission lines.
Working in the vicinity of electrical power lines presents a very serious hazard and special precautions
must be taken. For purposes of this manual we are considering the entire machine or its load, in
any position, that can reach to within the minimum distance specified by local, state and federal
regulations.
Safe operating practices require that you maintain the maximum possible distance from the lines
and never violate the minimum clearances.
Before working in the vicinity of power lines, always take the following precautions:
• Always contact the owners of the power lines or the nearest electric utility before beginning
work.
• You and the electrical utility representative must jointly determine what specific precautions
must be taken to insure safety.
• It is the responsibility of the user and the electric utility to see that necessary precautions are
taken.
2-6 BI652203
Operation Section
• Consider all lines to be power lines and treat all power lines as energized even though it is
known that the power is shut off and the line is visibly grounded.
• Slow down the operating cycle. Reaction time may be too slow and distances may be misjudged.
• Caution all ground personnel to stand clear of the machine at all times.
• Use a signal person to guide the machine into close quarters. The sole responsibility of the
signal person is to observe the approach of the machine to the power line. The signal person
must be in direct communication with the operator and the operator must pay close attention
to the signals.
DANGER: HIGH VOLTAGE! Death or injury could result should any part of the
machine approach the minimum distance of an energized power line
specified by local, state and federal regulations.
CONTROLS - LOCATION AND FUNCTION
Regardless of previous experience, the new operator of any machine must become familiar with
the location and function of all of the operating controls before beginning to operate the machine.
Since this manual covers all possible controls that could be used on this machine, become familiar
with both this manual and the particular machine being operated.
CAUTION: Read and become familiar with this manual before attempting to
operate any of the machine controls. Pay particular attention to the
caution and warning statements, and any federal, state, local or
company safety rules relating to the machine. Failure to be aware of
and understand the hazards associated with the operation of the
controls may lead to death, personal injury or serious machine
damage.
BI652203 2-7
Operation Section
OPERATOR’S CONTROL CONSOLES
The operator’s control consoles are mounted on each side of the operator’s seat. The display
monitor is mounted on the left console, as shown. An auxiliary control console is located to the
right of the operator.
NOTE: The operator controls are all electric. The switches, potentiometers and joysticks
operate electric controls, electromechanical controls, or electrohydraulically actuated
valves on the machine.
OPERATOR’S CONTROL CONSOLE - OVERVIEW
NOTE: The panels with controls as shown on the following pages are typical of what could be
included on a console.
2-8 BI652203
Operation Section
LEFT CONTROL CONSOLE
LEFT CONTROL CONSOLE - OVERVIEW

BI652203 2-9
Operation Section
PROGRAMMED DRILL CONTROL PUSHBUTTON — OPTION
The programmed drill control pushbutton is used to activate or deactivate the programmed drill
control system on the machine.
OPERATING MODE SELECTOR SWITCH
This four-position switch is used to select one of three drill operating modes.
PROPEL - Enables all propel functions while disabling the winch, mast and all rotary and pulldown/
hoist functions.
DRILL - Enables all drilling functions while disabling all propel functions.
MAST/WINCH - Enables all mast and winch functions while disabling all propel functions.
REMOTE - Enables all propel functions to be operated from the remote control unit and disables
the cab operator controls.
PULLDOWN / HOIST SPEED RANGE SELECTOR SWITCH
The pulldown/hoist speed range selector switch controls the operating mode and speed range of
the hoist/pulldown drive when in a drilling mode of operation. The operating mode selector switch
must be in the DRILL position for this speed selector to function.
The switch is a four-position switch with the following designations: PULLDOWN, HOIST LOW,
HOIST HIGH, and PIPE RACK/JOINT.
In the PULLDOWN setting, which is used for normal drilling, full pulldown force is available but the
speed range for both pulldown and hoisting is limited to about 25 FPM (7.62 MPM).
The HOIST LOW and HOIST HIGH settings are used for pipe raising at high speeds.
In the HOIST LOW position full hoisting and lowering force is allowed, but the speed is allowed to
reach a higher level (typically about 25 FPM [7.62 MPM]).
In the HOIST HIGH position maximum head speed capability is allowed for both hoisting and lowering.
Typically about 75 FPM (22.86 MPM).
As a result of obtaining a higher speed, the hoist force capability at full speed is not as large as is
obtainable in the HOIST LOW position.
2-10 BI652203
Operation Section
In the PIPE RACK/JOINT position, the speed limit is reduced to 25 FPM (7.62 MPM) the down force
is limited to head and drill steel weight. This is the switch position for any pipe rack operation.
NOTE: Pipe rack operation also requires the rotary head assembly to be above the pipe racks
before operation is allowed.
HOIST BRAKE SWITCH
The hoist brake switch is a two-position switch used to set or release the hoist brake. This switch
must be in the RELEASE position before the hoist/pulldown drive is allowed to move the mast
machinery. Placing the switch into the SET position during the machine operation immediately disables
hoist/pulldown drive operation.
Under normal operating conditions, the hoist/pulldown speed rheostat should be set to “OFF” before
setting the brake.
NOTE: Applying the hoist brake is a spring action. After the HOIST BRAKE switch is turned to
the SET position, the brake coil is de-energized allowing the springs in the brake to
apply force to the brake discs.
When releasing the hoist brake, the brake coil is energized; compressing the springs,
which release pressure on the brake discs.
MAIN AIR VALVE SWITCH
This two-position switch is used to control the butterfly valve on the air compressor’s discharge
line. The operating mode switch must be in the DRILL position (in other modes it defaults to the
closed position).
OPEN - Opens the butterfly valve.
CLOSE - Closes the butterfly valve and causes the air compressor to run unloaded.
DEPTH INDICATOR RESET PUSH-BUTTON
The depth indicator reset push-button is used to zero out the depth meter, as shown on the operator’s
display monitor, when one hole is completed and another is to be started.
BI6522032-11
Operation Section
EMERGENCY STOP PUSH-BUTTON
The emergency stop push-button on the left control console is a large red mushroom head push-
button switch. Pressing the emergency stop push-button will shut-down the air compressor, hydraulic
systems and shut-off all controls. It will also simultaneously provide immediate mechanical braking.
This button should only be used in emergency situations.
CAUTION: PRESSING THIS BUTTON WHEN ANY DRIVE IS IN MOTION MAY

RESULT IN COMPONENT DAMAGE.
BIT VIEW HATCH SWITCH
This two-position switch is used to move the hatch for viewing the drill bit on the ground. Moving the
switch to the CLOSE position will close the hatch. Turning the switch to the OPEN position will
open the hatch.
LEFT JOYSTICK (DUAL FUNCTION) - PROPEL TRACK / WINCH
NOTE: A neutral lock is provided to prevent accidental movement of the joystick. The joystick
automatically returns to neutral and the lock is engaged anytime that the joystick is
released. To enable movement of the joystick, lift up on the lock (located below the
joystick knob). Speed of operation increases as the joystick’s position is deflected
farther away from neutral.
LEFT TRACK PROPEL - Use to control the propel speed and direction for the left track when
the OPERATING MODE switch is at the PROPEL position.
NOTE: The propel brake must be released, the jacks fully retracted, the boarding stairs up.
1. PUSH the joystick away from you to propel the left track forward.
2. PULL the joystick toward you to propel the left track in reverse.
WINCH - Use to control the winch hoist/lowering speed, along with the direction of
travel when the OPERATING MODE switch is in the MAST/WINCH position.
1. PUSH the joystick away from you to hoist or raise the winch hook.
2. PULL the joystick toward you to lower the winch hook.

2-12 BI652203
Operation Section
ROTARY DRIVE SPEED SELECTOR SWITCH
The rotary speed selector switch is a three position switch located above the rotary rheostat. This
switch determines the speed/torque range of the rotary motor. In the LOW position, the motor has
the highest torque capability but is limited in speed to about 85-100 RPM at the bit. In the HIGH
position, the motor has a higher speed capability (110-140 RPM range) but motor torque will be
less (typically 68% to 74%). The MEDIUM position provides for operation between the HIGH and
LOW positions.
The switch should be set to the range that most closely matches the desired bit speed range. The
LOW setting is sufficient for most conditions. If more speed is desired, select the desired range as
needed.
HOIST/PULLDOWN RHEOSTAT
The hoist/pulldown rheostat controls the speed and direction of the hoist-pulldown motor for hoisting
or lowering the rotary drive unit.
Turning the rheostat in the hoist direction from the “0” position will raise the rotary drive unit.
Maximum speed is available at full clockwise position.
Turning the rheostat in the pulldown direction from the “0” position will lower the rotary drive unit.
Maximum speed is available at full counterclockwise position.
NOTE: The rheostat utilizes a reference scale and pointer. When the rheostat is turned, the
pointer indicates, on the reference scale, the relative percentage of full speed being set.
The panels with controls as shown on the following pages are typical of what could be
included on a console.
DUST CONTROL ON/OFF SWITCH — OPTION
The dust collector switch is a two position switch used to start the fan on the dust collector hopper.
When the switch is in the OFF position, it will shut the dust collector fan motor off.
DUST CURTAIN SWITCH — OPTION
The dust curtain switch is a two-position switch. Turning the switch to the UP position will raise the
dust curtains. Turning it to the LOWER position will lower the dust curtains.
BI6522032-13
Operation Section
DUST CONTROL FLOW CONTROL — OPTION
This switch is not used on this application.
UNDER DECK SPRAYERS — OPTION

2-14 BI652203
Operation Section
RIGHT CONTROL CONSOLE
RIGHT CONTROL CONSOLE - OVERVIEW

BI6522032-15
Operation Section
PIPE POSITIONER SWITCH
The pipe positioner switch is a three-position spring-return switch. Turning the switch to the OVER
HOLE position will retract the positioner alignment cylinders. When fully retracted it will then extend
the positioner jaw cylinder to clamp the drill pipe. Turning the switch to the STORE position will
retract the jaw cylinder, then extend the positioner alignment cylinders to the stored position.
RIGHT JOYSTICK (TRIPLE FUNCTION) - PROPEL TRACK / PIPE RACK / MAST
NOTE: A neutral lock is provided to prevent accidental movement of the joystick. The neutral
lock must be released for this joystick control to function. The joystick automatically
returns to neutral and the lock is engaged anytime that the joystick is released. To
enable movement of the joystick, lift up on the lock located below the joystick knob.
Speed of operation increases as the joystick is displaced farther away from the neutral
(center) position.
PROPEL - Use to assign the propel speed and direction for the right track when the OPERATING
MODE switch is in the PROPEL position.
NOTE: The propel brake must be released, the jacks fully retracted, the boarding stairs up.
1. PUSH the joystick away from you to propel the right track forward.
2. PULL the joystick toward you to propel the right track in reverse.
PIPE RACK - Use to manually control the pipe rack overhole and stored functions when the
OPERATING MODE switch is in the DRILL position.
1. PUSH the joystick away from you to extend the pipe rack toward the overhole position.
2. PULL the joystick toward you to retract the pipe rack toward the stored position.
MAST - Use to control the mast raising and lowering functions when the OPERATING MODE
switch is in the MAST/WINCH position.
1. PUSH the joystick away from you to raise the mast.
2. PULL the joystick toward you to lower the mast.

2-16 BI652203
Operation Section
ROTARY SPEED POTENTIOMETER
The rotary speed potentiometer is used to control the speed and direction of the rotary drive motors.
The OPERATING MODE switch must be in the DRILL position for this control to function.
NOTE: Speed of operation increases as the potentiometer knob is rotated from OFF toward
MAXIMUM in either direction. Maximum obtainable speed is determined by the position
of the ROTARY DRIVE SPEED RANGE switch.
Rotate the knob clockwise from OFF toward MAXIMUM to rotate the tool string clockwise.
Rotate the knob counterclockwise from OFF toward MAXIMUM to rotate the tool string
counterclockwise.
DUST SEAL SLIDER SWITCH
This is a three-position spring-return switch which is used to initiate movement of the drill deck dust
seal. Turning the switch to the REAR position will cause the dust seal mechanism to move toward
the rear of the machine. Turning the switch to the FRONT position will cause the dust seal mechanism
to move toward the front of the machine. This switch is functional whenever the hydraulic pumps
are running, and is only used on machines with the angle hole drilling package.
PROPEL SPEED RANGE SELECTOR SWITCH
This two-position switch is used to set the propel speed. In the LOW position, the propel is in a low
speed range (about 35% of maximum). This position is used when maneuvering in tight spots and
in drilling patterns. NORMAL position is used when moving from one site to another.
HORN PUSH-BUTTON
The horn push-button is used to sound the warning horn of the machine.
BI6522032-17
Operation Section
TOOL WRENCH SWITCH
This three-position, spring-return-to-center-OFF switch is used to control the tool wrench functions.
Turning and holding the switch in the EXTEND position will cause the tool wrench to extend to
engage the drill pipe. Turning and holding the switch in the RETRACT position will retract the
wrench, releasing the drill pipe.
Allowing the switch to spring-return to the center OFF position stops the motion of the tool wrench
from any position in its normal range of motion.
BREAKOUT WRENCH SWITCH
This three-position, spring-return-to-center-OFF switch is used to operate the Breakout wrench

cylinder. The pipe rack must be in the stored position for this switch to function.
Turning and holding the switch in the EXTEND position will cause the breakout wrench to extend to
clamp the drill pipe and break the made up joint. Turning and holding the switch in the RETRACT
position will cause the tool to open, release the drill pipe, and retract the wrench.
Allowing the switch to spring return to the center OFF position stops the motion of the breakout
wrench cylinder from any position in its normal range or motion.
NOTE: The breakout wrench must be in the fully-retracted position before raising the pipe
handling arm.
PIPE RACK SELECTOR SWITCH
The pipe rack selector switch is a four-position switch used to determine which pipe rack will be
operated. For machines without a pipe rack or with only one pipe rack, this switch is not used.
BIT CAROUSEL SWITCH

2-18 BI652203
Operation Section
LEVELING JACK CONTROL SWITCHES
The three toggle switches are used to manually raise or lower the leveling jacks.
AUTO LEVEL SWITCH
The automatic leveling switch is a three-position spring return switch. Pressing the switch to the
EXTEND position will extend the leveling jack cylinders and raise the machine. Pressing the switch
to the RETRACT position will retract the cylinders and lower the machine. When this switch is
being used, manual leveling toggle switches are not functional.
NOTE: The automatic leveling switch is a spring-return switch. The switch must be held until
the desired action of the leveling jacks has been achieved. Releasing the switch will
allow it to return to the neutral position but the jacks will remain in the position to which
they were moved.
BI6522032-19
Operation Section
AUXILIARY CONTROL CONSOLE
AUXILIARY CONTROL CONSOLE
EXTERIOR LIGHTS
The two position switch is used to turn the exterior lights ON and OFF.
TRAIL CABLE TRIP PUSH-BUTTON
The large mushroom head push-button is used to completely cut power to the entire machine.
Pressing the TRAIL CABLE TRIP button will disable power to the drill from its source.
CAUTION: PRESSING THIS BUTTON WHEN ANY DRIVE IS IN MOTION MAY

RESULT IN COMPONENT DAMAGE.
2-20 BI652203
Operation Section
FLOOR DEFROST SWITCH
The floor defrost switch is a two-position switch used to turn the heater ON or OFF.
HEATER / VENT / AIR CONDITIONER CONTROLS
The heater/vent/air conditioner controls consist of three controls.
The HVAC control switch selects the mode being used and has the following positions: OFF, FAN,
HEAT, and COOL. A temperature rheostat is used to adjust cab air temperature.
The fan speed switch controls air circulation. The three positions are: OFF, LOW and HIGH.
BOARDING STAIRS SWITCH
The boarding stairs switch is a two-position switch. A similar switch is located at the stairs. Depending
upon the position of the stairs, the switch must be moved from its present position to the opposite
position for the stairs to change position.
RADIO / CD PLAYER
The AM/FM radio receiver includes a CD player.

BI6522032-21
Operation Section
OPERATOR’S DISPLAY
The operator’s display provides the operator with an interface to the machine and it’s functional
areas. From this informational display, the operator can make inputs that effect machine operation,
monitor systems and make system adjustments. Through this display terminal the operator will
receive pertinent fault data to identify potential problems and prevent machine damage.
OPERATOR’S DISPLAY MONITOR
Refer to a separate manual for further operational procedures for the Operator’s Display Monitor.
The display monitor is mounted on a tilt-swivel bracket on the left control console. Individual operators
can position the screen in any desired position.
DISPLAY AREA & INDICATORS
The display area of the monitor screen is the large area in the center of the screen. This area is
“touch sensitive.” All information will be displayed on this area either in a text format or in the form
of visual icons. The buttons and icons that appear on the screen will respond to touching the
screen in the appropriate area of the icon.
These icons and buttons will react by activating the screen, switch activation or display information
relevant to the icon. The switches and buttons will be covered in the following pages under the
screen topic in which they appear.
2-22 BI652203
Operation Section
The indicators on the lower portion of the screen area are indicators and sensors, which indicate
functionality of the operator display and it’s interface with the machine’s PLC controller. They have
no effect on machine operational use.
All of the machine controls can be found on the Operator’s Display Panel touch sensitive screen or
the left and right Control Consoles of the operator’s seat.
DISPLAY SCREENS
The information provided in the central area of the title screen is machine specific and lists the
machine serial number and a copyright notice relating to the control and display software.
TITLE SCREEN
The Main Menu Icons appear at the bottom of all screens allowing quick navigation.
BI6522032-23
Operation Section
LEVELING SCREEN
The Leveling Screen provides detail on the machine’s level and jack status.
STATUS SCREEN
The Status Screen is the primary operational information tool visible to the machine operator during
daily use of this machine. The controls available on this screen will provide the operator with the
information needed to view “at a glance” the status of items required for drilling, and make changes
in control settings. The Status Screen is most commonly used during the drilling process.
2-24 BI652203
Operation Section
ACTIVE ALARM
The Active Alarm screen will provide a list of all active alarms and faults that have been initiated on
the machine and have not been RESET. Once an alarm or fault has been sensed, these messages
will remain visible and WILL NOT be removed from this screen until it is RESET.
STATUS SCREEN with Pop-up Ribbon
Any new alarms will pop-up automatically any time that a machine sensor detects a newly occurring
fault or warning message.
BI6522032-25
Operation Section
ALARM HISTORY
The Alarm History screen retains a chronological record of all alarms. This screen provides pertinent
information; fault codes, date, time and a brief description for each account.
HELP NAVIGATION
2-26 BI652203
Operation Section
PLC DIAGNOSTICS
This screen provides access to PLC troubleshooting data screens. The status of all inputs and
outputs on each of the primary remote I/O racks can be retrieved from this screen by pressing the
node buttons on the left side of the display.
CALIBRATION and LIMITS

The Calibration and Limits screen is used to set most machine limits required to control the
movements of the machine.
WARNING: When this screen is active, mast machinery limits are disabled.
Extreme care must be taken to prevent mechanical damage to the
drill.
BI6522032-27
Operation Section
OPERATING HOURS
The Operating Hours/Fault Counter screen provides the operator with information on the number
of faults that have occurred since last RESET. It also provides the total operating hours.
FIELD TESTS
This screen is used for field testing of the electrical, hydraulic, and mechanical subsystems. The
tests on this screen allow certain protective circuits to be bypassed for test purposes.
2-28 BI652203
Operation Section
MACHINERY HOUSE CONTROLS
NOTE: The controls shown on the following illustrations are typical of the controls on a
machine. Because of the variations of controls that can be supplied for customers
needs, be sure to become acquainted with the controls on the cabinets of your
machine. All controls will be identified with nameplates.
LIGHTING LOAD CENTER
The lighting load center is located on the left side of the front wall of the machinery house.
The lighting load center contains the breakers to control the interior and exterior lights and various
auxiliary functions.
LIGHTING LOAD CENTER
Each breaker is labeled as to its particular function on any particular machine.
The controls are three-position lever operated circuit breakers. Moving the lever in one direction
(ON) will close the circuit, while moving it in the opposite direction (OFF) will open the circuit. The
center position is the tripped position. The breaker may be reset by moving the lever to the OFF
position and then back to the ON position.
BI6522032-29
Operation Section
CONTROLS LOCATED ON LOW VOLTAGE START CABINET
The low voltage start cabinet contains the breaker for

the main compressor. Turning the breaker to the ON
position will activate the compressor circuits, allowing
the compressor to be started.
CONTROLS LOCATED ON LOW VOLTAGE CABINET
The low voltage cabinet contains most of the

breakers for the auxiliary equipment on the drill.
Because of the variations of equipment supplied
on a particular drill, a list of typical controls which
might appear on the cabinet is shown in figure.
2-30 BI652203
Operation Section
CONTROL LOCATED ON PROGRAMMABLE CONTROLLER CABINET
The typical programmable controller cabinet contains controls as shown in figure.
TYPICAL PROGRAMMABLE CONTROL CABINET
HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS
Typical controls on the Hoist/Pulldown and Rotary Drive Control cabinets are shown in the figure
below.
TYPICAL HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS

BI6522032-31
Operation Section
MISCELLANEOUS CONTROLS
Located about the machine are various miscellaneous controls and monitors which would be used
with optional equipment or do not fit in the previously described groups.
HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL
The hydraulic reservoir remote fill control panel is used to monitor the reservoir as it is being filled.
The instructions for use of these controls are printed directly below the controls.
Hydraulic Reservoir Remote Fill Control Panel
PORTABLE REMOTE PROPEL STATION (Optional)

The portable remote propel station is located in an enclosure under the operator’s cab on the right
side of the machine. In addition to storing the portable station the enclosure includes 40 feet of
cable and an enabling switch to energize or de-energize the station. Another enabling switch and
plug in socket are located at the front right corner of the drill main frame. The station includes two
joysticks, one for each crawler frame; an emergency stop push-button; a propel speed selector;
and a red indicator which will light up when the station is energized.
PORTABLE REMOTE PROPEL STATION

2-32 BI652203
Operation Section
RADIO REMOTE PROPEL STATION (Optional)
The radio remote propel station is located in the operator’s cab. To enable the station, position the
operating mode switch located on the left control console to Remote Propel. The station includes
two joysticks, one for each crawler frame; an emergency stop push-button; function selector
switches as described below; and an indicator which will light up when communication is established
between the transmitter and the receiver. There is also an indicator light for the status of the e-stop
and the battery charge.
BI6522032-33
Operation Section
2-34 BI652203
Operation Section
PRESTART CHECKS
Before starting the drill, inspect it to ensure it is ready to be put into operation. Failure to make such
a routine check could result in unnecessary downtime. For example, an undetected oil leak could
result in a dry gear case, which would lead eventually to excessive gear wear or destruction,
seized bearings, or other mechanical problems. A few minutes spent inspecting the machine often
results in considerable savings in time and machine efficiency. This inspection should be performed
before each shift.
EXTERNAL INSPECTION
1. Check areas around and under the machine for signs of water or lubricant leaks. If single
droplets of water or lubricant are noticed, leakage is minimal. Determine the source of the leak
and make note of it on the log sheet. If pooling of water or lubricant is noticed, determine the
source and take remedial action immediately.
15
12
LH VIEW RH VIEW
14
FRONT OF FRONT OF
MACHINE MACHINE
9 9
13
11 11
16 10 10 16
6 8 1 3 2 4 8 5 8 4 2 3 1 8 6
7 7 insp6640
BI6522032-35
Operation Section
2. Inspect the crawler belts for broken or cracked pads, missing lock pins, loose track pins, and
proper crawler belt tension.
3. Check the drive tumbler gearcase, hydraulic motor and hoses for leaks. Check the lubricant
level in the drive tumbler gearcase.
4. Inspect the crawler frames for cracks and dirt or ice buildup. Check the rollers and tumblers
for proper lubrication, free operation, and dirt or ice buildup. Check axle attachment pins and
bolts.
5. Check the dust curtains for tears. Be sure that the curtains are not frozen to the ground or
covered with cuttings.
6. Inspect the trail cable for proper placement out of the line of travel of the drill. Inspect the
insulation for cuts or abrasion. Make sure the cable is kept out of water and away from sharp
rocks. Have an electrician inspect the strain relief device and the condition of the cable where
it enters the machine.
CAUTION: The machine trail cable carries a lethal voltage. Handle the cable in an
approved manner with approved rubber gloves and insulated hooks
or tongs.
7. Inspect the underside of the machine for cracks, loose hoses or wires, dirt or ice accumulation,
or other deterioration or damage. If loose wires are noted, do not touch them but notify an
electrician immediately.
8. Inspect the leveling jack spuds for proper lubricant covering. Inspect the leveling jack pads for
cracks, broken or missing pins, or excessive dirt accumulation.
9. Inspect the mast braces and locking pins. Replace missing or defective components
immediately. Verify that all adjusting bolts are properly adjusted. Check all hoses and cylinders
for leaking.
CAUTION: Use a safety belt and lanyard to protect against falls when climbing
on the mast braces or working on the machinery house roof.
10. Inspect the mast hinge pins for loose or missing keepers or bolts. Replace missing or damaged
parts immediately. Check the pins for sufficient lubrication and lubricate if necessary.
11. Inspect the mast hoist cylinders for loose or missing pins or keepers, oil leaks, damaged
hoses or structural damage. Repair or replace any missing or damaged components
immediately.
12. Inspect the mast structure for bent or broken chords or plates, loose or broken parts, proper
rack lubrication or excessive rack wear. Inspect ladders, handrails and platforms for broken
or missing parts. Repair or replace broken or missing parts immediately.
13. Check the main air flex hose, lubrication lines, and electric lines running from the mast to the
rotary drive/pulldown unit for interference with the mast or excessive wear or leaks.
2-36 BI652203
Operation Section
14. Check the safety restraint cables on the mast. Be certain that the cables and supports are in
good repair with no cracks, missing or loose hardware or any damage that could affect their
effectiveness.
15. Every 160 hours inspect the upper auxiliary winch sheaves. All pins, keepers and hardware
should be secured.
16. Check the machinery house air filtering fan duct to see that it is clear of obstructions.
17. Inspect dust collector hoses for integrity.
ONBOARD INSPECTION
1. Inspect the air compressor lubrication lines for leaks. Correct any leaks found immediately.
2. Check the condition of the air compressor intake filter. Replace the filter cartridge if the red flag
is visible in the service indicator. Empty the dust hopper and clean the pre-cleaner element.
Inspect the housing and ductwork for damage or leaks. Repair or replace leaking components.
3. Check the oil level in the hydraulic tank. Fill the tank to the proper level as described on the
instruction plate on the tank.
4. Check hydraulic system for leaks. Correct all leaks immediately and clean up all oil spills
immediately.
5. If the machine is equipped with a bit lubricator for the main air system, check that the lubricator
is full.
6. Inspect the automatic lubrication central pumping stations for proper operation. Check the
supply of lubricant; refill tank as necessary.
BI6522032-37
Operation Section
7. Close and lock all electrical cabinet doors.
CAUTION: Assume all parts inside of the electrical cabinets are energized. All
electrical components should be serviced by qualified electrical
personnel only.
8. Inspect the compressor radiator and fan. Check for signs of deterioration or damage to hoses,
valves, fittings, etc. Check for leaks at all joints. Check the radiator core for blockage by dust,
dirt, leaves, paper, etc. and clean as necessary
9. Check the operator’s display terminal for any faults.
10. Inspect the machinery house for general cleanliness. Clean all dirt and debris from the
machinery house.
CAUTION: Do not use compressed air to clean the machinery house.

Compressed air will only move the dirt around. Use a vacuum cleaner
to remove the dirt from the machine. Failure to clean the inside of
the machinery house will cause damage to many of the components
located there.
11. Inspect the auxiliary winch and auxiliary winch line.

12. Check the oil level in the pump drive gearbox. Fill with recommended oil to the proper level.
13. Check all controls for free operation. Return all controls to the OFF or SET position.
14. Inspect the operator’s cab for housekeeping and cleanliness. Clean dirt and debris from the
cab. Clean the windows to give full visibility for proper operation.
CAUTION: Do not use compressed air to clean the operator’s cab. Compressed
air will only move the dirt around. Use a vacuum cleaner to remove
the dirt from the cab.
15. Inspect the tool wrenches for free operation, broken or missing parts, proper lubrication,
lubricant leaks or dirt accumulation. Repair or replace parts as necessary and clean the
drilling platform.
CAUTION: Before working near or under the rotary drive/pulldown unit, make
sure all of the operator’s controls are off and tagged and the hoist
brake set to prevent movement of the unit. Serious personal injury or
death could result should the rotary drive/pulldown unit fall when
personnel are working near or under it.
16. Inspect the automatic breakout wrench for free operation, broken or missing parts, proper
lubrication, lubricant leaks or excessive dirt accumulation. Repair or replace parts as necessary.
Be certain that the breakout wrench is retracted.
2-38 BI652203
Operation Section
17. Inspect the pipe racks for broken or missing parts, proper operation, dirt accumulation, or
lubricant leaks. Be certain that the upper gate is closed and that the rack is in the stored
position.
18. Inspect the guide bushing for excessive wear or dirt accumulation. Also inspect the retainer
lugs to be sure they are intact. Do not operate the machine without both retainer lugs intact
and securely welded to the deck.
19. Inspect the tool string for excessive wear, dirt accumulation, bent pipe and secure joints. The
bit cones and bearing should be in good condition. Manually turn the cones to make sure
they turn freely.
20. Inspect the rotary gear case for lubricant leaks, damaged lines, dirt accumulation and other
damaged or missing parts. Check the lubricant level in the gearbox. Fill to the recommended
level with an approved gear lubricant. Check the rotary motor ventilation inlets for leaves,
paper, rags, etc. blocking the flow of air.
21. Inspect the rotary drive unit for excessive wear or dirt accumulation. Inspect the guide rollers
for proper adjustment and excessive wear. Check for loose or missing bolts and bent or
cracked structural members.
22. Inspect the pulldown unit for excessive wear or dirt accumulation. Inspect the rack pinions for
excessive wear, proper lubrication, and tight retainer bolts. Inspect the guide rollers for proper
adjustment and excessive wear.
23. Inspect the pulldown gearcase for lubricant leaks, dirt accumulation and other damaged or
missing parts. Check the lubricant level in the gearbox. Fill to recommended level with an
approved gear lubricant . Check the pulldown motor ventilation inlets for leaves, papers, rags,
etc. blocking the flow of air.
24. Check the hoist brake for proper operation.
25. Check the dust or chip deflector for loose or missing parts, excessive wear or dirt accumulation.
The deflector should seal around the drill pipe securely.
26. If the machine is equipped with a fire suppression system, perform any applicable checks or
inspection as described in the fire suppression system owner’s manual.
27. If the machine is equipped with a dust collector system, inspect the filter dessicant color.
Change dessicant if required.
PRESTART LUBRICATION
Lubrication is an extremely important job. Most drills come equipped with automatic lubrication
systems that lubricate most of the necessary points at regular intervals. These systems, although
automatic, are not foolproof. Broken lines, dirty lubricant, faulty feeders, and a whole range of other
problems can cause wearing parts to loose lubrication. For this reason, it is important that all
lubrication points be inspected every shift to verify that they are receiving lubrication. Also, there are
several points for lubrication that either need lubrication very infrequently, or are not possible to pipe
into the automatic system. These points will need lubrication applied manually.
The lube charts in Section 3 of this manual provide the location and frequency of lubrication.
BI6522032-39
Operation Section
START-UP
Start-up of the drill is not a difficult operation, but it is very important. Improper start-up could cause
various safety and operating difficulties as well as damage to the machine. Following the step-by-
step procedure listed below to start the machine will help reduce the possibility of accidental injury
or machine damage.
MACHINE START UP
NOTE: THE MACHINE IS TO BE STARTED ONLY AFTER THE PRESTART INSPECTION

AND LUBRICATION AS DETAILED EARLIER IN THIS SECTION, HAVE BEEN
COMPLETED.
1. Go into the operator’s cab and verify that all controls on the operator’s console are in the off or
neutral position. Be sure that the EMERGENCY STOP push-button is in the pulled-up position.
NOTE: ON SOME MACHINES THERE ARE TWO OR MORE EMERGENCY STOP PUSH-
BUTTONS. BE SURE THESE PUSH-BUTTONS ARE IN THE PULLED-UP POSITION.
2. Go to the machinery house to the low voltage start cabinet. Turn on the main compressor
breaker.
3. On the low voltage cabinet turn all the breakers to the ON position.
4. On the programmable controller cabinet verify that the lockout control push-button is in the
RELEASED position.
5. Press the air compressor start push-button on the programmable controller cabinet to start the
main compressor.
NOTE: If the ambient temperature is below 32°F (0°C), the machine will normally use special
fluids in the hydraulic system and/or heaters for the system.
When the machine is shutdown, temporarily or for an extended time, power should be left on the
machine to maintain heater operation. If power is removed at shutdown, the machine fluids should
be warmed to at least 32°F (0°C) before attempting to start the machine.
2-40 BI652203
Operation Section
MACHINERY CHECK
The following is a list of points and equipment that should be checked for proper operation immediately
following start-up of the drill. If operating difficulties are not found during this procedure, they probably
will not be noticed until some point in time at which the system or component will cease to function
and cause serious damage to the machine.
1. Check the main air system for leaks.
2. Verify that the air compressor radiator fan is operating correctly. Check the coolant system for
leaks.
3. Check for leaks in the hydraulic system.
BREAK-IN OF NEW COMPONENTS
When a machine is new, is returned to service after a long period of storage, or is returned to
service after major repairs, certain precautions must be taken upon initial start-up and for a time
following the start-up. These precautions are necessary to insure that the full service life of the
components is realized.
ROTARY DRIVE UNIT BREAK-IN
Break-in of the rotary gear case is limited to reduced loading during the first 100 hours of operation
and a complete oil change at the end of the break-in period.
This break-in period applies only to new gearcases or gearcases in which a new gear has been
installed.
HOIST/PULLDOWN GEARCASE BREAK-IN
Break-in for the hoist/pulldown gearcase is limited to reduced loading during the first 100 hours of
operation and a complete oil change at the end of the break-in period.
The break-in period applies only to new gearcase or gearcases in which a new gear has been
installed.
ELECTRIC MOTOR BREAK-IN
Break-in of the rotary and hoist/pulldown motors is limited to reduced loading and inspection for the
first 8 hours of operation. This break-in period is intended to spot any problems in the motors before
BI6522032-41
Operation Section
they lead to serious damage to the motors or the machine. Inspection should include monitoring
the motor temperature and listening for unusual noises which might indicate a problem. Inspection
should also include verifying that all blower vents and intake openings are open.
OPERATION
Operation of this machine is the same as the operation of any other drill. But just because the
machines operate the same in principle does not mean they operate the same in all respects. For
this reason it is important that the operator becomes familiar with the particular machine that is being
operated.
The purpose of this section of the operator’s manual is to detail the procedures involved in operating
many of the major components and preparing to drill a hole. The actual drilling procedure is detailed
later within this section.
Become familiar with the controls and learn to operate at reduced speeds. As the machine and
drilling cycle become more familiar, increase speeds gradually to the full operating capability of the
machine.
The most important reason to operate slowly at first is safety. Operating at full speed means that
things happen quickly, perhaps more quickly than expected. This unexpected operation of equipment
can very easily lead to an accident.
For the purpose of this manual, we will assume that the drill has been left in the proper condition
for operating. If this is not the case, complete the prestart checks and start the machine using the
procedures as outlined.
PROPELLING
DEFINITIONS
“Listing” is a machine geometry condition which can occur on vehicles which have a pivotal axle
and a fixed axle. It is that condition when the upper works is tilting over onto the pivotal axle,
lifting one side of the fixed axle.
“Tipping” is defined as the point of impending overturning. A machine can tip to the rear without
listing first. Under all other conditions, the machine will “list” before tipping.
“Maneuvering slope” is the grade on which the machine can be propelled in any direction without
listing or tipping.
2-42 BI652203
Operation Section
PROPEL PROCEDURE
Before beginning the propel operation, the operator should first inspect the travel route for large
rocks, deep ruts, or uneven contours. When working on a grade, verify the slope and compare to
the allowable maneuvering slope limits at the end of this section.
CAUTION: Do not attempt to maneuver or steer the machine on grades which

exceed the allowable maneuvering slopes without consulting the
special propel section. Failure to follow these instructions could
result in a machine tip-over, damaging the equipment and resulting in
possible serious injury or death.
The operator’s display terminal leveling/propel screen should be monitored during propel to make
sure the allowable machine stability limits are not exceeded.
Once it has been verified that the travel route is in good condition, the machine is now ready to
propel.
NOTE: This machine should only be propelled long distances with the mast fully lowered, fully
raised and locked, or locked at an ANGLE HOLE setting.
For long propels of 1,000 feet (304.8 meters) or more, or if the machine is to be propelled over
grades which approach the allowable stability limits, the tool string should be disassembled, the
rotary drive unit lowered, and the mast lowered. This achieves the most STABLE condition for a
machine against tipping and also reduces stresses in the mast structure.
For long propels of 1,000 feet (304.8 meters) or more, the temperature of the undercarriage
components should be monitored. The lower rollers, take-up tumblers and propel planetaries should
operate below 95 degrees C. The propel motor should operate below 90 degrees C. If these
temperature limits are reached, stop the machine and allow the track components to cool down.
Note that propelling in low speed reduces the heat build up in these components.
If while propelling with the MAST-DOWN and the HEAD-DOWN the drill starts to list, it will continue
to list until the upper works contacts the pivotal axle. The machine will reach equilibrium when the
upper works contacts the pivotal axle and WILL NOT TIP OVER. With the mast-down and the
head-down, full listing will NOT cause the machine to tip over. The operator should attempt to
propel toward a more level area on the bench to correct this condition.
All of the stability values shown are based on a fully loaded machine (i.e. full water tank, cable on
cable reel, full compliment of specified pipe, all oils and operating fluids) as originally specified by
the Customer and shipped by manufacturer.
This machine is propelled using the controls on the operator’s console in the operator’s cab or
radio controlled from the remote propel station outside the machine.
BI6522032-43
Operation Section
1. Verify that the hoist brake is set. Verify that the tool string is clamped with the tool wrenches to
prevent the tools from moving during the propel operation. Also, verify that the tool string is
hoisted to a position to avoid striking the ground when the machine is propelled. Verify that the
leveling jacks are fully retracted and that the dust curtains are fully raised. Verify that the
boarding stair is raised.
2. Move the operating mode selector switch to PROPEL or REMOTE PROPEL. The remote
propel is radio controlled.
3. Press the drill/propel control ON push-button. The automatic leveling/propel screen will appear
on the operator’s display terminal. If the propelling is being done from the remote propel
station, turn the enabling key switch to the ENABLE position.
4. At the control console or remote propel station, turn the propel selector switch to the SLOW
SPEED position.
NOTE: There are two propel speeds available to the operator, SLOW SPEED (MAX = 0.27
MPH; 0.44 KM/H) and NORMAL (MAX = 0.9 MPH; 1.45 KM/H). For the inexperienced
operator or for maneuvering in tight spots and in drill patterns, the SLOW SPEED
setting allows for a more relaxed control operation.
When the operator becomes more proficient or when moving from one site to another, the increased
speed of normal propel is used.
5. To propel straight forward lift up on both joysticks to unlatch them and release the propel
brakes, then move both joysticks slowly forward. Speed is increased as the levers are moved
forward. To propel straight in reverse pull both joysticks slowly to the rear. Speed is increased
as the levers are pulled.
STRAIGHT PROPEL - FORWARD OR REVERSE

2-44 BI652203
Operation Section
6. To make a gradual forward right turn, leave the right joystick in neutral and operate the left
joystick forward.
GRADUAL RIGHT HAND TURN
GRADUAL LEFT HAND TURN
7. To make a gradual forward left turn, leave the left joystick in neutral and operate the right
joystick forward.
BI6522032-45
Operation Section
8. Gradual turns should be done in steps of 15 degrees each. After turning the machine a maximum
of 15 degrees, the machine should be propelled straight for about one-half of the length of the
machine to clear the crawler belts of dirt and rocks. Turning the drill in more than 15 degree
increments will subject the crawler belts to severe strain.
COUNTER-ROTATION LEFT HAND TURN
9. To make a sharp counter-rotation turn, push the left joystick forward and pull the right joystick
to the rear. To make a turn to the left, push the right joystick forward and pull the left joystick
to the rear.
ENSURE GRADUAL TURNS ARE MADE - 15° INCREMENTS
CAUTION: ENSURE THAT THE TURN IS STOPPED EVERY 15 DEGREES AND

THAT THE MACHINE IS PROPELLED FORWARD, OR REARWARD, AT
LEAST TEN FEET PRIOR TO RESUMING THE TURN. MAKING
GRADUAL TURNS WILL GREATLY EXTEND THE SERVICE LIFE OF
THE TRACKS.
2-46 BI652203
Operation Section
NOTE: When using the counter-rotation method for turning, have a helper available who can
watch that the trail cable does not get fouled and/or torn from the main junction box or
cable reel.
NOTE: The ability of the machine to counter rotate is dependent on the surface on which the
machine is setting. A soft surface will cause the crawlers to dig in and machine to bog
down.
NOTE: The propel brakes are released whenever either joystick is lifted from its mechanical
neutral detent. The propel brakes are set when both joysticks are returned to their
neutral detent and released.
TOWING PROCEDURE
CAUTION: Personal injury or death could result when towing a disabled machine
incorrectly. Block the machine to prevent movement before final
drives are disengaged. The machine can roll free if the machine is
not blocked properly. With final drives disengaged, the machine
cannot be stopped or steered. Follow the recommendations below, to
properly perform the towing procedure.
NOTE: To tow the machine, both final drives must be disengaged. Do not operate the travel
motors with the final drives disengaged. Damage could result.
These towing instructions are for moving a disabled machine for a short distance at low speed.
Move the machine at a speed of 1.77 km/h (1.1 mph) or less to a convenient location for repair.
NOTE: Do not tow at speeds greater than 1.77 km/h (1.1 mph) Excessive planetary gearbox
heating can occur. Damage to the roller and final drive will occur if temperatures to
these components exceed 70 degrees Celcius (158 degrees Fahrenheit).
Do not allow an operator to be on the machine that is being towed.

Before towing the machine, make sure the tow bar is in good condition. Make sure the tow bar has
enough strength for the towing procedure involved.
The strength of the tow bar should be at least 150 percent of the gross weight of the towing machine.
This requirement is for a disabled machine either stuck in the mud or for towing on a grade.
CAUTION: Do not use a chain for pulling a disabled machine. Chain links can
break and cause serious injury or death.
Position an observer at an adequate distance from the machines in order to watch the pulling
procedure. The observer can stop the procedure if the towing becomes unstable or the equipment
separates. Stop pulling whenever the towing machine moves without moving the towed machine.
BI6522032-47
Operation Section
Do not exceed a 30 degree angle from the straight ahead position.
Quick machine movement could overload the tow bar. This could cause the tow bar to fail. Gradual,
steady machine movement will be more effective.
Normally, the towing machine should be as large as the disabled machine. Make sure the towing
machine has enough brake capacity, enough weight, and enough power. The towing machine
must be able to control both machines for the grade involved and for the distance involved.
Equipment which provides sufficient control and sufficient braking must be used when moving a
disabled machine downhill. This may require a larger towing machine or additional machines that
are connected to the rear of the disabled machine. This will prevent the machine from rolling away
out of control.
All situation requirements cannot be listed. Minimal towing machine capacity is required on smooth,
level surfaces. On inclines in poor condition or on surfaces in poor condition, maximum towing
machine capacity is required.
Consult your Caterpillar dealer for the equipment necessary for towing a disabled machine.
1. Secure the machine by blocking tracks.
Notice: Optimum towing conditions will include lowered mast and retracting electric power
cable to the fullest extent possible.
2. Secure the tow bar to the towing vehicle.

2-48 BI652203
Operation Section
B C
Disengagement Flange Detail

D
B B
C c
3. Disconnect the drive sprocket gearbox from the propel motor as follows:
A. Ensure that the propel pump controls are in neutral position

B. Remove 2 M8x1.25x70 bolts from the disengagement flange
C. Insert 2 M8x1.25x120mm bolts in the original holes to secure the flange.
D. Thread two M10x1.5x70mm bolts equally into the two threaded holes in the
disengagement flange. Tighten the bolts until the flange is retracted 47 mm
Notice: To avoid damage of gear teeth it is absolutely necessary that disengagement and re-
engagement is carried out during standstill.
4. When towing is completed, reverse the above procedure.

BI6522032-49
Operation Section
CABLE REEL OPERATION
When the cable reel switch is in the AUTO position, is designed to pick up trail cable as the drill
moves toward its power source. It is not designed to drag the trail cable over the ground.
The line pull is proportional to operating pressure. The correct line pull is when there is sufficient
pull on the cable to wind it on the reel, but not too great to put unnecessary strain on the trail cable.
The line speed is dependent on the volume of hydraulic oil flowing through the system. The correct
line speed is slightly faster than the travel speed of the drill.
To manually operate the cable reel, proceed as follows:
1. Start the main air compressor motor.
2. To spool the trail cable onto the reel, turn the cable reel switch to the REEL IN position.
3. To spool the trail cable off of the reel, turn the cable reel switch to the REEL OUT position.
2-50 BI652203
Operation Section
LEVELING
To level the drill, proceed as follows:
1. Place the machine in the proper location to drill the

required hole. Verify that the leveling jack pads will
rest on solid footing. Cut or fill or reposition as
necessary to achieve solid footing. Maximum angle
for jack pad is 17°.
2. The operating mode selector switch must be in the

DRILL position and the main air compressor motor
must be energized.
NOTE: Normally the machine will be leveled using the

automatic leveling switch, Step 3. For manual
leveling use Step 4 through 7.
3. To level the machine automatically verify that

the operating mode selector switch is in the
drill mode, then turn the automatic leveling
switch to the EXTEND position and hold the
switch in that position. The Automatic Leveling/
Propel screen will come on automatically
on the operator’s display terminal. Use
the screen to monitor the drill as it is being
leveled. The jack cylinders will extend and
raise and level the machine. When the
machine is raised and leveled, release the
switch and it will spring return to the CENTER
or OFF position. This procedure can be
performed by the operator while he is seated
at the main operator’s console.
BI6522032-51
Operation Section
4. To level the machine manually, use the three jack switches and the automatic leveling screen
on the operator’s display terminal. The operator uses control switches on the right-hand
console and observes the operator’s display screen.
5. Lower all four leveling jacks until they are resting on the ground. Then, starting with the low
side (left or right) of the drill, slowly lower the jacks until the weight of the machine is resting on
them. The leveling jack controls should be operated in pairs while doing this operation. This
reduces the twisting of the drill frame. Once the weight of the machine is resting on the
downhill side leveling jacks, slowly lower the uphill side leveling jacks until the machine weight
is resting on them. The machine need not be raised a great deal during this operation, since
the purpose is only to get the weight of the machine resting on the leveling jacks.
CAUTION: During this and subsequent leveling procedures, it is important that

the drill stays as close to level as possible. Care should be taken
especially when working on steep grades.
6. Once the machine weight is resting on the leveling jacks, the machine may be leveled. Starting
with the downhill side of the machine, lower the two side leveling jacks to bring the machine
into side-to-side level as observed on the operator’s display terminal screen. Then, once the
machine is level from side-to-side, operate the leveling jack controls for the downhill end of
the machine to bring the machine into level end-to-end as observed on the operator’s display
terminal screen.
7. Once the machine is level, make sure that the weight of the machine is off of the crawlers.
The preferred method of doing this is to raise the machine until the closest point of the lower
rollers to the crawler belts is 2" to 7" (5.1 to 17.8 cm). This assures that the machine is
resting on the leveling jacks while maintaining a low center of gravity.
MAST RAISING AND LOWERING
The mast on this machine is normally left in the raised position for most situations including propelling
from hole to hole on a blast pattern. Lowering the mast is necessary under three conditions:
1. Maintenance work is not possible or too dangerous to perform with the mast up.
2. Long moves over 1,000 feet (304 m) where the drill will be towed into position, propelled at
high speed, or be loaded onto a trailer.
3. Any situation when steep slopes are encountered. Contact Caterpillar Global Mining Service
Department if unsure of slope limitation for propelling.
2-52 BI652203
Operation Section
MAST RAISING
CAUTION: Raising or lowering the mast is a two-person job. Do not attempt to

raise or lower the mast without the assistance of a helper familiar
with the procedures involved.
CAUTION: During the mast raising procedure personnel should be kept clear of
the machine and the area immediately surrounding the machine,
especially the front of the machine. No one is to be allowed on the
mast, operator’s cab roof, or machinery house roof while the mast is
in the air. Failure to heed this caution may result in the death or
serious injury of personnel struck by the mast should it fall for some
reason.
CAUTION: Limitations exist as to the length, diameter, wall thickness and

number of drill pipes that may be stored in the pipe racks when
raising or lowering the mast. Refer to the pipe size limitation chart in
the appendix before attempting to raise or lower the mast. Failure to
comply with these limitations will overload the mast, mast support
and hydraulic system possibly causing loss of control of the mast.
1. Inspect the mast and machine exterior to ensure that all wires, hoses, cables, etc. are clear of
the machine to prevent damage to the machine or equipment during the raising procedure.
Check that the mast cylinder pins, mast hinge pins, and mast brace pins are in place and
secured. Verify on the operator’s display terminal operator’s display screen that no reference
to A-frame pins is shown. Verify that the operating mode selector switch is in the DRILL
mode.
2. The main air compressor motor must be energized. Move the operation selector switch to
the MAST/WINCH position. Slowly raise the mast by lifting and then slowly pushing the mast
joystick, located on the right control console, forward. As the mast reaches an angle of 70
degrees it will begin to go over center and tend to come into the vertical position by itself.
Care should be used once the mast has gone over center since the speed of the mast will
increase sharply.
CAUTION: The mast joystick should be moved away from and returned to the
neutral position very slowly. Sudden starts and stops can be
damaging to the mast and hydraulic system. Be extremely cautious
as the mast approaches 70 degrees as once the mast goes over
center only a very slight movement of the joystick is necessary to
cause motion in the mast.
BI6522032-53
Operation Section
NOTE: Pay close attention to the hoses, wires and cables that run between the mast support
and the mast to prevent damage to the machine as the mast is being raised. Have a
helper watch from a safe position on the left side of the machine as the mast is going
up.
3. Once the mast is vertical, move the mast lock switch located on the mast screen on the
operator’s display to the LOCK position to lock the mast in the vertical position. Mast Pins
Locked light on operator’s display screen will illuminate when mast is locked in position. Turn
the mast brace lock switch to the LOCKED position to secure the mast and brace in the
vertical position.
NOTE: When moving the mast for angle hole drilling, on machines with mast lengths of 65 ft
(19.8 m) or more, the drill pipe must be stored in the racks and the rotary head lowered
to its lowest position.
4. If the mast is to be set up for angle drilling move the A-frame lock switch and the mast brace
lock switch to the UNLOCK position to release the A-frame front leg lock pin and mast brace
lock pins. The readout (A-Frame Pins Unlocked and Mast Brace Pin Unlocked) will show up
on the mast status screen on operator’s display screen.
MAST STATUS SCREEN
5. Verify that the operation mode selector switch is still in the mast/winch position, then lift and
pull the mast joystick slowly to the rear. Slowly lower the mast to the desired drilling angle,
then turn the mast brace lock switch to the LOCKED position to secure the mast and brace
in the desired position.
2-54 BI652203
Operation Section
MAST LOWERING
NOTE: Refer to cautions at beginning of mast raising.
To lower the mast:
1. Level the machine.
2. Remove the drill pipe from the rotary drive unit and store it in the pipe racks. Remove the bit
and stabilizer from the machine. Clear the drill deck of all tools and materials which could fall
off during the lowering procedure. Secure the auxiliary winch hook. Be sure the auxiliary
winch line is secured to the mast. Raise the dust curtains. Lower the rotary/pulldown unit to
its lowest position.
3. Check the condition of the mast hinge pins, lugs and cylinder pins.
4. If the machine is set up for angle drilling and the mast is at an angle proceed to step 4. If the
machine is set up for vertical drilling proceed to step 5.
5. Turn the mast brace lock switch to the UNLOCK position to release the mast lock pins, then
raise the mast to the vertical position. Turn the A-frame lock switch to the LOCK position to
lock the A-frame front leg. The readout (A-Frame Pins Locked) on the operator’s display will
appear when the A-frame pins are in the LOCKED position. Now proceed to step 5 to lower
the mast.
6. If the mast lock pins and/or mast brace lock switch have not been released, turn the switches
to the UNLOCK position to release the pins. The readout (Mast Pins Unlocked and Mast
Brace Pins Unlocked) will be shown on the operator’s display when the pins are released.
7. Slowly lower the mast by lifting and then pulling the joystick to the rear. As the mast moves
away from the vertical position, its speed will increase. Gently reduce the lowering speed by
moving the joystick toward neutral.
CAUTION: The joystick should be moved away from and returned to the neutral
position very slowly. Sudden starts and stops can be damaging to the
mast hydraulic system. Be extremely cautious as the mast
approaches the mast rests, as only a slight movement of the control
is necessary to cause motion in the mast. Lay the mast in the mast
rests gently to prevent damage to the mast or machine house.
BI6522032-55
Operation Section
NOTE: Pay close attention to the hoses, wires and cables that run between the mast support
and the mast to prevent damage to the machine as the mast is being lowered. Have
the helper observe the machine from a safe position on the left side of the machine as
the mast is coming down.
NOTE: Do not allow the mast, especially if near horizontal to lower too quickly. Damage may
result from the mast hitting the mast rests too hard.
8. Once the mast is resting in the mast rests, inspect the mast and the mast support to verify that
no hoses, wires or cables are kinked or damaged. Repair any damages found immediately.
PULLDOWN MACHINERY OPERATION
Use of the pulldown machinery is necessary during the tool handling and the drilling procedures.
The pulldown machinery supplies power to either raise or lower the rotary/pulldown unit. Power is
supplied to the pulldown gearbox by an electric motor.
To operate the hoist/pulldown machinery proceed as follows;
1. Move the operating mode selector switch to the

DRILL position.
2. Turn the hoist/pulldown selector switch to either

PULLDOWN, HOIST HIGH, HOIST LOW, or PIPE
RACK/JOINT.
For this procedure, turn the switch to the PULLDOWN position.
For a review of each switch position, refer to HOIST/PULLDOWN SPEED SELECTOR SWITCH.
3. Press the drill/propel control ON push-button. The Control Enable indicator will show on the
operator’s display screen.
4. Turn the hoist brake switch to the RELEASE position. The Head Brake Released indicator will
appear on operator’s display screen.
5. Rotate the hoist/pulldown rheostat in the hoist direction to hoist the rotary/pulldown unit. The
farther the rheostat is turned to the right the faster the unit will be raised.
2-56 BI652203
Operation Section
6. Rotate the pulldown force rheostat in the pulldown direction to lower the rotary/pulldown unit.
The farther the rheostat is turned to the left the faster the unit will be lowered.
7. When the hoist/pulldown operations are complete, set the hoist/pulldown speed rheostat to
the OFF position and then turn the hoist brake switch to the SET position.
CAUTION: Whenever the hoist/pulldown speed rheostat is in the OFF position,

the hoist brake switch must be in the SET position to prevent the
rotary/pulldown unit from creeping downward due to the weight of
the unit.
AUXILIARY WINCH OPERATION
To operate the auxiliary winch proceed as follows:
1. Place the operation mode selector switch in the MAST/WINCH

position.
2. To hoist the auxiliary winch line, lift and move the winch joystick,
located on the right console, forward. To stop the line, return
the joystick to the NEUTRAL position.
3. To lower the winch line, lift and move the joystick rearward. To
stop the line, return the joystick to the NEUTRAL position.
BI6522032-57
Operation Section
PIPE RACK OPERATION
The machine can be equipped with 1 to 4 pipe racks and depending upon the number of pipe racks
the pipe rack configuration and operation will be different.
On a machines with one pipe rack, the rack will be on a swing out arm and will be in #1 position .
On a machine with two pipe racks, the racks will be on swing out arms and will be in #1 and #4
positions.
On a machine with three pipe racks, two pipe racks will be located on a carousel that swings out
and then is rotated. This carousel houses pipe racks in #1 and #2 positions as shown. The third
pipe rack is a swing out rack that will be in #4 position.
On a machine with four pipe racks, there are two swing out carousels with two racks in each
carousel. The carousels rotate to make each rack available for use. The left carousel houses racks
#1 and #2 and the right carousel racks #3 and #4.
The general method of operating the pipe racks is as follows:
1. Place the operating mode selector switch in the DRILL position. The main air compressor
must be energized.
2. Verify that the operating mode selector switch is in the DRILL position and that the hoist/
pulldown speed selector switch is in the PIPE RACK/JOINT position.
3. Select the desired pipe rack.
4. Lift and move the pipe rack joystick, located on the left console, out of neutral to perform the
desired operation.
2-58 BI652203
Operation Section
PIPE RACK OPERATION

BI6522032-59
Operation Section
The following special sequence is required for each pipe rack configuration.
1. One pipe rack configuration.
a. Turn the pipe rack selector switch to the #1 position.
b. Operate the rack as described under general procedure.
2. Two pipe rack configuration.
a. If the first pipe rack is to be operated place the selector switch #1 position and
operate the rack as described under general procedure.
b. If the second pipe rack is to be operated place the selector switch in the #4 position
and operate the rack as described under general procedure.
NOTE: Take extra care to insure that one pipe rack is out of the way and locked in place before
operating the second pipe rack.
3. Three pipe rack configuration.
a. The first and second pipe racks are part of a carousel and require a special operating
sequence. The third pipe rack is a standard swing out rack.
To operate the third pipe rack place the selector switch in the #4 position and operate the rack as
described under general procedure.
b. The carousel configuration of pipe racks one and two requires a special sequence.
Position #1 of the selector switch will allow, when the joystick is pulled to the rear,
the carousel with pipe racks to be swung out over the guide bushing hole.
One of the pipe racks will be over the hole. Position #2 of the selector switch will allow, when the
joystick is pulled to the rear or pushed forward, the carousel to rotate to move the other pipe rack
over the hole. Returning the selector switch to position #1 and moving the joystick forward will
return the carousel to the stored position.
c. Because of the sequence of operation pipes must be removed from pipe rack #1
first and then pipe rack #2. When returning the pipes to the racks return pipe to #2
pipe rack, then #1 pipe rack.
NOTE: Take care to insure that one pipe rack is out of the way and locked in place before
operating the other pipe rack.
2-60 BI652203
Operation Section
4. Four pipe rack configuration.
a. The four pipe rack configuration consists of two swing out carousels with two pipe
racks to each carousel. Pipe racks #1 and #2 in the left carousel and pipe racks #3
and #4 in the right carousel work and are sequenced the same as the carousel in
the three pipe rack configuration. For pipe rack #3 and #4, the #4 position of the
selector switch controls the swing out of the right carousel and the #3 position
controls the rotation of the carousel.
b. Because of the sequence of operation, pipe must be removed from pipe rack #4
first, then pipe rack #3. When returning the pipes to the racks, return pipe to #3 pipe
rack, then #4 pipe rack.
TOOL HANDLING
This section describes the procedures necessary to load, unload, handle, assemble and
disassemble the drill tools.
The procedures detailed in this section are intended to be as universally applicable as possible. It
is, however, impossible to prepare a procedure that will take into account every possible machine
option or tool vendors’ products. For this reason it is important that the operator not only become
familiar with these procedures, but with the machine and the particular tools being handled.
PIPE LOADING AND UNLOADING
Loading pipe onto the drill is necessary when the drill is new and has not yet had the pipe installed
or when the pipe has been removed for changeout or for maintenance to the mast. The procedure
in this manual, unlike some more commonly used procedures, requires that the mast be in the
horizontal or lowered position to load the drill pipe. This is necessary for safety.
This procedure, while not the most expedient for machines requiring pipe changeout while the
mast is in the drilling position, is quite efficient while the mast is in the stored position. Proper
scheduling of maintenance and production requirements against pipe life will allow using this
procedure while reducing the downtime of the machine.
To load drill pipe onto the drill, proceed as follows:
1. If the mast is in the vertical or drilling position, lower the mast and store it in the mast rests.
Refer to the appropriate topic in this manual for the exact operating procedures.
2. Obtain a crane with suitable capacity and reach to place the drill pipe into the pipe racks with
the mast in the stored position. Normal placement of the crane is on the left side of the drill
since this allows the shortest reach and greatest boom angle.
BI6522032-61
Operation Section
CAUTION: Follow all applicable safety measures when working with cranes and
rigging. Failure to follow safe working procedures can cause an
accident, leading to the possible death or injury of personnel.
3. Position the pipe to be installed in such a position so as to be accessible to the crane. Normal
placement of the drill pipe is on the left side of the machine, laying at right angles to the
machine. This allows the crane to lift the pipe and swing without excessive boom hoisting and
lowering. The pipe may be stored on suitable blocking on the ground, or on a truck or trailer.
CAUTION: Make sure the drill pipe is secured against unwanted or unexpected
movement. Failure to secure the pipe properly may result in the pipe
shifting and causing death or serious injury to personnel in the area.
4. The upper gate is open when the pipe rack is empty. This function is controlled by a limit
switch in the lower pocket of the pipe rack.
5. Using suitable rigging, attach the crane to the drill pipe. The pipe should be rigged so that it will
remain horizontal while being lifted. Attach suitable tag lines to the pipe. Remove the thread
protectors and clean and lubricate the threads and shoulders on each end of the pipe. Install
an approved lifting bell to the pin (upper) end of the pipe. Lift the pipe into position over the
mast.
6. Using a tag line guide the pipe into the desired pipe rack. Place suitable blocking beneath the
pipe to allow the sling to be removed from the pipe.
CAUTION: Block the pipe securely to prevent it from moving unexpectedly.
7. Remove the slings from the pipe. Attach a sling to the lifting bell on the pin end of the pipe and
lift the pipe sufficiently to remove the blocking.
8. Slide the pipe down the pipe rack until it rests on the bottom of the pocket. Lay the pipe in the
pipe rack and remove the sling and lifting bell.
9. When the pipe rest in the bottom of the pocket it will trigger the limit switch and close the
upper gate.
10. Repeat the procedure for additional lengths of pipe.
11. Unloading the pipe is the reverse of the procedure used for loading the pipe.
2-62 BI652203
Operation Section
DRILL TOOL STRING ASSEMBLY
The tool string consists of one or more sections of drill pipe, a stabilizer (drill collar) and a bit. In
assembling the tool string, the stabilizer is the first item installed, then comes a section of drill pipe
and finally the bit.
To install the stabilizer proceed as follows:
1. Place the stabilizer to be installed in a position so as to

be accessible to the auxiliary winch line. Clean and
lubricate the threads and shoulders on each end of the
stabilizer. Install a lifting bell on the pin (upper) end of
the stabilizer and lift it onto the drilling deck with the
auxiliary winch line. Securely block the stabilizer
horizontally on blocking sufficient enough to place the
stabilizer 8-10 inches above the drill deck. Remove the
auxiliary winch line.
2. Remove the guide bushing from the hole in the drill deck.
Place the guide bushing on the upper end of the stabilizer
with the tapered end of the bushing toward the lower
(box) end of the stabilizer. Reattach the auxiliary winch
line to the lifting bell.
3. Install the stabilizer and drill bushing in the hole in the

drill deck. Make sure the drill bushing is seated properly.
Lower the stabilizer until the slots in the stabilizer are
aligned with the tool wrenches. Extend the tool
wrenches to hold the stabilizer in place.
4. Remove the auxiliary winch line from the stabilizer and

secure it out of the way. Remove the lifting bell from the
stabilizer and store it.
TOOL STRING
BI6522032-63
Operation Section
NOTE: The use of stabilizers that have been modified or that do not allow this procedure to be
used should be avoided. The use of nonstandard stabilizers will make assembly and
disassembly of the tool string difficult and dangerous.
STABILIZER INSTALLATION
To install a single section of drill pipe proceed as follows:
1. Lower the rotary/pulldown unit until the pipe coupling on the unit can be reached from the drill
deck. Set the hoist brake and press the drill/propel control OFF push-button. Clean the inside
threads on the coupling to remove any dirt or old lubricant. Apply a coat of drill thread
compound to the threads and shoulder of the coupling.
NOTE: Use only drill pipe thread compound on the pipe threads. Drill pipe thread compound
contains material that will prevent the threads from seizing and galling under the
severe pressure encountered on the pipe threads.
2-64 BI652203
Operation Section
2. Press the control ENABLE button and release the

hoist brake. Raise the rotary/pulldown unit to a
position mast so as to clear the pipe rack as it comes
in to place. Set the hoist brake.
3. Verify that the main compressor/hydraulic pump

motor is running, the hoist/pulldown speed selector
switch is in PIPE RACK/JOINTS position, the
operating mode selector switch is in DRILL position,
and on the operator’s display terminal that the head
is clear of pipe rack. Place the pipe rack selector
switch in #1 position. The pipe rack joystick will now
control only the #l pipe rack.
4. Lift and move the joystick forward (OVER HOLE

position) to move the pipe rack over the hole. Once
the rack is over the hole return the joystick to the
NEUTRAL position.
5. Release the hoist brake and lower the rotary/pulldown unit until it is approximately 1 foot
above the upper end of the drill pipe. Reset the hoist brake.
6. Turn the rotary rheostat clockwise until the rotary drive unit coupling begins to turn at
approximately 5 RPM as shown on operator’s display terminal operator’s display screen.
Release the hoist brake and carefully lower the rotary drive unit until the coupling contacts the
drill pipe. Allow the rotary/pulldown unit to lower under gravity while the coupling is threading
onto the pipe.
7. When the drill pipe begins to turn with the rotary coupling, stop the rotary motion and check
the joint between the coupling and the pipe. The shoulders on the pipe and coupling must be
together. If there is clearance between the shoulders, it will be necessary to tighten the joint
some more before the pipe is removed from the rack. If the shoulders of the pipe and coupling
are contacting, the joint is made up.
CAUTION: The threads on the drill pipe are tapered to make assembly and
disassembly of the pipe easier. The threads are designed to
disengage after only a few revolutions of the pipe. Failure to have
the pipe shoulders contacting may result in the pipe joint uncoupling
and the pipe falling from the rotary/pulldown unit.
BI6522032-65
Operation Section
There is no provision made for holding the pipe stationary in the rack while the joint is tightened. If
the joint does not tighten using the above procedure it may be necessary to apply a small amount
of hoist power to the rotary/pulldown unit to lift it slightly to remove the pressure from the drill
threads.
CAUTION: Do not lift the drill pipe. Lift the rotary/pulldown unit only enough to
relieve the pressure on the threads. Lifting the unit enough to lift the
pipe will not only put pressure on the other side of the threads, but
may also allow the pipe rack upper gate to open. Should the joint
uncouple at this point, the drill pipe may fall out of the rack, causing
death, serious injury or serious machine damage.
If the pipe joint does not make up by relieving the weight of the drive unit from the threads it will be
necessary to inspect and/or repair the threads on the rotary coupling and the drill pipe. Inspect the
threads for rough surfaces and burrs and apply a liberal coat of thread compound to them. The
threads should have a smooth finish and no burrs or dirt that will hinder joint make-up. The joint
shoulders should also be clean and smooth and should have compound applied.
After cleaning and repairing the threads, try making the joint again. If the joint cannot be made,
either the drill pipe or the coupling is defective. Replace the pipe or coupling as necessary.
8. Once the joint is made up between the coupling and the pipe, the pipe is now ready to be lifted
out of the pipe rack pocket. Lift the pipe approximately a foot above the top of the pocket to
allow the pipe rack to swing out of the way. Set the hoist brake.
9. Once the pipe has been lifted clear of the pipe rack, swing the pipe rack to the STORED
position by lifting and pushing the joystick rearward to the STORED position.
NOTE: Verify that the upper gate on the pipe rack is open before retracting the pipe rack.
Retracting the pipe rack with the gate closed will cause damage to the pipe rack.
10. Once the pipe rack has been stored the pipe should be cleaned out using the bailing air.
Remove all personnel from the area and turn on the bailing air for a moment. After cleaning the
pipe, clean and lubricate the threads and shoulder on the lower end of the pipe and the upper
end of the stabilizer.
CAUTION: Before working around the tool string set the hoist brake. Press the
control ENABLE button.
11. Release the hoist brake and lower the rotary/pulldown unit until the drill pipe is approximately
1 foot above the upper end of the stabilizer. Reset the hoist brake.
12. Turn the rotary rheostat clockwise until the drill pipe begins to turn at approximately 5 RPM as
shown on operator’s display terminal operator’s display screen. Release the hoist brake and
carefully lower the rotary drive unit until the drill pipe contacts the stabilizer. Allow the rotary
drive unit to continue to lower under gravity while the drill pipe is threading onto the stabilizer.
2-66 BI652203
Operation Section
13. When the stabilizer begins to turn with the drill pipe, check the joint between the stabilizer and
the pipe. The shoulders on the pipe and stabilizer must be together. If there is clearance
between the shoulders, it will be necessary to tighten the joint some more before the stabilizer
is released. If the shoulders of the pipe and stabilizer are contacting, the joint is made up.
Installation of the drill bit is the last step in preparing the tool string.
To install the bit, proceed as follows:
1. Hoist the completed drill pipe/stabilizer assembly 2 to 3 ft (0.6 to 0.9 m) off the drill deck. Place
the bit basket (furnished with machine) into the hole left by the guide bushing in the drill deck.
Remove all personnel from the drilling deck and the immediate area. Turn on the main air
stream to blow any contaminants from the drill pipe and stabilizer.
2. Place the bit into the bit basket. Coat the threads and shoulders of the bit and stabilizer with
drill pipe thread compound.
3. Turn the rotary rheostat clockwise until the tool string begins to turn at approximately 5 RPM
as shown on operator’s display terminal operator’s display screen. Release the hoist brake
and slowly lower the rotary/pulldown unit and tool string onto the bit. Lower the drive unit in
small increments until the threads catch and the stabilizer starts to thread itself onto the bit.
As soon as the threads start to catch, set the hoist brake and let the stabilizer screw itself
onto the bit.
4. When the joint is tight the rotary unit will slow down and the rotary load meter will show an
increased load. At this point return the rotary rheostat to the neutral position.
5. After making the bit to stabilizer joint, hoist the rotary drive unit to allow the bit basket to be
removed. Remove the bit basket and store it in a safe place.
6. Lower the completed tool string so that the guide bushing is seated in the hole in the drill deck.
Set the hoist brake and press the control ENABLE button. The tool string is now complete for
single pass drilling or for the first pass of multiple pass drilling.
BI6522032-67
Operation Section
BREAKOUT WRENCH OPERATION
CAUTION: When working with the breakout wrench it is important that the hoist
brake be set, the control ENABLE button is off to prevent operation
of the hoist or rotary controls. Failure to follow this caution may lead
to the controls being energized while personnel are in the area,
leading to the death or serious injury of those personnel.
Operation of the breakout wrench is necessary anytime a pipe joint, except the joint at the rotary coupling,
must be broken. This includes removing the bit or stabilizer, or separating two sections of pipe.
To break a joint with the breakout wrench, proceed as follows:
1. If a pipe joint between pipe sections or between the stabilizer and the pipe is to be broken, align the
slots in the lower pipe to be broken with the tool wrench jaws. Close the tool wrench by turning the
tool wrench control switch to the ENGAGE position. Make sure the lower tool is held securely by
the tool wrench and that the slots or flats in the tool are aligned with the tool wrench.
CAUTION: All personnel should be removed from the drill deck when operating
the breakout wrench.
2. To break the joint, turn and hold the breakout wrench switch to the EXTEND position. The
jaws of the breakout wrench should grip the upper tool and turn it while the lower tool is
held stationary by the tool wrench. Release the breakout wrench switch.
3. Once the joint has broken, repeat the cycle 2-3 times to loosen the joint sufficiently to allow
the rotary unit to finish disassembly.
4. Turn and hold the breakout wrench switch in the RETRACT position until the breakout wrench
releases the upper section of pipe and moves away from the pipe.
5. Using the rotary unit, continue disassembly of the joint. Refer to the appropriate topic for
exact operating procedures.
CAUTION: The joint must uncouple freely while using the rotary unit. If the joint
does not uncouple freely, repeat the procedure using the breakout
wrench until it does. Constantly observe the joint between the rotary
coupling and the first section of pipe when running the rotary motion
in reverse. If this joint begins to uncouple, stop the rotary motion
immediately and retighten the joint. If this joint uncouples the pipe
will fall, possibly causing death or serious injury to personnel.
6. If the lower tool is the bit, secure the bit with the bit basket as described in the topic BIT
REMOVAL. Operate the breakout wrench as described above, except that the lower tool (bit) is
secured by the bit basket, not the tool wrench.
2-68 BI652203
Operation Section
DRILL TOOL STRING DISASSEMBLY
The tool string is disassembled in reverse of assembly, that is the bit is removed first, then the drill
pipe and lastly the stabilizer.
To remove the bit from the tool string, proceed as follows:
1. Raise the tool string 2 to 3 ft (0.6 to 0.9 m) above the drill deck. Install the bit basket in the hole
in the drill deck.
2. Using the breakout wrench, break the joint between the stabilizer and the bit. After breaking
the joint, use rotary power to disassemble the joint. Use a slight amount of hoist power to lift
the tool string off of the bit to facilitate the disassembly.
3. Hoist the tool string 2 to 3 ft (0.6 to 0.9 m) off of the drill deck. Secure the rotary/pulldown unit
and controls. Attach a lifting bell to the bit. Attach the auxiliary winch line to the lifting bell and
lift the bit out of the bit basket.
4. After removing the bit, a new bit may be installed or the bit basket may be removed, allowing
removal of the drill pipe.
To remove the drill pipe from the rotary drive unit, proceed as follows:
1. Lower the tool string until the slots or flats on the upper end of the stabilizer are aligned with
the tool wrench. Clamp the stabilizer in the tool wrench. Using the breakout wrench to break
the joint between the stabilizer and the drill pipe. After breaking the joint, use the rotary unit to
disassemble that joint completely. Raise the rotary/pulldown unit and drill pipe 2 to 3 ft (0.6 to
0.9 m).
2. Press the control ENABLE button to the OFF position and set hoist brake. Go to the drill deck
and clean the pocket of the pipe rack to be used of dirt, cuttings or any material that will
interfere with the entrance of the pipe or the operation of the pipe rack gate controls. Verify
that the gate controls are intact.
3. Clean and lubricate the threads and shoulder on the lower end of the pipe. This is to prevent
rusting while stored in the pipe rack. After performing this function, return the controls to
operating condition.
4. After selecting the pipe rack to be used by turning the pipe rack selector switch to #l or #4,
swing the pipe rack over the hole. Then return the joystick to the NEUTRAL position.
5. Slowly lower the rotary/pulldown unit and place the lower end of the pipe into the pipe rack
pocket. Make sure that the pipe is seated firmly on the bottom of the pocket.
BI6522032-69
Operation Section
6. Quickly turn the rotary rheostat to the left (counterclockwise) to approximately one-half of full
speed. The joint should break at the rotary coupling.
NOTE: IF THE JOINT DOES NOT BREAK IMMEDIATELY, RETURN THE ROTARY
RHEOSTAT TO THE ZERO POSITION TO REDUCE THE CHANCE OF DAMAGING
THE MOTOR BY STALLING IT.
7. If the joint does not break, it will be necessary to index the slots on the drill pipe so as to allow
the rotary drive unit to build up speed before stopping the drill pipe. This is done by rotating the
drill pipe in the forward direction until the slots in the pipe are almost aligned with the pawls in
the sockets. This allows the drill pipe to rotate almost one-half turn before being stopped by
the pawls.
If the joint does not break in a second attempt, the drill string will need to be reassembled, a hole
drilled down and then use the breakout wrench to break the joint.
8. When the joint breaks, gently raise the rotary/pulldown unit as the joint is unthreading.
9. When the joint completely unscrews, the pipe will drop to the bottom of the pipe rack pocket.
The upper gate will automatically close around the drill pipe. When the joint is completely
unscrewed, raise the rotary/pulldown unit until it is in a position so as not to be struck by the
pipe rack when it is moved. Set the hoist brake.
10. Swing the pipe rack into the stored position.
To remove the stabilizer, proceed as follows;
1. With the stabilizer still clamped in the tool wrenches, attach a lifting bell to the upper end of
the stabilizer. Attach the auxiliary winch line to the lifting bell and lift the stabilizer and guide
bushing from the hole in the drill deck. Block the assembly in a horizontal position.
2. Remove the auxiliary winch line from the stabilizer. Remove the guide bushing from the
stabilizer and replace the auxiliary winch line.
3. Using the auxiliary winch line, remove the stabilizer from the drill. Replace the guide bushing
in the hole in the deck.
2-70 BI652203
Operation Section
ADDING ADDITIONAL DRILL PIPE
Installation of additional sections of drill pipe is necessary when the depth of the hole is to be
greater than the total length of one section of pipe. Installation of the second and third sections of
pipe is essentially the same procedure as installation of the first. The rotary/pulldown unit is raised
above the pipe racks, a pipe rack with pipe moved over the hole, the rotary coupling threaded to the
pipe, and the pipe removed from the rack and the rack stored.
To add an additional section of drill pipe, proceed as follows:
1. The first part of the hole should be drilled as deep as possible with the first section of pipe.
The hole should be drilled deep enough to place the joint between the rotary drive unit and the
top of the first section of the pipe even with the top of the tool wrench. After completing this
section of the hole, turn the main air stream off.
2. Raise the tool string until the slots or flats in the top of the first section of pipe are aligned with
the tool wrench. Clamp the tool wrench firmly around the drill pipe.
3. Quickly turn the rotary rheostat to the left (counterclockwise) to approximately one-half of full
speed. The rotary coupling should turn, breaking the joint between the pipe and the coupling.
NOTE: If the joint does not break immediately, return the rotary rheostat to the zero position to
reduce the chance of damaging the motor by stalling it.
4. If the joint does not break, use the breakout wrench to break the joint.
5. When the joint breaks, apply enough hoist power to raise the rotary/pulldown unit as the joint
is unthreading. Do not apply enough power to lift the tool wrench and cause it to lose its grip
on the pipe. Once the joint is completely disassembled, raise the rotary/pulldown unit to a
position to make the coupling accessible from the drill deck. Set the hoist brake, press the
drill/propel control OFF push-button to prevent operation. Clean and lubricate the threads and
shoulder of the rotary coupling. Use an approved drill thread compound on the threads and
shoulder. After cleaning and lubricating the coupling, raise the rotary drive unit to a position
above the pipe racks so as not to be struck by the pipe or rack as the rack swings into position
over the guide bushing.
6. Position the pipe rack and install the new section of pipe to the rotary unit.
7. Once the new section of pipe is attached to the rotary unit and the pipe rack stored, lower the
pipe until it is approximately 3 feet above the drilling deck. Set the hoist brake. Place a cover
over the threads on the pipe held by the tool wrench. Clear all personnel from the area and
turn the main air stream on to blow away any dirt from inside of the pipe attached to the rotary
unit. After turning off the main air stream, remove the cover from the lower pipe and clean and
lube both the pin threads on the lower pipe and the box threads on the upper pipe.
BI6522032-71
Operation Section
8. After cleaning and lubricating the threads, turn the rotary rheostat until the drill pipe is rotating
at approximately 5 RPM as shown on the operator’s display terminal operator’s display screen.
Lower the rotary/pulldown unit slowly by gravity until the threads begin to contact. Once the
threads begin to join the two pipes, attempt to minimize the pressure on the threads by
allowing the joint to close slightly while holding the upper pipe in position with the hoist brake,
then allowing the upper pipe to descend slightly to keep the tool wrench from losing its grip on
the lower pipe. Once the joint is tight, stop the rotary motion.
NOTE: Be sure that the joint is made properly before attempting to unclamp the lower pipe.
Should the joint not be made properly and fail, the lower pipe will fall into the hole and be
difficult to recover.
9. Disengage the tool wrench and retract it fully. The second section of pipe is now installed.
To install the third section of pipe, follow the procedure for installation of the second section of pipe,
except that the third section of pipe is now installed between the rotary unit and the second section
of pipe.
REMOVAL OF MULTIPLE SECTION DRILL PIPE
Disassembly of multisection pipe strings is essentially the same as disassembly of a single section
of pipe. The difference is that instead of the stabilizer being held by the tool wrench, it is the first
or second section of pipe.
The tool string is disassembled to reverse order of assembly. First, the last section of pipe to be
installed is removed, followed by the second section of pipe installed, and then the first. In each
case the lower section of pipe is held by the tool wrench while the joint is broken by the breakout
wrench. The joint is then disassembled by the rotary motion and the pipe stored in the pipe rack.
The procedure is then repeated as necessary to remove all, or part of the tool string.
NOTE: For normal operation it is not necessary to completely disassemble the tool string to
move from hole-to-hole within the drill pattern as long as the stability limitations are not
exceeded. Do not disassemble the tool string more than necessary.
2-72 BI652203
Operation Section
ANGLE DRILLING
ANGLE DRILLING EQUIPMENT

BI6522032-73
Operation Section
All tool handling procedures are carried out the same way either in angle drilling or in standard
vertical drilling. The only addition to the procedures is the use of the pipe positioner to hold the drill
pipe to be threaded together in position and a mast A-frame with adjustable front legs. It also
includes an adjustable pipe seal which can be moved to align with the drill pipe.
PIPE POSITIONER
During angle drilling the deck remains horizontal providing a horizontal surface to work from. The
drill pipe, however, is laying at the angle of the mast. In order to make a joint at the drilling deck,
such as when adding the stabilizer, bit or drill pipe or when removing these components, it is
necessary to hold the drill pipe in position so as to line up with the drill pipe or component being held
on the drill deck. This is the function of the pipe positioner.
The pipe positioner is moved into position by hydraulic cylinders. The pipe positioner jaws are
opened by a single hydraulic cylinder.
NOTE: Do not operate the rotary machinery except at low speeds to make and break joints while
the jaws are closed around the pipe. Operating the rotary machinery at high speeds or drilling while
the pipe positioner jaws are closed around the pipe will damage the jaws and positioner structures.
2-74 BI652203
Operation Section
To make a joint with the pipe positioner, proceed as with normal joint assembly. When the pipe rack
has been moved into position, retract the positioner into place and lock the jaws around the pipe.
Proceed as normal to make the joint. Once the joint is made, open the positioner jaws and extend
the positioner to the stored position.
To break a joint both the pipe positioner and the breakout wrench are utilized. The pipe positioner
is used to hold the pipe in position to be loaded into the pipe rack. The breakout wrench is used to
break the joint.
To break a joint, proceed as normal with joint disassembly. Proceed as normal with joint disassembly.
Before breaking the joint completely, clamp the pipe with the pipe positioner. After breaking the
joint, hoist the drill pipe and lower the pipe rack, release the jaws and extend the positioner.
Proceed as normal with the pipe joint disassembly procedure.
NOTE: IN CASES WHERE THE MACHINE IS EQUIPPED WITH A DRILL PIPE TONG
INSTEAD OF THE BREAKOUT WRENCH, THE DRILL PIPE TONG JIB CRANE IS
DESIGNED SO THAT IT CAN BE EXTENDED FROM 4 TO 7 FEET. FOR VERTICAL
DRILLING, THE CRANE SHOULD BE EXTENDED TO THE 5 FOOT POSITION. FOR
ANGLE DRILLING OF 25 DEGREES THE CRANE SHOULD BE EXTENDED TO THE
6.5 FOOT POSITION.
JIB CRANE
BI6522032-75
Operation Section
DUST SUPPRESSION SYSTEM OPERATION
Most drills are equipped with some sort of dust control system. This system may be either a dry
type filter or a water injection system. Dust control is necessary to contain the dust generated by
drilling from escaping to the environment. All machines are equipped with dust control curtains and
dust seal to contain the dust around the drill hole as standard equipment. The dust seal must be
adjusted to the pipe angle when angle hole drilling.
There are two ways to suppress dust generation or prevent the escape of the dust to the atmosphere.
The two methods cannot be used at the same time as they are not compatible. One method to
suppress the generation of dust is to inject water into the main air stream as it passes to the bit.
The water serves to conglomerate the dust particles into larger particles that may be treated as
cuttings. The other method to suppress the dust is to contain the dust in the dust curtain enclosure
then draw off the lighter particles and filter them out of the air before returning the air to the
atmosphere. The filtering is done by a filter unit, which forces the dust laden air through filters
where the dust is removed. In the filter system, the dust must remain dry as wet material will plug
the filters.
NOTE: When the machine is equipped with a dry-type dust filter system, the air for cleaning
the filters is drawn from the bailing air system. Air pressure to the dry-type dust filter
must be maintained at 40 PSI (276 kPa) to ensure proper cleaning of the filter
elements.
2-76 BI652203
Operation Section
WATER INJECTION SYSTEM

BI6522032-77
Operation Section
DRILLING
VERTICAL DRILLING
Once the drill has been inspected and started, positioned, leveled, and the tool string assembled,
it is now ready to begin drilling. There are two methods of drilling, vertical drilling and angle drilling.
Vertical drilling is, as the name implies, drilling a vertical hole. Angle drilling is drilling the hole at
some angle from vertical (up to 25 degrees). This section of the Operator’s Manual details the
procedures involved in the drilling of vertical holes.
The actual drilling procedure involves three main sections:
1. Starting the hole (collaring)
2. Drilling the hole
3. Cleaning or reaming the hole
Many types of formations are found in mining areas. Formations that are drilled may range from a
wet clay to solid taconite. Each formation, and the parts of the hole within each formation, requires
drilling techniques, expressly for that formation. A hole drilled through fragmented limestone is not
drilled the same way that a hole is drilled through consolidated taconite. For this reason it is
important that the operator not only become familiar with the basic drilling procedures and the
specific machine being operated, but that he also become familiar with the formation being drilled.
For the purpose of this section of the Operator’s Manual it is assumed that the hole will be drilled in
a consolidated rock formation. This is probably the simplest formation to drill in. Special
circumstances will be taken into account in the DRILLING IN DIFFICULT FORMATIONS section of this
manual. It is also assumed that the operator is familiar with the location and operation of all of the
controls on the machine and that the machine is in good repair.
During the actual drilling the operator’s display terminal should be turned on and the operator
display screen shown on the monitor. All of the drilling parameters noted in the following paragraphs
will appear on the operator’s display screen.
NOTE: The bar graphs on the operator’s screen on the operator display terminal shows the
condition of each of each functions. If a function operates beyond its normal operating
range, especially for rotary current and hoist/pulldown force, the bar graph color will
change from green to yellow or red when the graph valve raises into that particular
range. For details, refer to the Operator Display Manual.
2-78 BI652203
Operation Section
STARTING THE HOLE (COLLARING)
Since the first few feet of a hole are usually in unconsolidated material, the procedure for drilling
through this material will be different than for the remainder of the hole. This procedure is commonly
referred to as collaring the hole.
To begin, or collar the hole, proceed as follows:
1. Verify that the tool wrench and breakout wrench are retracted fully. Clear the drill deck of
personnel and material which is not necessary for the drilling procedure (i.e. oil drums, tools,
spare bits, etc.).
2. Place the operating mode selector switch in the DRILL position. Place the hoist/pulldown
speed selector switch in the PULLDOWN position. Press the control ENABLE button to the
ON position. Release the hoist brake and allow the tool string to lower so that the guide
bushing is firmly seated in the hole in the drill deck. Make sure that the slots in the bushing
align with the lugs on the drill deck. Reset the hoist brake.
3. Turn the rotary speed selector switch to LOW position. Turn the rotary rheostat clockwise
until the rotary speed bar graph on the operator’s display terminal screen indicates that the
tool string is turning at approximately 25 RPM.
4. Lower the dust curtains and turn on the dust control system. Place the main air valve switch
in the OPEN position to supply bailing air to the bit.
NOTE: While the bit is passing through the unconsolidated material laying on the top of the
formation, the pulldown speed sufficient to cause penetration of the bit is provided by
turning the hoist/pulldown rheostat slightly in the pulldown direction.
5. Release the hoist brake and allow the drill bit to contact the ground. Monitor the vibration
coming from the tool string. To reduce vibration slow the rotary speed with the rotary rheostat.
Keep the vibration to a minimum. As the vibration lessens, increase the rotary speed and the
pulldown speed while monitoring the rotary current bar graph and the air pressure bar graph
on the operator’s display terminal screen.
BI6522032-79
Operation Section
The objective is to penetrate the formation as fast as possible without damaging the machine or
plugging the hole with cuttings. Monitoring the rotary current, and keeping the load in the lower
portion of the bar graph (green) will eliminate damage to the rotary motor. Reducing the load on the
motor is accomplished by reducing the pulldown force on the bit. Reducing the pulldown force will,
in most instances, accomplish this. In some cases it may even be necessary to hoist the tool string
slightly to reduce the loading. Monitoring the air pressure graph will indicate the condition of the
hole. If penetration is too fast and the bailing air cannot remove the cuttings as fast as they are
generated, the hole will plug and the air pressure will rise. Varying the penetration rate will vary the
air pressure. Keep the air pressure in the normal working range by increasing or reducing the
penetration rate. Keep the vibration levels to a minimum by varying the rotary speed and the pulldown
force.
6. When the bit passes through the fragmented material (approximately 3-5 ft [0.9-1.5 m]) and
into the consolidated material underneath, the vibration and loading will reduce drastically.
When this occurs, the hole has been collared and normal drilling may commence.
NORMAL DRILLING
After the bit has passed through the unconsolidated material at the top of the hole, it is no longer
necessary to reduce the load on the bit to reduce vibration and rotary motor loading. More rapid
penetration and increased pulldown force may now be used to complete the hole as fast as possible
with minimum vibration. This is the normal drilling condition for the machine.
Normal drilling follows the same guidelines as collaring the hole. Penetration is increased to the
maximum determined by the rotary motor load, the vibration of the tool string, and the air pressure.
By keeping the penetration at or slightly below the optimum, the hole can be completed in the
shortest possible time.
To begin normal drilling proceed as follows:
1. When normal drilling is desired it is necessary to add pressure to the bit in addition to the
deadweight of the tool string and rotary/pulldown unit. This pressure is furnished with the
electric motor and pulldown gearbox. To activate the pulldown motor, turn the hoist/pulldown
rheostat in the pulldown direction as required for maximum drill rate and pulldown force.
Turning the control in the pulldown direction will increase the pressure on the bit by calling for
a desired pulldown speed.
Apply enough pulldown force to allow the bit inserts to chip the material being drilled, rather than
pulverizing it. If the pulldown force is not sufficient enough, the bit will ride over the top of the
material being drilled and will not create chips. This condition can be observed by monitoring the
cuttings. If the cuttings are finely pulverized material, the pulldown force is not enough. Another
cause of poor cutting is a worn bit. If pulldown force is high, but the cuttings are fine and penetration
is slow, change the bit.
2-80 BI652203
Operation Section
2. Monitor the rotary motor load (current) and adjust the pulldown force to keep the bar graph in
the lower (green) portion of the graph. It is permissible for the load to increase momentarily
into the yellow, but continuous running in the yellow or red portions will cause rotary motor
damage.
3. Monitor the vibration of the tool string and the machine. Keep the vibration to a minimum by
varying the pulldown speed and the rotary speed. If vibration increases, reduce the rotary
speed first. If this does not reduce the vibration to an acceptable level, reduce the pulldown
speed until the vibration is acceptable.
NOTE: Excessive or prolonged vibration of the tool string and machine will cause eventual
damage to the machine.
Monitor the air pressure. Keep the pressure in normal working range to eliminate compressor
overheating. Pressures above normal working range indicate that the hole is starting to plug with
cuttings. Stop the pulldown by returning the hoist/pulldown rheostat to the OFF position. Set the
hoist brake. Wait a moment and if the pressure starts to decrease, let the hole clear before returning
to drilling. If the pressure does not start to decrease it will be necessary to hoist the tool string to
clear the hole. To do this release the hoist brake and turn the hoist/pulldown selector switch to the
LOW position and the hoist/pulldown rheostat in the hoist direction. Hoist the tool string until the
hole is cleared. Leave the rotary motion activated since this will help clear the hole. If the pressure
is noticed slowly rising during drilling, reducing the penetration rate momentarily may eliminate the
need to cease pulldown and hoist the tool string.
4. Continue normal drilling until the hole is at the desired depth. It may be necessary to add drill
pipe to complete the hole. Refer to the appropriate sections in this manual for the procedures
necessary for adding drill pipe.
The operator’s display screen will show the hole depth in feet.
5. Once the finished hole depth is reached it is necessary to clean or ream the hole before it is
completed.
BI6522032-81
Operation Section
ENDING THE HOLE
Once the finished hole depth is reached normal drilling ceases. It is now necessary to ream the
hole before preparing the drill to move to the next hole. Reaming the hole removes cuttings that
have fallen to the bottom of the hole and also straightens and increases the diameter of the hole.
As the bit and tool string are cutting through the formation, the bit may tend to wander slightly. This
wandering is due to the fact that the stabilizer cannot be exactly the same diameter of the bit or it
would wear out quickly and create operation problems. The stabilizer tends to keep the bit on
course, but it cannot keep the hole exactly straight. Reaming the hole straightens the hole and
therefore increases the diameter of the hole slightly. Reaming the hole also removes any cuttings
that are lodged in the hole. These cuttings must be removed or they will eventually fall to the bottom
of the hole, reducing the drilling depth.
To complete the drilling procedure the hole is reamed as follows:
1. When the hole is drilled to the finished depth, leave the main air stream on and the rotary
rheostat to the MINIMUM position and the motion activated. Return the hoist/pulldown rheostat
to the “0” position and set the hoist brake. Allow the tool string to rotate and the air to bail the
hole for a moment. This removes all of the cuttings in suspension from the hole.
2. Turn the hoist/pulldown speed selector switch to the LOW HOIST position and the hoist/
pulldown rheostat in the HOIST direction while simultaneously releasing the hoist brake. Slowly
hoist the tool string out of the hole. If resistance is met, or if vibration increases, return the
hoist/pulldown rheostat to OFF position and set the hoist brake. Allow the obstruction to be
removed by the bit before continuing. If the hole is very crooked (indicating a worn stabilizer)
it may be necessary to repeat this procedure of hoisting, then stopping and allowing the bit to
clear, many times before reaching the top of the hole. This procedure straightens the hole
and allows the tool string to be removed.
3. Once the tool string has been removed and the hole reamed, it must now be cleaned out.
Reaming the hole loosens cuttings that have become lodged in the side of the hole. These
cuttings, and most of the cuttings generated during reaming will fall to the bottom of the hole.
This filling of the hole may reduce the actual depth of the hole significantly, so it is necessary
to remove these cuttings from the hole. To do this, release the hoist brake and turn the hoist/
pulldown rheostat slowly in the pulldown mode.
Leave the air on and the tool string turning at 25-30 RPM. When the bit reaches the point where the
cuttings have accumulated on the bottom of the hole, these cuttings will be forced out of the hole.
When the cuttings have been cleaned out of the bottom of the hole, the bit will contact the undrilled
formation at the bottom of the hole and stop penetrating. Once the flow of cuttings out of the hole
stops and the tool string stops penetrating, the hole is clean.
4. After cleaning the hole the tool string may be raised to the top. Turning the hoist/pulldown
rheostat control in the HOIST direction and the hoist/pulldown speed selector switch in the
HOIST HIGH position will hoist the tool string.
2-82 BI652203
Operation Section
ENDING THE HOLE (MULTIPLE PIPE SECTIONS)
Reaming the hole with multi-section tool strings is the same as reaming with single pipe section
strings. The reaming procedure must be done in stages as the pipe sections are removed.
While removing the drill pipe the cuttings dislodged from the sides of the hole and the cuttings
generated by reaming will fall to the bottom of the hole. To effectively clean the hole, it would be
necessary to reassemble the tool string and lower it to the bottom of the hole. This is not desirable
as it is time consuming. One method to eliminate the need to clean the hole is to overdrill the depth
and allow cuttings to fill the hole to the desired finishing depth. Experience in this area will show
how much to overdrill the hole. A good practice is to overdrill the hole by 1 to 2 feet (0.3 to 0.6 m)
over the estimated finished hole depth. This way, if the estimate is wrong, the hole will be 1 to 2
feet (0.3 to 0.6 m) too deep. This can easily be corrected by a few shovels full of cutting thrown into
the hole. Underestimating, on the other hand will require that the tool string be reassembled and
the hole cleaned.
DRILLING DIFFICULT FORMATIONS
For the purpose of explanation, the drilling procedure given in the DRILLING section of the manual
assumes that drilling takes place in consistent, consolidated rock formation. Unfortunately, not all
drilling is in this type of formation. This section of the Operator’s Manual will detail, in general,
some typical drilling difficulties encountered.
The main cause of difficult drilling are unconsolidated material or wet sticky material. Unconsolidated
material causes vibration far greater than experienced in consolidated formation, and if severe
enough, may also decrease the bailing velocity of the main air stream. Wet, sticky material causes
problems with cleaning the hole since the material may coat the hole and the drill pipe, increasing
the air pressure above the working range. Wet material may also plug the bit orifices, freeze the bit
cones, or compact into balls that refuse to be bailed out of the hole. The general procedure for
drilling in difficult formations is the same as the procedure for drilling in good formations. The hole
is collared, drilled, reamed, and cleaned using the standard operating procedures. Monitoring of
the machine is, however, critical while drilling in difficult formations.
NOTE: Failure to closely monitor the machine and its bar graphs as shown on the operator’s
display terminal operator’s display screen will result in damage to the machine or a
stuck drill pipe.
BI6522032-83
Operation Section
UNCONSOLIDATED MATERIALS
Drilling unconsolidated materials may present two problems. The first, and most severe, is the
vibration encountered if the penetration rate is too fast. As the bit rotates the cones pass over the
material and the teeth or inserts chip away at the material being drilled. Unconsolidated material,
however, has voids in it. When the bit passes over a void in the material it only contacts part of the
bottom of the hole. As each roller passes through the void, the tool string moves down, as the roller
falls into the void, and then back up as the roller climbs out. This continual up and down motion
results in shock loads being transmitted from the bit, through the tool string, to the machine.
To drill through an unconsolidated formation it is necessary to reduce the load on the bit as it is
passing over the voids. It is also helpful to isolate the shock loading to the tool string. This is
accomplished by first reducing the pulldown speed. If reducing the pulldown speed does not reduce
the vibration to the machine to an acceptable limit, it may even be necessary to hoist the bit above
the void and then lower the bit a small amount at a time so as to chip away at the sides of the void
a little at a time. Reduction of the rotary speed will also help reduce the vibration of the tool string.
This is the last procedure that should be tried since if the pulldown speed is left high and the rotary
speed diminished, the vibration will be just as severe, only at a different frequency.
Unconsolidated material presents another problem due to the fact that the voids in the material
may allow the bailing air to escape through the sides of the hole, rather than passing along the drill
pipe and exiting through the top of the hole. This loss of air reduces the volume of air available to
bail the hole, causing the cuttings to fall to the bottom of the hole and be reground by the bit. This
further reduces the penetration rate since these cuttings must be ground up by the bit and bailed
out of the hole or they will plug the hole. Unconsolidated material may also cause the hole to cave
in. This creates problems due to the sudden addition of material into the hole and the resultant loss
of bailing velocity due to the increased diameter of the hole.
If unconsolidated material is causing the loss of bailing air volume or caving of the hole it is necessary
to continually clean the hole as the recycled cuttings or the caved material will plug the hole. Closely
monitor both the bailing air pressure and the flow of cuttings from the hole. If the air is being lost the
air pressure will remain constant but the flow of cuttings will stop or drastically decrease while
penetration does not decrease. Continue drilling for a few feet to try and get past the leak. If the
bailing air pressure starts to rise, the hole is plugging. Immediately hoist the tool string until the
pressure drops and allow the drill string to rotate for a few moments to clear itself. Then lower the
tool string to the bottom of the hole and clean it out. It may be necessary to regrind the cuttings to
make them small enough to seal the leak and be bailed out of the hole by reduced air volume. Once
the hole is clean, repeat the hoisting and lowering procedure every 2 to 3 feet (0.3 to 0.6 m) to keep
it so.
If the material tends to cave in from the sides of the hole, the tool string can become stuck in the
hole quickly. If the caved material is small, it will fit between the cones of the roller and fall to the
bottom of the hole. The hole can then be cleaned out using the same procedure as for a leaky
hole. If the caved material is large it will be necessary to pull the tool string out of the hole and then
redrill the caved material.
2-84 BI652203
Operation Section
NOTE: Be very cautious when drilling in formations which tend to cave in easily, especially if
the material caves in large blocks. Should the material that caves into the hole be too
large to lift with the rotary drive unit or too hard to break with the top of the bit, the tool
string will have to be abandoned in the hole.
Experience will dictate what procedure to follow when encountering material which tends to cave
in. When the formation is unfamiliar always be cautious. Caution may result in lower production,
but it could save a great amount of work and a complete tool string should the tool string become
stuck. Always clean the hole often and monitor the air pressure constantly. If the air pressure starts
to climb, hoist the tool string immediately — do not wait to see if the pressure will level off or not.
By the time it is determined what the air pressure will be, the hole is plugged. Cleaning the hole
often accomplishes two things.
First, it removes the caved in materials from the hole. Second, it loosens any potentially hazardous
material and causes it to cave in while the stool string is being hoisted. If the hole caves in while in
the hoist mode there is a better chance of recovering from the cave in.
If the hole should become plugged there are two ways to recover the tool string. Each method
depends upon what type of material has plugged the hole. If the material that is plugging the hole
is small (less than 6 inches [15.2 cm] square), it is possible to grind the material sufficiently to allow
it to pass between the lobes of the bit and fall to the bottom of the hole. This condition can be
observed if the bailing air pressure increases over normal working range. Large, chunky material
will let the bailing air through, while fine material won’t. Also, when attempting to hoist out of the
hole the tool string will not vibrate greatly, due to the small size of the material. Large material will
cause the tool string to be shocked every time a lobe on the bit strikes the block.
To recover the tool string from a hole plugged with smaller material hoist the bit until it runs into the
plug and stops hoisting. With rotary motion turning at approximately 50-60 RPM keep high hoist
loading on the bit and allow the bit to work its way through the plug. Monitor the rotary motor loading
(current) and reduce the hoist loading (force) to keep the load in the lower portion of the bar graph.
Once the plug is passed, clean the hole and return to drilling. The main air pressure may or may not
exceed the safety valve setting and cause the main air compressor to overheat. If the safety valve
opens when the hole is plugged, continue to attempt to free the tool string. The safety valve will
close when the plug has been removed. If the compressor overheats and shuts down continue to
attempt to free the tool string without the compressor. Allow the compressor to cool for a few
minutes and restart it. Continue this procedure until the tool string is free.
If the material plugging the hole is large it will be necessary to try and force the material back into
position enough to let the bit go past, and then try and redrill through the plug. Large material is
indicated when the tool string experiences severe vibration when being hoisted. To free the tool
string apply maximum hoist power. If the plug does not clear itself within a few moments lower the
tool string a few feet if possible and try again.
BI6522032-85
Operation Section
If the plug does not clear itself after repeated attempts at clearing it, there are two options available.
The tool string can be abandoned immediately without further trial or an attempt to drill through the
plug using the top of the bit can be made. In either case the hole being drilled will have to be
abandoned. In the first case the cost of the abandoned tool string is known, while in the second
case a gamble is being taken as the bit and stabilizer will almost certainly have to be scrapped and
there is no guarantee that the rest of the drill pipe will be recovered. If it is decided to abandon the
tool string, attempt to unscrew a section of pipe to recover some of the tool string. If this cannot be
done, lower the tool string to the bottom of the hole and then, using a suitable burning torch, cut the
drill pipe at ground level. It will be necessary to move over an existing hole to remove the stub of
pipe from the rotary drive unit.
CAUTION: Before cutting the drill pipe verify that the main air compressor is
shut down. Burning the pipe with the main air compressor running
may cause a fire or explosion as hot slag is introduced to the main air
stream or may cause hot material to be blown back onto the torch
operator.
If an attempt is to be made to free the drill string by drilling with the top of the bit, apply only enough
hoist pressure to keep the vibration and rotary motor load levels in an acceptable range. Vary the
hoist pressure by alternately placing the hoist/pulldown selector in the hoist and neutral positions.
Vary the rotary speed to help reduce vibration. Drilling through a large block with the top of the bit
can be a lengthy procedure and it is important to prevent damage to the rest of the machine. Once
the tool string is free, check the bit and stabilizer as well as the drill pipe for damage. Replace
components and move to a new location for the hole. Do not try and drill the same hole again as
this will almost certainly cause the tool string to become stuck again.
WET OR STICKY FORMATIONS
Drilling in wet or sticky formations presents three possible problem areas. The three problems that
may be encountered are coating of the hole and pipe with material, conglomeration of the material
into pieces too large to remove with the bailing air stream and caving of the hole. Either of these
problems may be present, or any combination of the three may be present at the same time.
Drilling in wet formations follows the same practices as drilling any other formation. Drilling wet
formations, however, requires that particular attention be paid to the bailing air pressure and
penetration rates. Wet formations are more susceptible to plugging the hole, but recovering the tool
string from the plugged hole is easier than with unconsolidated material.
In the case where the material is adhering to the drill pipe and coating the sides of the hole it is
necessary to ream and clean the hole every 5 to 10 feet (1.5 to 3.0 m) to remove the offending
material. It is also necessary to clean the drill periodically to remove the caked on material. This
can be accomplished by removing the tool string from the hole and allowing the material to be
scraped off by the guide bushing. It is important then, if the guide bushing is to be used to clean the
tool string, that the bushing be kept in good repair.
2-86 BI652203
Operation Section
In the case where the material is conglomerating into large pieces, these pieces fall back down to
the bottom of the hole and are recycled through the bit to be broken up. If the amount of recycled
material is too great it will accumulate at the bottom of the hole and restrict the main air stream. To
keep this material at a minimum, clean the hole periodically. When hoisting the tool string, allow the
material to be ground by the bit and fall to the bottom of the hole before cleaning the hole.
In the case where the material is caving from the sides of the hole, treat the formation as
unconsolidated and drill according to the procedure detailed in this manual for unconsolidated
material.
It is important when drilling through difficult formations to constantly monitor the machine and tool
string. Allowing the tool string to become stuck is an expensive mistake and can be avoided by
cautious drilling practices. Reaming and cleaning the hole may only take a few moments, but it
could be the difference between an abandoned hole and tool string and a successfully completed
hole.
ANGLE DRILLING
NOTE: When moving the mast for angle hole drilling on machines with mast lengths of 65 ft. or
more, the drill pipe must be stored in the racks and the rotary head lowered to its
lowest position.
Angle drilling follows the same general drilling procedures as vertical drilling. The main difference in
the drilling procedures, besides the fact that the hole is at an angle, is the need to monitor the
condition of the different systems more closely while angle drilling. The differences in the operating
procedures for the different systems on the machine are limited to handling the tool string and
raising and lowering the mast to the proper drilling angle.
When drilling an angle hole, monitoring of the system indicators such as the drilling air pressure,
the rotary load and the machine vibration, becomes more critical than when drilling a vertical hole.
The reason these monitors become more important is the fact that an angle hole will tend to
wander downward as the hole is being drilled. This wandering is due to the drill steel assuming a
natural camber as it is being extended past the guide bushing. This camber is unavoidable and
becomes worse as the angle of the hole approaches 25 degrees.
The force of gravity continually acts upon the tool string causing it to bend downward. This downward
bending is known as the camber of the drill pipe. This camber causes the hole to be drilled with a
gradual bend in it. This causes the drill pipe to contact the side of the hole, increasing the load on
the rotary motor. This also tends to inhibit the bailing of the hole since the cuttings are not flowing
vertically. The flow of the bailing air (and suspended cuttings) must be diverted around the points
that the drill pipe is resting on the side of the hole. This contributes to the increased air pressures
needed to drill an angle hole. The vibration of the tool string will be increased while drilling at an
angle, due to the tool string resting on the side of the hole, rather than on the bottom.
BI6522032-87
Operation Section
PROGRAMMED DRILL CONTROL DRILLING
P.D.C. Drilling is similar to normal drilling in that the machine must be positioned, leveled and set-
up manually by the operator. The actual drilling operation will be controlled by the automated
system. To start the automated system use the following start-up sequence.
1. Make sure the hoist/pulldown rheostat and the rotary rheostat are in the OFF position.
2. Verify that the desired drilling depths, collaring depth, and wet hole depth have been set per
P.D.C. operating parameters screen on operator’s display terminal.
3. Place hoist/pulldown speed selector switch in the PULLDOWN position.
4. Place the operating mode selector switch in the DRILL position.
5. Press the drill/propel control ON push-button.
6. Place the Main Air Valve switch in the OPEN position.
7. Verify on the operator’s display terminal that no PDC faults exist. If a fault exits, it must be
cleared before the PDC control can be activated.
8. With the operator’s display screen shown in the operator’s display terminal, press the depth
indicator reset push-button to reset the hole depth and bit depth indicators to zero.
9. Place hoist brake control in the RELEASE position.
10. On the operator’s display terminal with operator’s display showing, press keypad button F5
to turn on P.D.C. The readout above the F5 key will then read “PDC on.”
After the above start-up procedure has been initiated the automatic controls will take over the
actual drilling of the hole. Water injection (if so equipped) will be shut off at preset depth. When the
total depth of the hole is reached, as preset, the tool string will be automatically hoisted and when
the bit approaches the top of the hole, the control will stop the bit, shut off the air and set the hoist
brake.
If problems arise in the P.D.C. functions, the system will have to be corrected by a qualified electrician.
In most cases, if a malfunction occurs in the automated system, the automated system can be
turned off and the drilling completed manually.
2-88 BI652203
Operation Section
PREPARING TO MOVE
Once the hole has been completed and the tool string removed from the hole it is necessary to
move the drill to the next hole location to prepare to drill the next hole. Preparing to move the drill
consists of proper storage of the tool string, lowering the machine to the ground, and inspection of
the machine and travel route prior to propelling.
To prepare the drill to move, proceed as follows:
1. Upon completion of the current hole, hoist the tool string from the hole. If using multiple pipe
sections, remove and store all pipe necessary to remove the entire tool string from the hole.
Turn off the dust control system and raise the dust curtains.
2. Clamp the stabilizer with the tool wrench to prevent movement of the tool string during propel.
CAUTION: Do not propel with the tool string in a position where it will be struck
against the ground while propelling. Should the tool string hit the
ground while propelling, damage to the machine and tool string will
result.
3. Press the automatic leveling switch to the RETRACT position to raise the jacks and lower the
machine. Hold the switch in the RETRACT position until the jacks are fully retracted. Refer to
the auto leveling screen on the operator’s display terminal to verify all four jacks are fully
retracted.
NOTE: If the machine is to be lowered manually, refer to steps 4, 5 and 6 and operator’s
display terminal screen auto leveling.
4. Using the manual leveling jack controls, lower the machine so that it remains level, but is
touching the ground. Use the leveling jack controls in pairs (i.e. either both side controls, or
both end controls simultaneously) to reduce the twisting loads on the drill frame.
5. Once the machine is touching the ground, it may be lowered completely. To lower the machine
completely, first lower the uphill side or end of the machine to the ground, then lower the
downhill side or end to the ground. It is important that the machine be lowered in stages to
minimize both the angle of the machine and the bending stresses placed on the machine.
CAUTION: While manually lowering the machine to the ground it is imperative

that the machine be kept as level as possible. It may be necessary to
lower the machine in stages to keep it as level as possible.
6. Once the machine is completely lowered, retract the leveling jacks to the maximum retracted
position.
BI6522032-89
Operation Section
NOTE: When manually lowering the machine be sure that the leveling jacks are fully retracted
before propelling the machine. Propelling the machine with a leveling jack not fully
retracted will result in serious damage to the jack and machine structures.
7. Inspect the machine, travel route as outlined in the PROPELLING topic in this manual. After
completing the inspections the machine is ready to propel.
MACHINE SHUTDOWN
Shutting down the machine is necessary any time that the operator must leave the machine, either
at the end of the shift, or for a period of time during the shift. Machine shut down is also necessary
for most maintenance work to be performed.
Shutting down the machine is essentially the reverse of starting it up. The degree of storage work
to be done is determined by the length of time the machine will be shut down. Shut down for a
short period involves little extra work, while shutting the machine down for a lengthy period will
involve considerable effort.
SHUT DOWN PROCEDURE
To shut down the machine, proceed as follows:
1. Complete the hole, if any, currently being drilled. If the hole is not completed before the machine
is shut down, it will be necessary to abandon the hole and drill another in its place. Do not try
and redrill a hole that has been left unfinished as releveling and placing the drill in the exact
same position is extremely difficult.
2. Remove the tool string from the hole. If multiple pipe sections are used, remove and store
pipe sections as necessary to remove the entire tool string from the hole.
NOTE: Do not shut the machine down with the tool string in the hole. To do so may cause
damage to the drill pipe and may lead to the abandonment of the tool string and the
hole.
3. Determine the length of time the drill is to be idle. Refer to the appropriate storage topic in this
manual for the degree to which the tool string must be disassembled. If necessary, disassemble
and store the tool string at this time.
4. If possible lower the rotary drive unit to its lowest position and set the hoist brake. If the tool
string is not to be removed, clamp the stabilizer with the tool wrench and set the hoist brake.
2-90 BI652203
Operation Section
5. Following the procedures in the PREPARING TO MOVE topic in this manual, lower the drill to the
ground. Place the leveling jack pads on the ground, but do not place any weight on them.
6. Shut off the main air compressor. Place all controls in the off or neutral position.
7. Go to the machinery house and turn off all breakers. If the machine is to be shut down for a
short period of time and it is necessary to leave the lights on, it is permissible to leave the
lighting breaker and lights on.
8. Inspect the machine for obvious damage or wear. Make note of any operating difficulties
discovered while drilling and any problems discovered during this inspection. Report the
difficulties to the appropriate personnel.
9. Close all doors and windows tightly.
SHORT TERM STORAGE
If the machine is to be shut down for more that 3 eight hour shifts, but less than 3 weeks, short term
storage precautions are necessary. These precautions are necessary to insure that the machine is
not damaged or does not deteriorate during the storage period.
Short term storage is primarily concerned with placing all components in a safe position and providing
additional protective lubrication to normally lubricated components.
To store the machine for a maximum of 3 consecutive weeks, proceed as follows:
1. If not already done so previously, complete all shut down procedures as detailed in the MACHINE
SHUT DOWN topic in this manual. During the shut down procedure it is necessary to remove
and store the complete tool string. Remove the bit from the stabilizer and store it in a protected
place. Coat the bit with a suitable oil to prevent rusting while stored. As the drill pipe is being
disassembled, clean and lubricate the threads on each end of the pipe before storing in the
pipe racks.
2. Lower the rotary/pulldown unit to the lowest position and set the hoist brake. Inspect the
rotary/pulldown unit for damage or wear and note any problems discovered. Cover the rotary
and pulldown motors with waterproof tarps or covers. Raise the dust curtains. Retract the
drill pipe tong cylinder.
3. Check the oil level in the rotary/pulldown unit. Check the cases to see if there is water in the
oil. If there is water in the cases, drain and refill the cases with suitable oil. If no water is
present, fill the cases to the proper level.
BI6522032-91
Operation Section
4. Manually cycle the lube system and verify that all points on the mast are receiving lubricant. If
the auto lube system is not functioning properly, repair or replace components as necessary.
5. Lower the leveling jacks until the jack pads are resting on the ground, but no machine weight
is on them.
6. Inspect the air compressor for signs of wear or damage. Make note of any damage discovered.
7. If the air compressor motor is equipped with anti-condensation heaters, turn them on at this
time. If the motor is not equipped with heaters, have a qualified electrician install heaters or a
suitable substitute. Cover the motor with a waterproof tarp or cover.
8. Close and lock all electrical cabinet doors.
9. Fill the radiator to the top with the proper oil on machines equipped with screw compressors.
10. Manually cycle the auto lube system to verify that all points on the machine are receiving
lubricant. Repair the system as necessary to lube all points.
11. Lube all manual lube points.
12. Clean the dust hoppers on the dust control system if required.
13. Close and lock all windows and doors.
LONG TERM STORAGE
Long term storage procedures are necessary any time the machine is to be left for a period exceeding
3 weeks. Long term storage includes all procedures necessary for short term storage, and depending
on the situation, some additional precautions.
There are two procedures involved in long term storage of the drill, the choice of which depends
upon whether the machine can be attended to while in storage. If the machine can be started and
the majority of the machinery operated once a month during the storage period, much less protective
work is necessary. If the machine must remain unattended, special precautions are necessary to
prevent damage to the machine.
NOTE: If the machine is to be unattended during the storage procedure the procedures
necessary to store the machine properly will take considerable time and restoring the
machine to production will take even longer. Do not utilize the unattended long term
storage procedure unless absolutely necessary.
2-92 BI652203
Operation Section
ATTENDED LONG TERM STORAGE
The attended long term storage procedure combines the short term storage procedure with monthly
start-up and running periods. To store the machine for a long period of time it is necessary to
complete the procedures listed in the SHORT TERM STORAGE topic in this manual. Then, once a
month for the duration of the storage period, complete all start-up inspection and lubrication
procedures listed in this manual and start the drill. Run all of the gear trains for 10-20 minutes to
distribute the oil over the gears and bearings. Hoist and lower the rotary/pulldown unit the full
length of the mast 4-6 times to distribute lubrication to the mast and rotary/pulldown unit components.
Cycle the tool racks 2-3 times. Run the air compressor for 1 hour. Propel the drill at least 6 times
the length of the machine. After running the machine components, follow the short term storage
procedure once again and store the machine for another month. Repeat this procedure every
month until the machine is returned to service.
UNATTENDED LONG TERM STORAGE
It is not within the scope of this manual to detail the procedures involved in the long term storage
of a drill. These procedures will involve disassembly of the major units on the drill, duties that are
not usually performed by operating personnel. Refer to the Mechanical Maintenance Manual for
details concerning the long term storage of the machine.
The procedure listed here is an outline intended only to give a general idea of the effort involved in
proper storage of the machine. To store the unattended machine for an extended period of time,
proceed as follows:
1. Complete all short term storage procedures.
2. Remove the motors from the drill and store in a heated building.
3. Completely fill the rotary and pulldown gear cases with an approved oil. Both cases can be
filled completely by adding the oil through the breather openings. Remove all water from the
cases.
4. Loosen the guide rollers on the rotary/pulldown unit frame to provide one-half inch clearance
between the rollers and the mast.
5. Remove the auxiliary winch line.
6. Cover the rotary gear case and hoist/pulldown gear case with a waterproof tarp.
7. Remove the air compressor from the machine and store in an attended heated building.
BI6522032-93
Operation Section
8. Close and completely seal all electrical cabinets.
9. Close and completely seal the operator’s cab.
10. Close and completely seal the machinery house. Completely seal the filter fan unit.
11. Completely drain the compressor coolant system.
12. Propel the machine onto blocks to prevent the crawler belts from rusting. Coat the entire
crawler belts with a rust preventative oil. Coat the propel chains with a rust preventative oil.
13. Block the leveling jacks in the full retracted position.
14. Manually grease every lube point (including auto lube points).
TOOL RECOVERY
Normally the drill tools are always either connected to the rotary drive unit or are held by the tool
wrench. Mistakes, however, do happen and the drill tools may be dropped down the hole. Tool
recovery (or tool fishing) is the procedure used to recover these tools.
There are two situations where the tool recovery procedures are necessary and each situation
dictates the procedure to be used. The first situation is when the tools have been uncoupled and
have fallen below the guide bushing. It is possible in this situation to recover the tool string and, if
no damage was done, return to drilling. The other situation is where the drill pipe has broken and
has either fallen below the guide bushing or cannot be handled normally.
If the tools have uncoupled and the upper end of the tool string is still above the guide bushing,
recouple the tools as would normally be done for tool joint make-up. Clamp the tool string with the
tool wrench to aid in making the joint. When the tools are coupled, remove the tool string from the
hole, remove the bit and turn the main air on momentarily to clean the inside of the drill pipe. Clean
and reinstall the bit and return to drilling.
If the tools have uncoupled and the upper end of the tool string is below the guide bushing but still
above ground level, re-couple the tool string as would normally be done to tool joint make-up,
except use caution when making the joint. Caution is necessary when making the joint as the tools
in the hole will now be at an angle with respect to the tools on the drill. Cross threading of the joint
is possible in this situation and should be avoided since it will not only damage the threads but
result in an unreliable joint. One method to realign the tools would be to attach a suitable pulling
device to the tools in the hole and center the tools with blocking (make sure it doesn’t fall down the
hole). This would allow normal joint make-up without abandoning the hole. If this is not possible, the
leveling jacks may be adjusted to align the tools. Be sure that the stability limits of the machine are
not exceeded. It will be necessary to abandon the hole since the drill cannot be repositioned in the
exact same orientation as before losing the tools. When the tools are recovered, clean the pipe and
bit as detailed in the first procedure of this section and return to drilling.
2-94 BI652203
Operation Section
If the tool string has uncoupled and the upper end of the lost tool string is below ground level, there
are two methods of recovering the lost tools. One method is to attempt to make the joint using the
drill pipe still connect to the rotary drive unit. The other method is to use special equipment (not
supplied) to recover the tools.
If the top of the lost tool string is not reachable from ground level, very gently lower the remaining
tool string until it contacts the tools in the hole. Using very slow rotary speed and low torque,
attempt to re-make the joint. If the joint can be made, very gently raise the tools to a position where
the top of the recovered tools can be clamped in the tool wrench. Rebreak the joint and inspect the
threads on both sections of pipe. Repair the threads if necessary before continuing. When the tool
string is repaired, remove the bit and clean both it and the drill pipe to remove any dirt that may
have entered while the joint was uncoupled.
If the joint cannot be made using the above procedures, or if the pipe has been broken or been
damaged to an extent that it cannot be handled normally, it will be necessary to use special equipment
and techniques to continue drilling or recover the lost tools. It is not within the scope of this manual
to detail the procedures necessary to handle broken or lost tools, and the use of these tools should
be described by the manufacturer.
CAUTION: WHEN PERFORMING SPECIAL PROCEDURES NOT DETAILED IN

THIS MANUAL, ALWAYS FOLLOW THE RECOMMENDATIONS OF THE
TOOL MANUFACTURER AND PRUDENT SAFETY GUIDELINES.
FAILURE TO FOLLOW SAFE PROCEDURES MAY RESULT IN THE
DEATH OR SERIOUS INJURY OF PERSONNEL OR SERIOUS DAMAGE
TO THE MACHINE.
BI6522032-95
Operation Section
DRILL STABILITY CHARTS
Drill Stability Chart - Special Propel Conditions

2-96 BI652203
Operation Section
Drill Stability Chart - Typical Propel Conditions

BI652203 3-1
Lubrication Section
Section 3
Lubrication
Table of Contents
LUBRICATION PRINCIPLES ......................................................................................................... 3

Auto Lube Reservoir & Control Panel .......................................................................................... 4
Auto Lube Piping ~Mainframe (View #1) ...................................................................................... 5
Auto Lube Piping ~Mainframe and Axles (View #2) ..................................................................... 6
Auto Lube Piping ~Mast (View #1) .............................................................................................. 7
Auto Lube Piping ~Mast (View #2) .............................................................................................. 8
LINCOLN TYPE SL-1 LUBRICANT INJECTORS .................................................................... 9
LUBRICANT INJECTOR OPERATION ............................................................................ 10
INJECTOR ADVANTAGES .............................................................................................. 11
TROUBLESHOOTING .......................................................................................................... 12
BIT LUBRICATOR ................................................................................................................. 13
FLOWMASTER PUMP SERVICING ..................................................................................... 14
PRESSURE CONTROL VALVE ADJUSTMENT .............................................................. 14
FLOW CONTROL VALVE ADJUSTMENT ............................................................................. 15
FlowMaster Rotary Driven Hydraulic Pump Schematic ................................................................ 15
CRANK CASE OIL ................................................................................................................ 15
PUMP DISASSEMBLY PROCEDURE .................................................................................. 16
FlowMaster Rotary Driven Hydraulic Pump Assembly ................................................................. 17
PUMP ASSEMBLY PROCEDURE ........................................................................................ 18
FlowMaster Rotary Driven Hydraulic Pump Components ............................................................. 19
TROUBLESHOOTING .......................................................................................................... 20
Lube Pump Hydraulic Schematic ............................................................................................... 21
LUBRICATION POINTS ............................................................................................................... 22
GEARCASE AND RESERVOIR CAPACITIES ...................................................................... 22
LOWER WORKS LUBRICATION ......................................................................................... 23
MAIN FRAME LUBRICATION ................................................................................................. 24
MAST LUBRICATION ~PART 1 ............................................................................................. 25
LUBRICANT CLEANLINESS ................................................................................................. 28
LUBRICANT SELECTION ........................................................................................................... 29
ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT ................................................ 30
MPO - MULTIPURPOSE OIL................................................................................................. 31
RWRL - RUNNING WIRE ROPE LUBRICANT ..................................................................... 32
HYDO – HYDRAULIC OIL ..................................................................................................... 34
3-2 BI652203
Lubrication Section
PAO SYNTHETIC HYDRAULIC FLUID ............................................................................ 35

Recommended Viscosity vs. OAT Chart .................................................................................... 35
PARAFFINIC BASE PETROLEUM HYDRAULIC FLUID .................................................. 35
Recommended Viscosity vs. OAT Chart .................................................................................... 36
ADDITIONAL LUBRICATION BENCHMARKS:

EGL - ENCLOSED GEARCASE LUBRICANT ................................................................... (insert)
MPG - MULTIPURPOSE GREASE .................................................................................... (insert)
OGL - OPEN GEAR LUBRICANT ...................................................................................... (insert)
CERTIFIED LISTING FOR OGL, MPG, AND EGL LUBRICANTS ...................................... (insert)
BI652203 3-3
Lubrication Section
Section 3
Lubrication
LUBRICATION PRINCIPLES
The proper lubrication of this machine is vital to its successful, continued operation. Application of
the CORRECT lubricant in the CORRECT amount at the CORRECT place as part of a PROVEN
maintenance program is required to keep the machine operating at a level of productivity. Proper
lubrication will provide better component service life with a reduction of repairs and downtime.
When not properly lubricated, moving parts wear quicker and fail sooner.
The primary wear items of this machine are lubricated by an automatic system that dispenses lube
to selected points at pre-selected, timed intervals during machine operation. This system is covered
in more detail further on in this section. It is important to the operation of this automatic lube system
that you become familiar with it and understand its operation in order to properly maintain and
service it, thus keeping it operable. It is also necessary that you inspect on a regular basis the
points for automatic lubricant application to insure the system is performing its job adequately.
Some components, due to their location and function, can not be readily covered by the automatic
lube system. You should become familiar with these points so you can service them properly at
the intervals listed. A listing of the parts covered by the automatic lubrication system is included
later in this section. The standard lubrication fittings used for manual service are the hydraulic type,
push-on fittings having 1/8 inch or 1/4 inch NPT threads.
Bushings and bearings operating in a highly contaminated atmosphere (dust, grit, etc.) should be
lubricated until clean grease seeps out around the journal or seal, or comes out the purge fitting, if
one is provided.
Overfilling an anti-friction bearing can cause it to run excessively warm. After lubricating anti-friction
bearings (those that are sealed such as in electric motors must use electric motor grease) remove
the pressure fitting, or the relief plug when provided, allowing the bearing to purge itself of any
excess lube during the first 10-15 minutes of operation. Replace the fitting or plug after that time.
Grease in a bearing generally deteriorates gradually, not suddenly. Only a small amount needs to
be added to it at regular intervals to maintain the proper lubricant level. Adding a small quantity of
grease to the bearing every 600 operating hours, unless otherwise specified, is adequate.
Open gears and pinions require a constant coating of high grade lubricant which is specified for
operation. Inspect all open gear sets at least once daily (every 24 hours) to ensure they are coated
with OGL.
CAUTION: Contact with or ingestion of petroleum products can be harmful.

Automatic lubrication systems operate under pressure. Before
opening any lube supply line, relieve the system and that line in
particular, of any residual pressure.
3-4 BI652203
Lubrication Section
Auto Lube Reservoir & Control Panel

BI652203 3-5
Lubrication Section
Auto Lube Piping ~Mainframe (View #1)

3-6 BI652203
Lubrication Section
Auto Lube Piping ~Mainframe and Axles (View #2)

BI652203 3-7
Lubrication Section
Auto Lube Piping ~Mast (View #1)

3-8 BI652203
Lubrication Section
Auto Lube Piping ~Mast (View #2)

BI652203 3-9
Lubrication Section
LINCOLN TYPE SL-1 LUBRICANT INJECTORS
These pressure-operating, spring-reset, series-installed injectors are supplied in banks mounted

on manifolds or individually. Each injector expels a maximum of .08 cu. inch of lubricant from its
outlet port each cycle. Dual outlet ports on each injector permit the injectors to be piped in series for
increased lube supply to a common point. The quantity of lube to each point on this machine has
been carefully designed by our engineers for proper coverage. Each injector output can be adjusted;
however it is recommended that injectors initially be set and used at their maximum setting.
NOTE:: MAXIMUM Operating Pressure: 3,500 PSI

RECOMMENDED Operating Pressure: 2,500 PSI
MINIMUM Operating Pressure: 1,850 PSI
MAXIMUM Recharge Pressure: 600 PSI
CAUTION: STORED ENERGY! Contact with or ingestion of petroleum products

can be harmful. Automatic lubrication systems operate under
pressure. Before opening any lube supply line, relieve the system
and that line in particular, of any residual pressure.
To set an injector for maximum output:
1. Loosen locknut.
2. Turn adjusting nut until there is a small gap at the top of the stem.
3. Orient the adjusting nut so that the opening is toward the front of the
injector.
4. Tighten the locknut.
To reduce an injector’s output:
1. Loosen locknut.
2. Turn adjusting nut clockwise (CW) until desired discharge rate is
obtained. This forces the stem into the body, retarding the stem’s
movement.
3. Set the locknut.
CAUTION: Do not turn adjusting nut down (clockwise)

more than 5 full turns from the maximum
discharge setting. Check output flow from
injector at this time to ensure it is still
operating. If not, back off adjusting nut until
injector does consistently operate. Inspect
the adjusted injector for operation over 3 or
4 cycles after returning machine to work to
make sure it is functioning.
3-10 BI652203
Lubrication Section
LUBRICANT INJECTOR OPERATION
STAGE 1: The injector piston is in its normal or reset position. The

discharge chamber is filled with lubricant from the previous
cycle. Under the pressure of incoming lubricant, the slide valve
is about to open the passage leading to the piston.
STAGE 2: When the slide valve uncovers the passage, lubricant is admitted
to the top of the piston, forcing the piston down. The piston forces
lubricant from the discharge chamber through the outlet port to
the bearing.
STAGE 3: As the piston completes its stroke, it pushes the slide valve
past the passage, cutting off further admission of lubricant to
the passage. The piston and slide valve remain in this position
until lubricant pressure in the supply line is vented (relieved)
at the pump.
STAGE 4: After the pressure is relieved, the compressed spring moves the
slide valve to the closed position. This opens the port from the
measuring chamber and permits the lubricant to be transferred
from the top of the piston to the discharge chamber.
BI6522033-11
Lubrication Section
NOTE: The injectors may be mounted individually, or grouped in a manifold at one location.
INJECTOR ADVANTAGES
3-12 BI652203
Lubrication Section
TROUBLESHOOTING
AIR LOCKS:
When the system is not primed properly, air is often trapped in the pump, supply line, injectors, or
feed lines. Since the air pockets, with their great compressibility, provide a cushion against the
normal rapid rise in supply line pressure, they serve to make the cycling of the system sluggish and
erratic. In some extreme cases, particularly when the pump is air locked, they may make the
system inoperable.
NOTE: If cycling time of a new installation greatly exceeds the cycling time determined from
the system planning, it is an indication of an air lock in the system.
When the pump fails to prime and pump due to air locks, the vent plug located on or near the pump
outlet on all Lincoln models should be opened while the pump is in operation and all of the air
allowed to escape. The use of oil as an aid to priming is recommended. Air in the supply lines is
expelled by loosening pipe plugs at the end of each line (main supply lines, etc.) and allowing
generous quantities of lubricant to escape carrying with it the entrapped air. Air locks in the injectors
are corrected, in the case of the SL-1 injectors, by opening the lube fitting and allowing the lubricant
and air to escape. Air locks in the feed line can be corrected by loosening the feed line connection
at the bearing inlet and allowing lubricant and air to escape as the system is cycled repeatedly. Do
not loosen any connections which are under pressure.
DIRTY SUPPLY LINES:
This is a preventive maintenance problem and should be thoroughly checked before the system is
installed. However, a malfunction of the injectors or the vent valve can usually be traced, by the
disassembly of the unit and examination, to foreign material from the supply line inner surfaces
preventing proper operation.
After the trouble has been encountered, only the disassembly and complete cleaning of the affected
units will restore the system to its original state. Preventively, the supply lines should be thoroughly
cleaned and blown out before installation.
ALL INJECTORS DO NOT WORK PROPERLY:
On a newly installed system, the indicator stems on one or more injectors fails to move to the
discharge position. As a result, some of the bearings do not receive the measured amount of
lubricant.
BI6522033-13
Lubrication Section
Those units equipped with a pressure switch must be adjusted to allow a higher developed pressure,
at which level all of the injectors will discharge.
3500 PSI maximum for high pressure systems.

1000 PSI maximum for low pressure systems.
(For long life, keep pressure to a minimum permissible for proper injector operation.)
INDICATOR STEMS DO NOT RETURN TO NORMAL:
This condition could be due to the sluggish operation of all new assemblies and after a few operations
this stiffness may disappear.
However, it could be an indication that, after venting, the residual supply line pressure is too high to
allow the injectors to operate normally. This is due to a restriction in the supply line which hampers
the rapid venting pressure. This condition may be the result of many things: notably, lubricants, low
temperatures at which lubricants stiffen, or coupled with the above, an extremely short lubrication
cycle. This condition is usually encountered when the lubrication cycle is relatively short. In the
automatic system, where the cycle can be as low as 3-3/4 minutes, it can be a big problem.
CORRECTIONS:
1. The lubricant should be checked. The use of the centralized system eliminates the need (in
most cases) for the heavy soap additive which only lengthens the effective line of the individual
lubricant application.
2. The lubricant can be made more resistant to physical change by the use of low temperature
additives.
3. The output of lubricant per cycle can be increased and the lubrication interval lengthened.
4. Be sure lubricant used meets requirements of system.
When hand operated systems are being tested after installation, repeated operations can use
short intervals between cycles. Under normal conditions, the cycling of a hand operated system
will usually be infrequent (once an hour at the most), allowing plenty of time for proper venting.
BIT LUBRICATOR
The Bit Lubricator is located at the right, front of

the machine, beneath the house air filter.
3-14 BI652203
Lubrication Section
FLOWMASTER PUMP SERVICING
CAUTION: To reduce the risk of serious bodily injury, including fluid injection,
injury from moving parts, and splashing in the eyes or on the skin:
always follow the following Pressure Relief Procedure whenever you
shut off the pump; when checking or servicing any part of the spray
system; when installing, cleaning or changing dispense valve
nozzles; or whenever you stop dispensing.
PRESSURE RELIEF PROCEDURE
1. Close the shut-off valve to the

material supply line.
2. Turn power OFF to lube pump at

the control panel. Disconnect
24DCV power supply at the solenoid
valve.
3. Relieve pressure at safety

unloader.
The lube pump is factory set at 350 PSI working inlet hydraulic pressure with a flow rate of 2.5
GPM. Maintain hydraulic pressure between 300-450 PSI. Maximum flow rate is 7 GPM. However,
adjusting the lowest pump outlet pressure and hydraulic fluid flow to obtain the desired to results
will minimize pump wear.
Pump pressure and flow rate will vary depending on operating temperatures. DO NOT ADJUST
THE PUMPS PRESSURE BEFORE THE INITIAL START-UP PROCEDURE. For more information
on installation and start-up, refer to the manufacturer’s literature included with this machine.
PRESSURE CONTROL VALVE ADJUSTMENT
1. Loosen the locknut on the pressure reducing valve by turning the nut COUNTER-CLOCKWISE.
2. Turn the valve stem COUNTER-CLOCKWISE until it reaches the stop. This adjustment allows
the minimum pressure setting which is approximately 170 psi.
3. With the pump stalled against pressure, turn the pressure control valve stem CLOCKWISE
until the desired pressure is attained on the manifold pressure gauge. DO NOT EXCEED 450
PSI.
4. Tighten (CLOCKWISE) the locknut to 20-25 Ft.Lbs.
BI6522033-15
Lubrication Section
FLOW CONTROL VALVE ADJUSTMENT
1. Loosen the locknut on the flow control valve by turning the nut COUNTER-CLOCKWISE.
2. Adjust the flow by turning the valve stem CLOCKWISE to reduce the flow and COUNTER-
CLOCKWISE to increase it. The flow valve can be turned in until the valve is completely
closed, and out a maximum of 2-1/2 turns.
3. After adjusting the flow to the desired setting, tighten (CLOCKWISE) the locknut to 20-25
Ft.Lbs.
FlowMaster Rotary Driven Hydraulic Pump Schematic
WARNING: Relieve pressure from the pump and supply lines before servicing or
repairing the pump, to reduce the risk of an injury from injection,
splashing fluid or moving parts.
CRANK CASE OIL
Check the crank case oil every 100 hours of operation. Change
the crank case oil every 500 hours of operation. Use SAE 10W30
motor oil in all units except Model 85610. In Model 85610, the
manufacturer recommends Mobil Arrow HFA Low Temp oil for
use at -70°F ambient temperatures.
The crank case should be filled to the center of the drain plug
located on the back of the crankcase.
3-16 BI652203
Lubrication Section
PUMP DISASSEMBLY PROCEDURE
1. Remove and separate manifold (37) from the hydraulic motor (42).
2. Remove the pipe plug (45) and drain the crank case oil from the pump housing (46).
3. Remove the housing cover (30) and cover gasket (31).
4. Remove the retaining ring (57) and pull the shovel plug (56) from the housing tube (55).
5. Remove and separate the hydraulic motor (42) from the pump housing (46).
6. Remove the 2 outlet pin nuts (50) from the pump housing (46).
7. Remove the pump sub-assembly (1-28) from the pump housing (46). Pushing the sub-
assembly up with a wooden or plastic rod .75 inch O.D. against the check seat housing (28)
is helpful.
8. Remove the housing tube (55) from the pump housing (46) by inserting a .75 inch O.D. rod
through the inlet holes at the bottom of the housing tube (55) and unscrewing it.
9. Remove the bronze bearing (51), o-ring (52) and back-up washer (53) from the housing tube
(55).
10. Remove the crankrod assembly (1-8) from the pump by unscrewing the screws (12) and
then pulling out the wrist pin bushings (13).
11. Remove the check seat housing (28) from the reciprocating tube (21).
12. Unscrew the wrist pin anchor (14) from the reciprocating tube (21) and pull the plunger
assembly (9-20) from the tube.
13. Using a .50 inch O.D. rod, push the cup seal (22) and pump cylinder (24) from the reciprocating
tube (21).
14 Remove the pump plunger (20) from the plunger link rod (17). A spanner wrench is required.
15. Unscrew the plunger link rod (17) from the plunger tube (11) and slide off the cup seal (16),
back-up washer (15) and the wrist pin anchor (14).
16 Unscrew the plunger tube (11) from the outlet pin (9).
17. To dismantle the crankrod assembly (1-8), remove the screws (1) and counter weights (2).
18. Remove the retaining rings (6) and press the crank eccentric (7) out of the ball bearing (8). Be
sure to support the ball bearing (8) on the inner race.
BI6522033-17
Lubrication Section
FlowMaster Rotary Driven Hydraulic Pump Assembly

3-18 BI652203
Lubrication Section
PUMP ASSEMBLY PROCEDURE
1. When the pump is disassembled, it is recommended to replace all seals and gaskets. For
replacement parts and service kits, refer to part sheet, “PUMP, HYDRAULIC, ROTARY
DRIVEN” in the parts manual for this machine.
2. In the process of disassembly, examine the following components and replace if excessive
wear is indicated:
• Ball Bearing (8)
• Crank Eccentric (7)
• Crank Rod (5)
• Wrist Pin (13)
• Plunger Tube (11)
• Pump Plunger, Ball & Spring (18-20)
• Pump Cylinder (24)
• Check Seat Housing & Ball (26 & 28)
• Upper Bronze Bushing (51)
• Housing Tube (55)
• Shovel Plug (56)
• Reciprocating Tube (21)
3. The assembly procedure is reverse of the disassembly procedure except for the following:
4. Install parts (22-28) into reciprocating tube (21) after the plunger assembly (9-20) is installed.
5. Install the pump sub-assembly (1-28) into the pump housing (46) before tightening the housing
tube (55) to the pump housing (46). Be sure the reciprocating tube (21) is inserted through
both bushings before tightening the housing tube (55).
6. Use LocTite 242 (or similar product) medium strength thread lock on all torqued threaded
connections. Extreme care must be exercised to prevent excess compound from flowing
into critical areas such as clearance fits and ball check. Allow a minimum of 30 minutes cure
time before operating the pump.
7. Torque Specifications:
A. Plunger Tube (11) to Outlet Pin (9) ~ Tighten to 100-110 In.Lbs.
B. Button Head Screws (12) to Wrist Pin Anchor (14) ~ Tighten to 100-110 In.Lbs.
C. Plunger Tube (11) to Plunger Link Rod (17) ~ Tighten to 100-110 In.Lbs.
D. Plunger Link Rod (17) to Pump Plunger (20) ~ Tighten to 100-110 In.Lbs.
BI6522033-19
Lubrication Section
E. Flat Head Screws (1) to Counter Weight (2) ~ Tighten to 100-110 In.Lbs.
F. Wrist Pin Anchor (14) to Reciprocating Tube (21) ~ Tighten to 20-25 Ft.Lbs.
G. Check Seat Housing (28) to Reciprocating Tube (21) ~ Tighten to 20-25 Ft.Lbs.
H. Outlet Pin Nut (50) to Pump Housing (46) ~ Tighten to 30-35 Ft.Lbs.
I. Housing Tube (55) to Pump Housing (46) ~ Tighten to 20-25 Ft.Lbs.
J. Socket Head Screw (44) to Pump Housing (46) ~ Tighten to 50-55 Ft.Lbs.
K. Pressure Reducing Valve (38) to Manifold (37) ~ Tighten to 20-25 Ft.Lbs.
L. Flow Control Valve (39) to Manifold (37) ~ Tighten to 20-25 Ft.Lbs.
M. Solenoid Valve (34) to Manifold (37) ~ Tighten to 15-20 Ft.Lbs.
N. Socket Head Screws (33) to Manifold (37) ~ Tighten to 20-25 Ft.Lbs.
FlowMaster Rotary Driven Hydraulic Pump Components

3-20 BI652203
Lubrication Section
TROUBLESHOOTING
Condition Possible Cause Corrective Action
Pump does not run. No pressure on gauge (32):

- Closed Supply line shut off valve. Open shut-off valve.
- No power to solenoid valve (34). Correct electrical fault.
- Faulty Solenoid (35). Replace solenoid (35).
- Pressure Reducing Valve (38) is Reset Pressure Reducing Valve (38).
Set too low.
- Insufficient Hydraulic Fluid supply. Check hydraulic supply for proper
pressure and flow.
Pressure is shown on gauge (32):

- Closed Fluid outlet line. Check outlet line and clear
obstructions.
- Flow Control valve is fully closed. Readjust valve to 3/4 turn open.
- Pump is stalled due to grease Readjust valve to 3/4 turn open.
backpressure.
Pump is seized or damaged. Dismantle the pump and repair
defective or seized component. See
disassembly and assembly procedure.
Pump speeds up or runs erratically. Low level of grease or reservoir Refill reservoir.
is empty.
Follower plate is stuck and Check follower plate and container
separated from grease. for damage.
Pump piston or checks are worn. Disassemble the pump and repair.
Pump runs, but output is low. Insufficient hydraulic fluid supply. Check hydraulic supply and adjust
flow using valve (39).
Inlet pressure too low. Increase pressure using valve (38).
Faulty inlet (25, 26, 27) or Replace faulty components.
discharge check valve (18, 19, 20).
Weepage from housing cover (30). Cup seal (16) or O-Ring (48) wore out. Check the seals and replace if
necessary.
Pump becomes noisy. No crank case oil. Add crank case oil. Remove Pipe
Plug (45) from Pump Housing (46).
Oil level should be at the bottom of
the Pipe Plug opening. For Models
85480, 85481, 85482, 85483 and
85247Add 10W30 motor oil until
the crankcase is full.
For Model 85610, add light weight
Mobil Arrow HFA Hydraulic Oil until
the crankcase is full.
Worn wrist pin bushing (13). Check the bushings and replace if
necessary.
Pump does not build pressure. Foreign material holding lower Dismantle & clear check. Consider
check open. installing inlet screen (63)
before returning pump to service.
BI6522033-21
Lubrication Section
Lube Pump Hydraulic Schematic

3-22 BI652203
Lubrication Section
LUBRICATION POINTS
The lubrication charts in this section show the principal points on the machine to be lubricated.
Automatic lube systems should be checked daily to see that they are operating properly and that
each lube point is receiving the correct amount of lubricant. The types of lubricants are described
in LUBRICANT BENCHMARKS in this section of the manual.
GEARCASE AND RESERVOIR CAPACITIES

BI6522033-23
Lubrication Section
The frequency of lubrication given in each chart is intended as a guide. Under unusual operating
conditions, some points may require more frequent lubrication or other special attention. Use good
judgment in lubricating the machine. If a bearing is showing signs of trouble, such as overheating or
unusual noise, it should be given immediate attention. Make sure the lubricant is not dirty or of the
wrong grade. Then the machine is operated for more than one shift each day, all crews must
cooperate on checking lubrication. This is so that no lubrication point will be missed, and none will
be over-lubricated. It is usually best to do this at the beginning of each shift.
LOWER WORKS LUBRICATION

LUBE NO. OF POINTS TYPE HOURS AS AUTO COMPONENTS
POINT LUBRICATED LUBRICANT 8 40 160 1000 REQ.
1 SEALED N/A LOWER ROLLER BUSHINGS

2 SEALED N/A TAKE-UP TUMBLER BUSHINGS
3 4 MPG X X REAR AXLE*
4 2 MPG X X EQUALIZER AXLE END PINS
5 SEALED NA UPPER ROLLER BUSHING
* Pack cavities at crawler frame and bearing block; Check annually.
NOTE: The above frequencies are for manual lubrication. When equipped with an automatic
lube system the frequencies are set at the lube control station.
On automatic lube systems the injectors should be set at full opening at start-up of a
new machine and then readjusted as required. Refer to LUBRICANT INJECTORS in
this section of the manual.
3-24 BI652203
Lubrication Section
MAIN FRAME LUBRICATION

1 12 MPG X X LEVELING JACK CASING - LOWER

2 1 MPG X X EQUALIZER AXLE CENTER PIN
3 2 MPG X X MAST LOCK PINS
4 2 MPG X X A-FRAME LOCK PINS (OPTIONAL)
BI6522033-25
Lubrication Section
MAST LUBRICATION ~PART 1

1 2 MPG X X TOOL WRENCH CYLINDER GUIDES

2 4 MPG X X TOOL WRENCH BEARING BLOCKS
3 2 MPG X TOOL WRENCH CYLINDER PINS
4 6 MPG X DUST CURTAIN LEVER BUSHINGS
5 2 AUXILIARY WINCH ROPE SHEAVE
BEARINGS (SEALED)
6 1 RWRL X AUXILIARY WINCH ROPE
7 2 MPG X MAST BRACE LOCK PINS
8 2 MPG X HOOK BLOCK (OPTIONAL)
3-26 BI652203
Lubrication Section

1 1 MPG X X AIR SWIVEL SEAL

2 1 MPG X X UPPER ROTARY SHAFT BEARING
3 1 MPG X X ROTARY SHAFT LOWER SEAL
4 1 MPG X X INT. SHAFT UPPER BEARING
5 2 MPG X X SHIPPER SHAFT BEARING
6 2 MPG X X RACK AND PINIONS
7 1 MPG X SHOCK SUB OR ROTARY
COUPLING SEAL
8 6 MPG X X GUIDE ROLLERS
9 2 MPG X X 1ST INT. & SHIPPER SHAFT BEARINGS
10 1 MPG X 1ST INT. GEAR BRGS - SEE NOTE
11 2 MPG X BOGIE FRAME PIVOT PIN
12 4 MPG X BOGIE ROLLER BEARING
NOTES: • Lube Point 10 must be accessed by removing the plug (or cover) on the side of the gearcase
cover then carefully aligning the lube fitting in the pulldown gear accordingly.
• The above frequencies are for manual lubrication. For automatic lube systems the frequencies
are set at the lube control station.
• On automatic lube systems, the injectors should be set at full opening at initial start-up, then
readjusted as required. Refer to LUBRICANT INJECTORS in this section of the manual.
BI6522033-27
Lubrication Section

1 1 MPG X X L.H. PIVOT POST UPPER BUSHING

2 1 MPG X X L.H. PIVOT POST LOWER BUSHING
3 1 MPG X X R.H. PIPE RACK UPPER BUSHING
4 1 MPG X X R.H. PIPE RACK LOWER BUSHING
5 1 MPG X L.H. PIVOT POST LOCK PIN
6 1 MPG X R.H. PIVOT POST LOCK PIN
7 1 MPG X X UPPER GATE PIN
8 1 MPG X X MIDDLE PIVOT ASSEMBLY BUSHING
9 1 MPG X X SENSING DEVICE
3-28 BI652203
Lubrication Section
LUBRICANT CLEANLINESS
Even the best lubricant is a useless wear preventative if it has become contaminated by careless
handling and storage. The lubricant manufacturer packs the lubricant in a tight container to keep it
clean. It is the responsibility of the person performing the machine lubrication to be sure that no dirt
gets into the lubricant.
Follow these points of good lubrication practice:
• Keep all oil and other lubricants in tightly covered containers.
• Wipe off covers before opening containers.
• Keep funnels, oil cans, grease guns, etc., in a clean place and wipe them off before
using them.
• Wipe off each fitting before attaching the lubricant gun.
• Wipe off oil filler caps or covers and the surrounding area before removing them
BI6522033-29
Lubrication Section
LUBRICANT SELECTION
The selection of the proper lubricants for use on this machine is critical to its reliability. Improperly
lubricated bearings, gears, couplings, and other precision parts quickly fail. For this reason, lubricants
selected in accordance with the “American Standards Testing Material” (ASTM) standards are
recommended. These standards were compiled in cooperation with major petroleum suppliers to
ensure the consumer of an exact supply to specific requirements, regardless of source.
We recommend you advise your petroleum supplier of the following information to assist him in
selecting the proper product for each application of this machine.
Final acceptance of all lubricants supplied to this standard will be based upon their satisfactory
performance in the intended application, and does not relieve the supplier of performance
responsibility for brand name products.
Operation of this machine in extreme temperatures (below -20°F/-29°C or above 110°F/44°C)

requires special lubrication. Note the temperature ranges on the following lubricant specification
sheets. Contact your local supplier, your Caterpillar Global Mining representative, or the Service
Department of your local Caterpillar Global Mining office for recommendations if you require additional
information or advice.
• STORE LUBRICATION DRUMS ON THEIR SIDE, WITH THE OPENING TOWARD THE
TOP.
• STORE ALL LUBRICANTS IN TIGHTLY COVERED CONTAINERS!
• WIPE OFF COVERS AND SURROUNDING AREA BEFORE OPENING!
• FILTER ALL OIL BEFORE ADDING IT TO THE SYSTEM!
• USE ONLY CLEAN and PROPER LUBRICANTS!
• DO NOT MIX TYPES or BRANDS of LUBRICANTS!
Even the best lubricants are less useful in preventing wear if they become contaminated by dirt or
water due to careless handling or storage.
3-30 BI652203
Lubrication Section
ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT
SCOPE: Lubrication performance requirements and recommendations for Air Compressor

(Screw-type) Lubricants.
IMPORTANT NOTE
These lubricant performance requirements for screw-type air compressors are only
good for A-C Compressor Corporation screw compressors. If the machine is
equipped with air compressors manufactured by other than A-C you must refer to
the vendor’s maintenance information provided with the machine and Section 7 of
this manual.
LUBRICANT RECOMMENDATIONS:
The following lubricants are recommended:
1. If the ambient temperature is expected to always be above -26°C (-15°F), use either:
Automatic Transmission Fluid (ATF) - General Motors Dexron III or Ford Type F.
or
Synthesized Hydrocarbon Fluid - Mobil Rarus SHC 924.
2. If the ambient temperature is expected to drop to -40°C (-40°F), use Mobil Rarus SHC 1024
or Phillips Philesco ISO32 or equivalent.
NOTE: If the ambient temperature drops below -26°C (-15°F), it may cause the lubricant to
thicken in the oil cooler and could result in unit shutdown after a short run. If this
happens often and the compressor is being lubricated with ATF, it is recommended that
a synthesized hydrocarbon lubricant be used, instead.
NOTE: These performance requirements are bench marks and not a specification. Therefore,
meeting these limits as described above does not relieve the supplier of the
responsibility associated with brand name products.
BI6522033-31
Lubrication Section
MPO - MULTIPURPOSE OIL
SCOPE: Lubricant performance requirements for Multi-Purpose Oil.
APPLICATION: The addition of a lubricant to the compressed air system (not for screw-type
air compressor systems - see ACSL), hand oil cans, etc.
GENERAL REQUIREMENTS:
1. Must be fluid at temperature applied.

2. Should contain rust inhibitor.
3. Motor oil - API service classification “MS”.
VISCOSITY RECOMMENDATIONS:
1. Air Line Lubricant
AMBIENT TEMPERATURE SAE NUMBER

Below 10°F 5W
Above 10°F 10W
2. Hand Oil Can - Viscosity suitable for application and temperature.
3-32 BI652203
Lubrication Section
RWRL - RUNNING WIRE ROPE LUBRICANT
SCOPE: Lubrication performance requirements for hoist rope lubricant.
APPLICATION: Primarily for hoist ropes or any other running ropes where fatigue and not
wear is of prime concern.
GENERAL REQUIREMENTS:
1. Penetrate between adjacent wires in order to lubricate and protect them against wear and to
keep the rope core from drying out and deteriorating.
2. Provide a lubricant between sheaves and wire rope.
3. Resist being washed off.
4. Protect against rusting or corrosion.
5. Form a non-sticky film so that dust and dirt will not build up on the wires.
6. Remain pliable and resist stripping at the lowest temperatures to which the rope will be exposed.
7. Preferably, it should form a light colored transparent film so that wear, corrosion or broken
wires can be readily detected by inspection.
8. Be capable of easy application, both manually and by devices without being heated.
COMPOUNDING:
Suitable for penetrating between the adjacent wires of a rope in order to lubricate them and also to
replenish the lubricant in the core.
BI6522033-33
Lubrication Section
SPECIAL REQUIREMENTS:
1. Must pass United States Steel Retention Test Using a Timken Tester
2. Shell Four Ball E.P. - (ASTM D-2596)
Load wear index, kg., min.: 40

Load weld kg., min.: 250
3. Shell Four Ball Wear - (ASTM D-2266)
Wear scar diameter, mm., max.: 0.60
4. Timken O.K. Load lbs., min. - (ASTM D-2782): 45
5. Copper Strip Corrosion - (ASTM D-130): pass
6. Suggested Application Temperature Ranges
There should be a lubricant for each of the following temperature ranges:

110°F to 30°F
40°F to 9°F
10°F to -50°F
3-34 BI652203
Lubrication Section
HYDO – HYDRAULIC OIL
Hhydraulic oil suitable for year-round use is recommended, rather than summer or winter only,
which can create a mixing of viscosities if a complete draining of oil is not accomplished. This can
compromise the intended oil viscosity.
The oil viscosity benchmark for this machine is 3,000 centistokes (CST) maximum on the coldest
day for start-up, and 10 centistokes absolute minimum on the hottest day during machine operation.
Optimum oil viscosity at normal operating temperatures is 30 to 60 centistokes.
For climates that rarely see ambient temperatures drop much below freezing (25°F to 32°F), a
paraffinic-based petroleum hydraulic oil with little or no viscosity improver (VI) can be acceptable.
For climates where ambient temperatures drop as low as -40°F on their coldest day and are as
high as 104°F on their hottest day, a higher VI fluid is required. Paraffinic-based fluids should NOT
be used where ambient temperatures reach freezing or slightly below freezing. At freezing or slightly
below freezing temperatures, the paraffin wax starts to solidify causing the fluid to have a thicker
viscosity than the temperature-viscosity curve actually implies. In addition, the VI additive in petroleum-
based oils has the ability to be mechanically sheared, causing the viscosity to drop. This can result
in a fluid that can be totally incorrect for use after it has been in service for some time.
For all the above reasons, plus concerns of the oxidation-rate and water-ingestion that leads to
sludging, recommended draining intervals of 2,000 hours when using petroleum-based paraffinic
or naphthenic-type hydraulic oils should be followed.
The preferred hydraulic oil for this machine is a PAO (poly-alpha-olefin) synthetic fluid with a naturally
high VI. Examples being: 198 for Shell® Oil Tellus T 722, a range of 135 to 145 for Mobil® Oil SHC
500 series, 134 for Esso/Exxon® Terrestic SHP 22 Hydraulic Fluid, or 135 for Conoco® SYNCON
AW Oil.
The 3 to 4 times multiplier in the cost of synthetic fluids, as compared with paraffinic-based petroleum
oils, is offset by the fact that the synthetic oil can be left in the system 4 times longer (i.e. 8,000
hours) before a drain interval requirement. The savings with synthetic fluid use results because the
frequency of draining intervals is decreased by a factor of 4. This reduces the maintenance time
dedicated to changing the system oil and the cost of system oil disposal to 1/4 of what they would
otherwise be.
With all of the above in mind, using a SHC-type oil from Shell®, Mobil®, Esso/Exxon® or Conoco®
can result in considerable cost savings, whether the mine is located in a cold or warm climate.
BI6522033-35
Lubrication Section
PAO SYNTHETIC HYDRAULIC FLUID
The following bar graph shows recommended viscosity grades for SHC hydraulic oil for various
ambient temperatures. For temperatures outside of these ranges, contact the Caterpillar Global
Mining Service Department for recommended oil.
Recommended Viscosity vs. OAT Chart
PARAFFINIC BASE PETROLEUM HYDRAULIC FLUID
Approved oils will typically have Denison HF-O specification certification. In general, the oils will
meet the following minimum requirements:
1. Maximum Viscosity = 14,000 SUS (3,000 CST) at the minimum expected ambient
temperature (for start-up).
CAUTION: Starting with viscosities greater than 3,000 CST could void warranty.
2. Minimum Viscosity = 65 SUS at the maximum operating temperature of the hydraulic

system.
3. Ideal Viscosity = 100 SUS at normal operating temperature of the hydraulic system.
4. Minimum Viscosity Index = 90
5. Neutralization Number = 10 or less for new oil.

3-36 BI652203
Lubrication Section
6. Oxidation Hours to 2.0 Neutralization Number per D-943 = 1,500 hours minimum.
7. Demulsibility (easy separation from water) per D-1401 = 30 ±15 minutes to 3

ml. max. of emulsion.
Recommended Viscosity vs. OAT Chart
CAUTION: In general, water will not separate from motor oils or automatic
transmission fluids, therefore these fluids are NEVER recommended
as hydraulic system fluids.
8. Hydrolytic Stability per D-2619 = Copper wt. loss not to be more than .50 mg/cm2
The oil should contain rust and oxidation (R+O) inhibitors and foam depressants.
CAUTION: The use of water or glycol base or any other fire resistant fluid is
prohibited since serious damage to the hydraulic system will occur
which will void the warranty on the machine hydraulic system.
Obtain oil from a reputable supplier. Contact the Caterpillar Global Mining Service Department for
specific oil recommendations or approval.
BI6522033-37
Lubrication Section
The lower figure on the previous page illustrates the acceptable temperature range for various
viscosity grades (VG) of oil assuming a viscosity index of 125.
1. The left side of the bars show the absolute minimum ambient temperature for cold startup.
2. The right side of bars show the absolute maximum oil temperature.
3. Ideal maximum operating oil temperature is a viscosity of 100 SUS.
NOTE: When determining an oil for the hydraulic system, the system was designed for an all-
year oil and for use without heaters. The hydraulic system is tailored to the ambient
temperature at the customer’s mine and the correct type of hydraulic fluid is selected.
For extremely cold temperatures, a very light fluid is used with oversize oil coolers to
accommodate higher summer temperatures. With this procedure, viscosity limits as
little as 30° above ambient can be met.
3-38 BI652203
Lubrication Section
BI652203 4-1
Preventive Maintenance Section
Section 4
Preventive Maintenance
Table of Contents
INTRODUCTION ........................................................................................................................... 3
ELEMENTS OF AN EFFECTIVE MAINTENANCE PROGRAM ............................................... 5
SCHEDULED PREVENTIVE MAINTENANCE PROGRAM ..................................................... 5
GENERAL SAFETY CONSIDERATIONS ................................................................................ 6
MAINTENANCE DURING MACHINE OPERATION ........................................................................ 6
MAINTENANCE PRECAUTIONS .................................................................................................. 7
PREVENTIVE MAINTENANCE FOR LUBRICATION..................................................................... 8
LUBRICANT CLEANLINESS ................................................................................................... 9
FREQUENCY OF INSPECTION AND MAINTENANCE ............................................................... 10
MAINTENANCE SCHEDULE & CHECK POINTS ....................................................................... 10
DAILY ..................................................................................................................................... 11
EXTERNAL INSPECTION ............................................................................................... 11
ONBOARD INSPECTION ............................................................................................... 14
AFTER START-UP INSPECTION ................................................................................... 18
EVERY 100 HOURS, OR WEEKLY ...................................................................................... 20
ON-BOARD INSPECTION .............................................................................................. 23
EVERY 500 HOURS, OR MONTHLY .................................................................................... 25
EVERY 2500 HOURS, OR SEMI-ANNUALLY ....................................................................... 27
4-2 BI652203
BI652203 4-3
Section 4
Preventive Maintenance
This section of the manual describes those aspects of preventive maintenance on the machine
such as inspection, adjustment and routine repetitive tasks. Information related to lubrication
techniques, frequency and service points is also partially included. Further detailed information
can be found in Sections 3 and 5 of this manual.
At the end of this section are reproducible maintenance schedules that may assist in record keeping
and maintenance scheduling.
INTRODUCTION
A Preventive Maintenance Programs is a systematic series of operations performed periodically

on equipment to prevent breakdowns.
Any breakdown WILL reduce productivity and increase overhead expense. Machinery is only new
at one point in time. From that moment, the machinery begins to deteriorate through use and
aging. A well organized maintenance program will avoid unexpected high-cost breakdowns and
will increase component life.
A systematic approach to the program should be followed and detailed records of all findings kept,
to detect potential problem areas. Valuable time and effort can be saved if defects are corrected
before they lead to a major breakdown. The records should be reviewed often and kept on file for
future reference.
Personnel involved in the program should go through an established training program, to know
WHAT to check and HOW to rectify any potential problem area. When personnel are able to do
routine maintenance and normal repairs efficiently, downtime is reduced and machine productivity
increased. Also, to keep the machine in good running condition, the necessary parts, tools and
current information should be kept on hand.
4-4 BI652203
Equipment maintenance is a science and its practice an art. This art can be divided into 6 types of
operations - they are:
Inspection is probably the most important operation. Careful observation is required of

all parts of the equipment. Slight abnormalities may not interfere with the equipment
performance BUT those that are a deviation from the normal should be discovered
early. When inspecting, notice placement, state of cleanliness, color, etc. of part(s).
Example: discoloration indicates overheating; all guards, bolts in place and good
housekeeping.
Cleaning and keeping clean is essential for good operation. Periodic cleaning should
be more frequent on exposed parts than those which are contained within cabinets.
Parts, connections and joints should be free of dust, corrosion and other foreign
matter.
A Feeling operation is used more often to check guarded rotating machinery for vibration
due to worn parts, lack of lubrication, overheating, etc. Feeling operation on electrical
items should be performed as soon as possible AFTER power has been removed
and the circuit grounded. Feeling of excessive heat may indicate an overloaded
condition and should be corrected.
A Tightening operation should be done on all connections that have worked loose due
to vibration, etc. Loose parts are a definite hazard because they may fall out of
place and damage nearby components. The importance of firm mounting and tight
connections cannot be overemphasized. Always replace missing or broken bolts
with proper size and use the correct tools.
Adjusting should be done when inspection indicates that it is required to maintain
normal operating conditions. Specific adjustment is contained in the “Mechanical
Adjustment Section” of this manual, the electrical manual or the component
manufacturer’s manual.
Lubrication refers primarily to the application of CORRECT LUBRICANT in the
CORRECT AMOUNT to bearings and other rotating parts. It also means the
application of a light oil to door hinges or other sliding surfaces. Use only clean and
proper lubricant.
Planned maintenance, common sense and good judgment is less costly and more effective than
panic maintenance. Action taken on recommendations made on the following suggested inspection
Check Lists by the maintenance department, should reduce repair and maintenance costs and
increase production.
Replacing worn components with genuine oem parts on a scheduled basis will avoid costly down
times and emergency repairs. The cost of parts is small when compared to unscheduled
breakdowns that result in excessive overtime man-hours and lost machine production.
Whenever a problem is indicated, the inspector should briefly explain it on the maintenance report
(a suggested form is at the end of this section) along with his signature. Then, an authorized
person should briefly explain a solution to the problem. Finally, CORRECT THE PROBLEM.
BI652203 4-5
ELEMENTS OF AN EFFECTIVE MAINTENANCE PROGRAM
• Preventive Maintenance Program.
• Well Trained and Motivated Work Force.
• Effective Communications.
• Proper Equipment Selection and Procurement.
• Meaningful Documentation.
• Cooperation with the Operations / Maintenance Department.
• Warehouse Support.
• Good Shop Facilities.
SCHEDULED PREVENTIVE MAINTENANCE PROGRAM
Economically maintaining the productivity and performance of this mining drill requires maintenance
and inspection activities in a scheduled manner. Manpower requirements and performance of needed
maintenance during scheduled downtime dictates a system which recognizes the recommended
inspection interval. By staggering the inspection or servicing of these items, labor time and work-
force size is balanced.
Maintenance and component inspection should be performed simultaneously during scheduled

downtime. History of machine maintenance practices has shown that parts replacement and
component rebuild in advance of destructive failure yields the lowest operating costs. Keeping
good records is vital to support any preventive maintenance program. Early “change-out” reduces
unscheduled downtime and prevents secondary damage. Record keeping should be an “easy to
use” format and contain enough detail to isolate the function. Since basic machine life extends
over thousands of operating hours, maintenance records can be utilized to forecast budgets for
maintenance expenditures. This makes records a very valuable planning tool for mine management.
Use the routine maintenance program that is outlined here to formulate a schedule suited to the
work-force and mining environment. Over a period of time, additional inspection or planned work
may supplement the activities described in this manual.
4-6 BI652203
GENERAL SAFETY CONSIDERATIONS
The importance of overall safety in the maintenance of a mobile machine should always be
emphasized; excavating operations may involve a variety of hazardous conditions. Many critical
components are subject to wear and other deterioration which limits their useful life; thus making
them expendable. When new, all such parts have a built in reserve strength against unknown
factors and reasonable loss of durability from gradual wear. If however; inspection and adjustment
are neglected, these parts eventually reach a condition where they become a potential problem.
Similarly, failure to replace various mechanisms to ensure proper performance of the machine
could constitute a problem. Study this manual carefully to avoid unsafe conditions. Review the
manual periodically to refresh knowledge of these procedures. Supervisors, operators and
maintenance men should continuously follow safe practices.
MAINTENANCE DURING MACHINE OPERATION
Safety requirements dictate that all machines in active service be inspected at regular intervals for
proper adjustment of operating mechanisms, excessive wear of components, system cleanliness
and any other defects. Deficiencies during machine operation should be carefully investigated. It
should be determined if a safety problem exists. Maintenance is vital to safe operation! It should be
performed systematically by competent personnel.
From an economic standpoint, it is advisable to perform as much of the upkeep as can be safely
accomplished while the machine is running. Obviously, there are some maintenance procedures,
such as gear tooth inspections and replacement which require machine shut down. However;
many support duties can be effectively handled at shift change when the machine is still activated.
Automatic lubrication systems function throughout the operational cycles of the machine. These
systems release pre-measured lubricant which extends the wear life of the machinery units. Other
parts of the machine may be manually lubricated in a safe manner through extended grease or oil
fittings designed to keep the operator’s hands at a safe distance. Where this is not possible, the
machine must be shut down during the required lubrication.
CAUTION: A repair or maintenance job is not complete until all guards, plates
and other safety devices have been replaced before the equipment
is restored to operation.
BI652203 4-7
MAINTENANCE PRECAUTIONS
The operator must be sure that the machine equipment is in a safe position before repairs or
adjustments are made. The machine should not be endangered by falling rock or a possibly yielding
support surface. Before beginning repair or adjustment, the operator shall:
1. Set all brakes.
2. De-energize control functions.
3. Do whatever else is necessary to prevent accidental movement of the machine.
DANGER: HIGH VOLTAGE! IF POWER IS ESSENTIAL TO THE REPAIR, SUCH

AS FOR TESTING, IT SHOULD ONLY BE ENERGIZED WHEN ALL
PERSONNEL ARE CLEAR OF ELECTRICAL AND MECHANICAL
HAZARDS. The power should only be energized during the testing
period and not when repair work is actually being done.
Prior to undertaking any work, maintenance personnel should notify the operator about the nature
and location of the job. If work is to be done on or near moving parts, the starting controls should
be locked in the OFF position and tagged. The lock and tag should be removed only by the
maintenance people who installed them, or other authorized personnel. During all phases of
maintenance, use extreme caution when working near electrical equipment. Never work near
exposed, energized high voltage connections.
Approved protective equipment such as gloves and insulated hooks or tongs should always be
used when high voltage electrical cables are handled.
DANGER: Only qualified electricians are permitted to directly maintain electrical

equipment such as motors, transformers and switches.
While performing maintenance, the awkward positions assumed and the handling of heavy parts
often increases the possibility of injuries. As a precautionary measure, use mechanical handling
equipment whenever possible. The mining foreman can facilitate safer and easier maintenance
work by providing blocking materials. Service crews should have a fundamental knowledge of
lifting practices so their knees and legs are used rather than their backs.
DANGER: Many of the components comprising the machine are heavy, bulky
items. EXTREME CAUTION SHOULD BE USED WHEN LIFTING
THESE ITEMS. PERSONNEL SHOULD BE CERTAIN OF THE
WEIGHTS OF COMPONENTS BEFORE ATTEMPTING TO LIFT
THEM, EITHER MANUALLY OR WITH A LIFTING DEVICE. ALL
APPLICABLE SAFETY RULES MUST BE FOLLOWED WHEN USING A
CRANE OR OTHER LIFTING DEVICE. Be aware of the load rating,
lifting height and swing radius of the lifting device before lifting a
load. Failure to follow all applicable safety rules when performing
maintenance could result in serious injury, or death.
4-8 BI652203
PREVENTIVE MAINTENANCE FOR LUBRICATION
Lubrication may well be the most important portion of a preventative maintenance program. Do not
allow anything to interfere with the lubrication of the machine. Experience will dictate how to adjust
the amount of lubricant to use at each servicing. However; the extra effort will result in a smooth
running machine with less wear and breakdowns.
It is difficult to predict how much lubricant should be applied to a particular bearing. It varies with
how hard the machine is being worked, how much the bearing has previously worn and the grade
of lubricant being used. Watch all the bearings closely to insure that the lubricant added at one
servicing is enough to last until the next.
Most wearing parts require that lubricant be applied regularly in small quantities as with the automatic
lubrication system instead of large amounts applied occasionally. Make regular inspections of the
machine and watch for signs of improper lubrication such as the accumulation of excess lubricant
or discolored lubricant. Ensure that the lubricant has not come from a broken or disconnected line
or lubricant pipe. Normally excess lubricant pumped into a plain bearing is not used. However,
certain bearings in locations which may collect dirt should have extra lubricant added to purge all
of the old lubricant which may have collected abrasive dirt.
New bushings sometimes overheat because they are too tight to allow normal distribution of lubricant.
Old bushings may overheat because they are so worn that lubricant will not stay in until the next
time of servicing. In the case of the new bushing, it may be necessary to give it more frequent
lubrication until it is worked in. It may be necessary to do the same for the old bushing, until it can
be replaced. It is much better to lose a little time on a shift to give some extra lubricant to a point
which needs it rather than trying to run it to the end of the shift.
The most common cause of overheating an anti-friction bearing is churning of the lubricant. This
happens when the bearing is packed excessively full. If lubricant leaks out of an anti-friction bearing,
it is almost a sure sign that too much lubricant was added to the bearing. Continue to lubricate it as
often as before, but use less lubricant.
Section 3 of this manual will provide more detailed and specific information on lubricants and their
usage.
BI652203 4-9
LUBRICANT CLEANLINESS
Even the best lubricant is a useless wear preventative if it has become contaminated by careless
handling and storage. The lubricant manufacturer packs the lubricant in a tight container to keep it
clean. It is the responsibility of the person performing the machine lubrication to be sure that no
dirt gets into the lubricant.
Follow these points of good lubrication practice:
• Keep all oil and other lubricants in tightly covered containers.
• Wipe off covers before opening containers.
• Keep funnels, oil cans, grease guns, etc., in a clean place and wipe them off with a
clean lint-free cloth before using.
• Wipe off each fitting before attaching the lubricant gun.
• Wipe off oil filler caps or covers and the surrounding area before removing them.
Refer to the topic “Lubricant Benchmarks” in Section 3 of this manual for an explanation of each
type of lubricant required for servicing this machine. Make sure the lubricant was not dirty or of
improper viscosity. When the machine is operated for more than one shift each day, all crews must
cooperate on checking lubrication. This is to ensure that no lubrication point will be missed or over-
lubricated. It is usually best to do this at the beginning of each shift. Reproducible service schedules
are provided for recording service information.
NOTE: Lubrication instructions provided by any vendor for a vendor supplied item have priority
over lubrication intervals and procedures indicated here.
CAUTION: When not possible to work on the machine with a safety harness, use
a “cherry picker” or “man basket” when inspecting or servicing
elevated areas. A slip or fall can result in severe personal injury or
death.
4-10 BI652203
FREQUENCY OF INSPECTION AND MAINTENANCE
The suggested maintenance schedule is developed on a planned usage of 5,000 operating hours
per year. This is a planned reference only. The actual conditions within the mine site, operator’s
abilities and habits, along with the quality of components and consumables will ultimately drive the
inspection schedule used on the machine.
Care should be taken to properly evaluate the

maintenance approach during the initial period after
machine commissioning.
MAINTENANCE SCHEDULE & CHECK POINTS
The following maintenance schedule is based on a typical machine. Certain features or configurations
may be different on a specific machine. This maintenance schedule is intended to outline the
intervals for the various repetitive maintenance requirements. For any assistance, refer to the
appropriate section in this Maintenance and Operation Manual, or contact the Caterpillar Global
Mining service representative.
NOTE: This maintenance schedule is not to be substituted for Section 5 ~ SERVICE

PROCEDURES in this manual.
BI6522034-11
MAINTENANCE INSPECTION
CHECK POINTS MD6640
DAILY Blast Hole Drill
pmc_6640
EXTERNAL INSPECTION ITEM NOTED DISCREPANCY

#
1. Check areas around and under the

machine for signs of water or lubricant
leaks. If single droplets of water or
lubricant are noticed, leakage is minimal.
Determine the source of the leak and
make note of it on the log sheet. If
pooling of water or lubricant is noticed,
determine the source and take remedial
action immediately.
2. Inspect the crawler belts for broken or

cracked pads, missing lock pins, loose
track pins, and proper crawler belt
tension.
3. Check the drive tumbler gearcase,

hydraulic motor and hoses for leaks.
Check the lubricant level in the drive
tumbler gearcase.
4. Inspect the crawler frames for cracks

and dirt or ice buildup. Check the rollers
and tumblers for proper lubrication, free
operation, and dirt or ice buildup. Check
axle attachment pins and bolts.
5. Check the dust curtains for tears. Be

sure that the curtains are not frozen to
the ground or covered with cuttings.
CAUTION: The machine trail

cable carries a lethal Date:
voltage. Handle the Shift:
cable in an approved
Inspected By:
manner with
approved rubber Supervisor:
gloves and insulated
hooks or tongs.
4-12 BI652203
DAILY Check Points (cont.)

MD6640
Blast Hole Drill
6. Inspect the trail cable for proper pmc_6640
placement out of the line of travel of

ITEM NOTED DISCREPANCY
the drill. Inspect the insulation for cuts #
or abrasion. Make sure the cable is
kept out of water and away from sharp
rocks. Have an electrician inspect the
strain relief device and the condition
of the cable where it enters the
machine.
7. Inspect the underside of the machine

for cracks, loose hoses or wires, dirt
or ice accumulation, or other
deterioration or damage. If loose wires
are noted, do not touch them but notify
an electrician immediately.
8. Inspect the leveling jack spuds for

proper lubricant covering. Inspect the
leveling jack pads for cracks, broken
or missing pins, or excessive dirt
accumulation.
9. Inspect the mast braces and locking

pins. Replace missing or defective
components immediately. Verify that
all adjusting bolts are properly
adjusted. Check all hoses and
cylinders for leaking.
CAUTION: Use a safety belt and

lanyard to protect
against falls when
climbing on the mast
braces or working on
the machinery house
roof. Date:
Shift:
10. Inspect the mast hinge pins for loose Inspected By:
or missing keepers or bolts. Replace Supervisor:
missing or damaged parts
immediately. Check the pins for
sufficient lubrication and lubricate
if necessary.
BI6522034-13

MD6640
Blast Hole Drill
11. Inspect the mast hoist cylinders for pmc_6640
loose or missing pins or keepers, oil

leaks, damaged hoses or structural #
damage. Repair or replace any
missing or damaged components
immediately.
12. Inspect the mast structure for bent or

broken chords or plates, loose or
broken parts, proper rack lubrication
or excessive rack wear. Inspect
ladders, handrails and platforms for
broken or missing parts. Repair or
replace broken or missing parts
immediately.
13. Check the main air flex hose,

lubrication lines, and electric lines
running from the mast to the rotary
drive/pulldown unit for interference
with the mast or excessive wear or
leaks.
14. Check the safety restraint cables on

the mast. Be certain that the cables
and supports are in good repair with
no cracks, missing or loose hardware
or any damage that could affect their
effectiveness.
15. Check the machinery house air

filtering fan duct to see that it is clear
of obstructions.
Date:
Shift:
Inspected By:
Supervisor:
4-14 BI652203
ONBOARD INSPECTION
MD6640
Blast Hole Drill
pmc_6640

1. Inspect the air compressor #
lubrication lines for leaks. Correct
any leaks found immediately.
2. Check the condition of the air

compressor intake filter. Replace the
filter cartridge if the red flag is visible
in the service indicator. Empty the dust
hopper and clean the pre-cleaner
element. Inspect the housing and
ducting for damage or leaks. Repair
or replace leaking components.
3. Check the oil level in the hydraulic

tank. Fill the tank to the proper level
as described on the instruction plate
on the tank.
4. Check hydraulic system for leaks.

Correct all leaks immediately and
clean up all oil spills immediately.
5. If the machine is equipped with a bit

lubricator for the main air system,
check that the lubricator is full.
6. Inspect the automatic lubrication

central pumping stations for proper
operation. Check the supply of
lubricant and change or refill drums as
necessary.
7. Close and lock all electrical cabinet

doors.
Date:
DANGER: HIGH VOLTAGE!
Assume all parts inside Shift:
of the electrical cabinets Inspected By:
are energized. All
Supervisor:
electrical components
should be serviced by
qualified electrical
personnel only.
BI6522034-15

MD6640
Blast Hole Drill
8. Inspect the compressor radiator and pmc_6640
fan. Check for signs of deterioration ITEM

or damage to hoses, valves, fittings, NOTED DISCREPANCY
#
etc. Check for leaks at all joints. Check
the radiator core for blockage by dust,
dirt, leaves, paper, etc. and clean as
necessary
9. Check the operator’s display terminal

for any faults.
10. Inspect the machinery house for

general cleanliness. Clean all dirt and
debris from the machinery house.
NOTE: Do not use compressed air to clean

the machinery house. Compressed
air will only move the dirt around.
Use a vacuum cleaner to remove the
dirt from the machine. Failure to
clean the inside of the machinery
house will cause damage to many of
the components located there.
11. Inspect the auxiliary winch and

auxiliary winch line.
12. Check the oil level in the pump drive

gearbox. Fill with recommended oil to
the proper level.
13. Check all controls for free operation.

Return all controls to the OFF or SET
position.
Date:
14. Inspect the operator’s cab for Shift:
housekeeping and cleanliness. Clean
dirt and debris from the cab. Clean Inspected By:
the windows to give full visibility for Supervisor:
proper operation.
4-16 BI652203

MD6640
Blast Hole Drill
NOTE: Do not use compressed air pmc_6640
to clean the operator’s ITEM

cab. Compressed air will NOTED DISCREPANCY
#
only move the dirt around.
Use a VACUUM CLEANER TO
REMOVE DIRT FROM THE
OPERATOR’S CAB
15. Inspect the tool wrenches for free

operation, broken or missing parts,
proper lubrication, lubricant leaks or
dirt accumulation. Repair or replace
parts as necessary and clean the
drilling platform.
CAUTION: Before working near

or under the rotary
drive/pulldown unit,
make sure all of the
operator’s controls are
off and tagged and the
hoist brake set to
prevent movement of
the unit. Serious
personal injury or
death could result
should the rotary drive/
pulldown unit fall when
personnel are working
near or under it.
16. Inspect the automatic breakout

wrench for free operation, broken or
missing parts, proper lubrication,
lubricant leaks or excessive dirt
accumulation. Repair or replace
parts as necessary. Be certain that the
Date:
breakout wrench is retracted.
Shift:
17. Inspect the pipe racks for broken or Inspected By:
missing parts, proper operation, dirt
Supervisor:
accumulation, or lubricant leaks. Be
certain that the upper gate is closed
and that the rack is in the stored
position.
BI6522034-17

MD6640
Blast Hole Drill
18. Inspect the guide bushing for pmc_6640
excessive wear or dirt accumulation. ITEM

Also inspect the retainer lugs to be NOTED DISCREPANCY
#
sure they are intact. Do not operate
the machine without both retainer lugs
intact and securely welded to the deck.
19. Inspect the tool string for excessive

wear, dirt accumulation, bent pipe and
secure joints. The bit cones and
bearing should be in good condition.
Manually turn the cones to make sure
they turn freely.
20. Inspect the rotary gear case for

lubricant leaks, damaged lines, dirt
accumulation and other damaged or
missing parts. Check the lubricant
level in the gearbox. Fill to the
recommended level with an approved
gear lubricant. Check the rotary motor
ventilation inlets for leaves, paper,
rags, etc. blocking the flow of air.
21. Inspect the rotary drive unit for

excessive wear or dirt accumulation.
Inspect the guide rollers for proper
adjustment and excessive wear.
Check for loose or missing bolts and
bent or cracked structural members.
22. Inspect the pulldown unit for excessive

wear or dirt accumulation. Inspect the
rack pinions for excessive wear,
proper lubrication, and tight retainer
bolts. Inspect the guide rollers for Date:
proper adjustment and excessive
Shift:
wear.
Inspected By:
Supervisor:
4-18 BI652203

MD6640
Blast Hole Drill
23. Inspect the pulldown gearcase for pmc_6640
lubricant leaks, dirt accumulation and

other damaged or missing parts. #
Check the lubricant level in the
gearbox. Fill to recommended level
with an approved gear lubricant.
Check the pulldown motor ventilation
inlets for leaves, papers, rags, etc.
blocking the flow of air.
24. Check the hoist brake for proper

operation.
25. Check the dust or chip deflector for

loose or missing parts, excessive wear
or dirt accumulation. The deflector
should seal around the drill pipe
securely.
26. If the machine is equipped with a fire

suppression system, perform any
applicable checks or inspection as
described in the fire suppression
system owner’s manual.
27. Check dust collector supply air filter

dessicant color through sight glass. If
pink, change dessicant.
28. Inspect dust collector dropout hose has

no holes, rips, or tears.
AFTER START-UP INSPECTION Date:

Shift:
29. Check all brakes for proper setting and
releasing. Inspected By:
Supervisor:
30. Listen for unusual noises in the
gearcase.
BI6522034-19

MD6640
Blast Hole Drill
31. Check all bearings for unusual noises pmc_6640
and excessive heat. ITEM NOTED DISCREPANCY

#
32. At the end of any drilling cycle, turn dust
collector blower system off, and pulse
filter elements.
33. While operating, observe dust collector

blower outlet for dust. If dust appears,
inspect and replace dust collector filter
elements.
Date:
Shift:
Inspected By:
Supervisor:
4-20 BI652203
CHECK POINTS MD6640
EVERY 100 HOURS, OR WEEKLY Blast Hole Drill
pmc_6640
(WHICHEVER OCCURS FIRST)

#
1. Check for missing or worn crawler link
pins and retaining pins.
2. Check for cracked or worn crawler links.
3. Check the tumblers and rollers for
cracking, wear and lubrication.
4. Check for cracking of the crawler
frames.
5. Check for excessive dirt accumulation.
6. Check for proper belt adjustment (1-3
inch sag between end of upper slide
and drive or take-up tumbler).
7. Check drive tumbler for cracking and
wear.
8. Check the oil level in the propel planetary
gearboxes.
CAUTION: Be careful when
removing the plugs,
especially if the unit
is hot. Pressure
builds in the
gearcase and as the
last thread of the
plug is removed, the
plug may fly-off with
great force.
9. Check the propel gearbox. Hydraulic

motor and hydraulic lines for leaks.
10. Check that rear axle bearing block bolts Date:

are tight. Shift:
11. Check front equalizer axle for wear and Inspected By:
cracking. Supervisor:
BI6522034-21
100 HOURS, OR WEEKLY (cont.)

MD6640
12. Check equalizer axle pins for wear and
Blast Hole Drill
pmc_6640
lubrication.
#
13. Check dust curtains for wear or
damage. Check that the curtains are
not frozen to the ground.
14. Check the curtain raising levers for

wear, damage, lubrication.
15. Check the curtain raising cylinders for

wear, damage or leaking.
16. Check the dust deflector for wear or

damage.
17. Visually check the condition of the trail

cable.
18. Check the cable reel for damage, wear

and lubrication. Manually lubricate the
drum shaft bearings - 2 points.
19. Check the cable reel controls for ease

of operation and hydraulic leaks.
20. Check the cable reel drive chains for

wear, damage, lubrication and
adjustment.
21. Check the leveling jack frames for

cracking.
22. Check the leveling jack shoes for Date:

cracking. Clean off any dirt or rocks. Shift:
Inspected By:
23. Check for missing or worn shoe pins
and retaining pins. Supervisor:
24. Check the leveling jack spuds for

proper lubrication.
4-22 BI652203

MD6640
25. Check the leveling jacks for oil leaks.
Blast Hole Drill
pmc_6640
26. Check the mainframe for cracking. ITEM NOTED DISCREPANCY

#
27. Check the retractable stairway for
proper operation.
28. Check the outside of the machinery

house and cab for damage or cracking.
29. Check that all blowers for ventilating and

radiators are not obstructed.
30. Check dry-type dust collection unit duct

and hoses for leaks.
31. Check lube drive shaft bearings on dry-

type dust collection unit.
32. Check that water tank is full.
33. Check the condition of the mast braces

and brace pins.
34. Check the mast brace lock cylinders and

hydraulic lines for leaks.
35. Check that the mast hoist cylinder pins

and retaining pins are in place.
36. Check the mast structure for wear,

damage or cracking.
37. Check the mast’s racking for wear,

damage and lubrication.
38. Check the mast ladder, safety guards

and platforms for cracking and missing Date:
bolts.
Shift:
39. Check the condition of the auxiliary Inspected By:
winch line. Supervisor:
40. Check the condition of the mast head
sheaves.
BI6522034-23

MD6640
Blast Hole Drill
41. Check the condition of the upper pmc_6640
portion of the tool racks. ITEM NOTED DISCREPANCY

#
42. Check the condition of the mast air
pipe, bull hose and lube lines. Visually
check the condition of the electrical
lines.
ON-BOARD INSPECTION
43. Check oil level in the pump drive

gearbox. Add oil if required.
44. Check the mast hoist cylinder anchor

pin and retaining pins.
45. Check the guidebushing for wear, on

the drilling deck.
46. Check the tool wrenches for wear,

lubrication and oil leaks.
47. Check the lower portion of the tool

racks for wear or damage.
48. Check the pawls in the rack pockets

that they work freely.
49. Check that the rack levers work freely.
50. Check the cylinders. Lubricate the rack

lower arms. Date:
Shift:
51. Check the rotary coupling for cushion Inspected By:
wear and tightness of bolts. Supervisor:
52. Check the oil level in the rotary

gearcase. Add oil if required.
4-24 BI652203

MD6640
Blast Hole Drill
53. Check the gearcase and frame for pmc_6640
cracking and oil leaks. ITEM NOTED DISCREPANCY

#
54. Check the guide rollers for proper
adjustment.
55. Check the pulldown gearcase for

cracking and oil leaks.
56. Check the oil level in the pulldown

gearcase. Add oil if required.
57. Check the hoist brake on the pulldown

gearcase for proper operation.
58. Check the oil level, in the machinery

house, in the hydraulic reservoir. Add oil
if required.
59. Check all oil filters. Change if required.
60. Check all belt drives for proper belt

tension.
61. Check the oil level in the screw

compressor separator. Add oil if
required.
62. Check all hydraulic, air, lube piping for

leaks.
63. Check dust collector filter elements.

Replace as needed.
Date:
64. Inspect dust collector suction hose for Shift:

obstructions. Inspect hose joints for Inspected By:
integrity. Supervisor:
BI6522034-25
CHECK POINTS MD6640
EVERY 500 HOURS, OR Blast Hole Drill
pmc_6640
MONTHLY
(WHICHEVER OCCURS FIRST) #
1. Check the crawler belt adjustment and

adjust belts if required.
2. Position the machine so that crawler

rollers and take-up tumblers can be
checked for excessive movement
which indicates bushing wear.
3. Take sample of propel gearcase oil for

testing.

removing the plugs,
is hot. Pressure
builds in the
gearcase and as the
last thread of the
great force.
4. Remove rotary gearcase inspection

cover and inspect gearing.
5. Take sample of rotary gearcase oil for
testing.
6. Check the rotary gearcase drive shaft
bearing adjustment and adjust if
required.
7. Remove pulldown gearcase
inspection cover and inspect gearing.
Date:
8. Take sample from the pulldown
gearcase oil for testing. Shift:
Inspected By:
9. Check the rotary air seal and replace
it if required. Supervisor:
10. Take sample of hydraulic oil from
reservoir for testing.
4-26 BI652203
500 HOURS, OR MONTHLY (cont.)

MD6640
Blast Hole Drill
11. Check and clean or replace all air filters. pmc_6640

12. Check and clean or replace all oil filters. #
13. Take a close look at all structural units,

including crawler frame, axles,
mainframe and mast. Check for
cracking, stress marks or buckling.
14. Take care of any deficiencies found

during prior inspections which did not
require immediate action.
Date:
Shift:
Inspected By:
Supervisor:
BI6522034-27
CHECK POINTS MD6640
Blast Hole Drill
pmc_6640
EVERY 2500 HOURS, OR SEMI-
ANNUALLY ITEM NOTED DISCREPANCY
#
(WHICHEVER OCCURS FIRST)
1. Position the machine so that one take-

up tumbler and lower roller can be
removed for inspection of the
bushings.
2. Drain the propel gearcase and fill with

new oil.

removing the plugs,
is hot. Pressure
builds in the
gearcase and as the
last thread of the
great force.
3. While the gearcase is drained, inspect

the gears, pinions, bearings and seals.
4. Drain the pump drive gearbox and fill

with new oil.
5. Drain the rotary gearcase and fill with

new oil.
6. While the gearcase is drained, remove

the motor and inspect the gears,
pinions, bearings and seals.
Date:
7. Drain the pulldown gearcase and fill
with new oil. Shift:
Inspected By:
8. While the gearcase is drained, inspect
Supervisor:
the gears, pinions, bearings and seals.
9. Re-pack the bearings in the masthead

winch sheaves.
4-28 BI652203
2500 HOURS, OR SEMI-ANNUALLY (cont.)

MD6640
Blast Hole Drill
10. Drain the auxiliary winch and fill with pmc_6640
new oil.
#
11. Drain the hydraulic reservoir and fill
with new oil.
12. Change all hydraulic oil filters.
13. Correct any deficiencies found during

prior inspections which did not require
immediate action.
14. Clean up around the machine and

touch-up paint any parts of the
machine where paint is missing and
rusting could occur.
Date:
Shift:
Inspected By:
Supervisor:
BI652203 5-1
Service Procedures Section
Section 5
Service Procedures
Table of Contents
UNDERCARRIAGE TRACKS ....................................................................................................... 5

SAFETY INFORMATION.................................................................................................... 5
MAINTENANCE SECTION ...................................................................................................... 5
FINAL DRIVE OIL LEVEL - CHECK ......................................................................................... 5
FINAL DRIVE OIL – CHANGE .................................................................................................. 7
TRACK ADJUSTMENT – ADJUST ................................................................................................ 8
MEASURING TRACK TENSION ............................................................................................. 8
ADJUSTING TRACK TENSION ............................................................................................. 10
TIGHTENING THE TRACK .................................................................................................... 11
LOOSENING THE TRACK .................................................................................................... 12
TRACK ADJUSTMENT – INSPECT ...................................................................................... 13
UNDERCARRIAGE – CHECK .............................................................................................. 14
LUBRICANT SPECIFICATIONS ................................................................................ 15
Planetary Gearbox Lubrication Specifications ............................................................................ 15
Oil Change Intervals ................................................................................................................... 15
AXLES ................................................................................................................................... 16
Equalizer Axle - Details .............................................................................................................. 16
REPAIR ........................................................................................................................... 17
Rear Axle - Details ..................................................................................................................... 17
MAINFRAME ................................................................................................................................ 19
REPAIR ........................................................................................................................... 20
BIT VIEWING HATCH ............................................................................................................ 20
Bit Viewing Hatch - Details ......................................................................................................... 20
MAST A-FRAME .................................................................................................................... 21
REPAIR ........................................................................................................................... 21
LEVELING JACKS ................................................................................................................. 22
Leveling Jack - Details ............................................................................................................... 22
REPAIR ........................................................................................................................... 23
MACHINERY HOUSE ............................................................................................................ 26
REPAIR ........................................................................................................................... 26
HOUSE VENTILATION FAN AND FILTER ............................................................................. 27
Machinery House Ventilation Fan ............................................................................................... 27
WALKWAYS AND LADDERS ................................................................................................ 28
Retractable Boarding Stairway - Details ...................................................................................... 28
OPERATOR’S CAB .............................................................................................................. 29
Operator’s Cab Location Mounting .............................................................................................. 29
OPERATOR’S SEAT ............................................................................................................. 30
OPERATOR’S CONTROLS ................................................................................................. 30
Operator’s Controls .................................................................................................................... 30
5-2 BI652203
AIR CONDITIONING UNIT WITH HEATER ............................................................................ 31

Operator’s Cab Heating/Air Conditioning Unit ............................................................................. 31
HYDRAULIC PUMP DRIVE ................................................................................................... 32
Hydraulic Pump Drive ................................................................................................................. 32
Hydraulic Pump Drive Gearbox - Details ..................................................................................... 33
CABLE REEL .............................................................................................................................. 35
CHAIN TENSIONING ................................................................................................................... 37
HYDRAULIC ADJUSTMENTS ......................................................................................... 38
View A - Hydraulic Adjustment Locations ................................................................................... 38
HYDRAULIC DRIVE START UP INSTRUCTIONS .......................................................... 39
LUBRICATION ................................................................................................................. 41
REPAIR ........................................................................................................................... 41
MAST STRUCTURE ................................................................................................................... 42
REPAIR ................................................................................................................................. 43
MAST SAFETY SLINGS ........................................................................................................ 43
Upper Safety Sling ..................................................................................................................... 43
REPAIR ........................................................................................................................... 44
Lower Safety Sling - Optional ..................................................................................................... 44
ROTARY GEARCASE ........................................................................................................... 45
Rotary Machinery/Gearcase ....................................................................................................... 45
DRIVE SHAFT ADJUSTMENT ......................................................................................... 46
Rotary Machinery Intermediate Shaft .......................................................................................... 47
REPAIR ........................................................................................................................... 48
REMOVE THE UPPER BEARING RETAINER. ......................................................... 48
Rotary Machine Driveshaft - Details ............................................................................................52
ROTARY MOTOR ................................................................................................................. 55
Rotary Drive Motor - Details ........................................................................................................ 55
ROTARY SHOCK COUPLING .............................................................................................. 57
REPAIR ........................................................................................................................... 57
ROTARY/PULLDOWN GUIDE FRAME ................................................................................. 59
Rotary Pulldown Guide Frame - Details ...................................................................................... 59
GUIDE ROLLER ADJUSTMENT ........................................................................................... 60
Rack Pinion and Upper Guide Roller - Details ............................................................................ 60
Lower Guide Rollers - Details ..................................................................................................... 61
REPAIR ........................................................................................................................... 62
COUPLING ALIGNMENT ........................................................................................................... 64
PULLDOWN GEARCASE ..................................................................................................... 66
Pulldown Machinery - Overview ................................................................................................... 66
REPAIR ........................................................................................................................... 67
Pulldown/Machinery Gearcase and Base .................................................................................... 67
Pulldown/Machinery First Intermediate and Shipper Shaft .......................................................... 68
Pulldown Machinery Second Intermediate Shaft ......................................................................... 69
Pulldown Machinery Input Shaft .................................................................................................. 71
HOIST BRAKE ...................................................................................................................... 74
INSPECTION ................................................................................................................... 74
Brake Wear Adjustment ............................................................................................................. 74
Hoist Brake - Details .................................................................................................................. 75
BRAKE WEAR ADJUSTMENT ........................................................................................ 76
REPLACEMENT OF FRICTION DISCS .......................................................................... 76
DISASSEMBLY OF MAGNET BODY AND ARMATURE .................................................. 77
BI652203 5-3
RE-ASSEMBLY OF MAGNET BODY AND ARMATURE .................................................. 77

RH Pipe Rack - Details .............................................................................................................. 78
LH Pipe Rack - Details .............................................................................................................. 79
REPAIR ........................................................................................................................... 79
Pipe Rack Variable Equipment .................................................................................................. 81
TOOL WRENCH ................................................................................................................... 82
Tool Wrench - Details ................................................................................................................. 82
REPAIR ........................................................................................................................... 83
REPAIR ........................................................................................................................... 83
BREAKOUT WRENCH ......................................................................................................... 83
REPAIR ........................................................................................................................... 84
GENERAL GUIDELINES FOR DISASSEMBLY ............................................................... 84
AUXILIARY WINCH ................................................................................................................ 85
MAST BRACES ..................................................................................................................... 86
Mast Braces - Details ................................................................................................................. 86
REPAIR ........................................................................................................................... 87
ADJUSTMENT ................................................................................................................. 87
HYDRAULIC SYSTEM................................................................................................................. 88
SYSTEM OPERATION .......................................................................................................... 88
Hydraulic Components Overview ................................................................................................. 88
CYLINDER CIRCUIT HYDRAULIC SYSTEM ........................................................................ 89
PROPEL CIRCUIT HYDRAULIC SYSTEM ............................................................................ 90
GENERAL MAINTENANCE ................................................................................................... 90
HYDRAULIC SYSTEM CLEANLINESS ........................................................................... 90
OIL REQUIREMENTS ............................................................................................... 91
OIL AND FILTER CHANGES ..................................................................................... 91
WEEKLY MAINTENANCE CHECKS ......................................................................... 92
OIL RESERVOIR REPAIRS .................................................................................................. 92
LEVELING JACK COUNTERBALANCE VALVE PRESSURE RELIEVING PROCEDURE ... 92
REAR JACKS .................................................................................................................. 93
FRONT JACK .................................................................................................................. 93
PRE-START INSPECTION ................................................................................................... 94
HYDRAULIC SYSTEMS TESTS ........................................................................................... 95
PROPEL PUMP CHARGE PRESSURE CHECK ................................................................. 95
CONTROL PRESSURE CHECK .................................................................................... 96
PROPEL ENABLE VALVE AND LOW SPEED SELECT CHECK ........................................ 96
JACK CYLINDER CHECK IN MANUAL MODE ...................................................................... 97
FLOW CONTROL CHECK ................................................................................................... 98
JACK CYLINDER DRIFT TEST .......................................................................................... 100
BRAKE RELEASE PRESSURE CHECK ........................................................................... 100
PROPEL BRAKE EMERGENCY RELEASE CHECK ......................................................... 101
PROPEL PUMP MAIN RELIEF PRESSURE CHECK ......................................................... 101
CRAWLER FUNCTION CHECK ......................................................................................... 102
BIT VIEWING HATCH CHECK ............................................................................................ 103
BOARDING STAIR CHECK ................................................................................................ 103
MAIN FLOW VALVE CHECK ............................................................................................... 103
BREAKOUT WRENCH AND TOOL WRENCH CHECK ..................................................... 103
DUST CURTAIN CYLINDERS ............................................................................................. 103
DUST SEAL SLIDER ........................................................................................................... 104
5-4 BI652203
MAST LOCK ........................................................................................................................ 104

MAST BRACE LOCK CYLINDERS ..................................................................................... 104
A-FRAME LOCK CYLINDERS ............................................................................................ 104
MAST LOCK CONSTANT PRESSURE CHECK ................................................................ 105
MAST BRACE CONSTANT PRESSURE CHECK .............................................................. 105
A-FRAME LOCK CONSTANT PRESSURE CHECK .......................................................... 105
MAST RAISE/LOWER ........................................................................................................ 106
AUXILIARY WINCH .............................................................................................................. 107
HYDRAULIC CENTRAL LUBE DRIVE PRESSURE CHECK .............................................. 108
WINDOW GUARD FUNCTION CHECK - OPTION ............................................................ 108
CHECK JACKS IN AUTO LEVEL MODE ............................................................................. 109
PIPE RACK POSITION CHECK ......................................................................................... 110
PIPE RACK LOCK AND GATE CYLINDER PORT RELIEF SETTING ................................ 110
PIPE THREAD LUBRICATOR CHECK ............................................................................... 110
PIPE POSITIONER FUNCTION CHECK ............................................................................ 111
CENTER GUIDE FUNCTION CHECK ................................................................................ 111
AUTOMATIC BREAKOUT WRENCH CHECK .................................................................... 112
DUST CONTROL ..................................................................................................................... 112
GENERAL MAINTENANCE ................................................................................................. 112
DRILLING PLATFORMS AND DUST CURTAINS ................................................................ 113
WATER INJECTION - OPTION ........................................................................................... 113
OPERATION ................................................................................................................. 113
FILLING WATER TANK ................................................................................................. 114
SCHEMATICS, HYDRAULIC .............................. LOCATED AT THE END OF THIS MANUAL

BI652203 5-5
Section 5
Service Procedures
UNDERCARRIAGE TRACKS
The tracks and chains should be inspected frequently to prevent an unexpected breakdown.
SAFETY INFORMATION
Track adjusting systems use either grease or oil under high pressure to keep the track under
tension. Grease or oil under high pressure coming out of the relief valve can penetrate the body
causing injury or death. Do not watch the relief valve to see if grease or oil is escaping. Watch the
track or track adjustment cylinder to see if the track is being loosened. The pins and bushings in a
dry track pin joint can become very hot. It is possible to burn the fingers if there is more than brief
contact with these components.
MAINTENANCE SECTION
FINAL DRIVE OIL LEVEL - CHECK
CAUTION: Hot oil and hot components can cause personal injury. Do not allow hot oil
or hot components to contact skin
DRAIN .
2
5-6 BI652203
1. Position one final drive so that oil drain plug (2) is at the bottom.
2. Remove oil level plug (1).
3. Check the oil level. The oil should be near the bottom of the level plug opening.
4. Add oil through the level plug opening, if necessary.
Note: If the oil fills slowly, the fill hole may be blocked by the planetary gear. Rotate the final
drive in order to move the planetary gear away from the fill hole.
Note: Overfilling the final drive will cause the seals on the travel motor to allow hydraulic oil or
water to enter the final drive. The final drive may become contaminated.
5. Clean oil level plug (1). Inspect the O-ring seal. Replace the O-ring seal if the O-ring seal is worn
or damaged.
6. Install oil level plug (1).
7. Repeat the procedure for the other final drive.

BI652203 5-7
FINAL DRIVE OIL – CHANGE
CAUTION: Hot oil and hot components can cause personal injury. Do not allow hot oil
or hot components to contact skin
DRAIN
1. Position one final drive so that oil drain plug (2) is at the bottom.
2. Remove drain plug (2) and level plug (1). Allow the oil to drain into a suitable container.
3. Clean the plugs and inspect the O-ring seals. If wear or damage is evident, replace the drain
plug, the level plug, and/or the O-ring seals.
4. Install drain plug (2).
5. Fill the final drive to the bottom of the opening on level plug (1).
Note: If the oil fills slowly, the fill hole may be blocked by the planetary gear. Rotate the final
drive in order to move the planetary gear away from the fill hole.
Note: Overfilling the final drive will cause the seals on the travel motor to allow hydraulic oil or
water to enter the final drive. The final drive may become contaminated.
5-8 BI652203
6. Install level plug (1).
7. Perform Step 1 to Step 6 on the other final drive. Use a different container for the oil so that the
oil samples from the final drives will be separate.
8. Completely remove the oil that has spilled onto surfaces.
9. Start the engine and allow the final drives to run through several cycles.
10. Stop the engine. Check the oil level.
11. Check the drained oil for metal chips or for particles. If there are any chips or particles,
consult your Caterpillar dealer.
12. Properly dispose of the drained material. Obey local regulations for the disposal of the material.
TRACK ADJUSTMENT – ADJUST
Caution: Personal injury or death can result from grease under pressure.
Grease coming out of the relief valve under pressure can penetrate
the body causing injury or death.Do not watch the relief valve to see
if grease is escaping. Watch the track or track adjustment
cylinder to see if the track is being loosened. Loosen the relief valve
one turn only. If track does not loosen, close the relief valve and
contact your Caterpillar dealer.
NOTICE
Keeping the track properly adjusted will increase the service life of the track and drive components.
Note: The track tension must be adjusted according to the current operating conditions. Keep the track as
slack as possible if the soil is heavy.
MEASURING TRACK TENSION
1. Operate the machine in the direction of the idlers.
2. Stop with one track pin directly over the front carrier roller. Park the machine and turn off the
engine.
BI652203 5-9
3. Place a straight edge on top of the track grousers between the front carrier roller and the idler.
The straight edge should be long enough to reach from the front carrier roller to the idler.
Note: If your machine is equipped with three carrier rollers, place a straight edge on the
tracks between the carrier rollers. The straight edge should be long enough to reach
from one carrier roller to another carrier roller.
5-10 BI652203
4. Measure the maximum amount of sag in the track. The sag is measured from the highest
point of the track grouser to the bottom of the straight edge. A track that is properly adjusted
will have a sag of 40.0 to 55.0 mm (1.57 to 2.17 inch).
5. If the track is too tight, or if the track is too loose, adjust the track tension according to the
appropriate procedure below.
Personal injury or death can result from

improper accumulator charging. Dry Nitrogen
ACCUMULATOR (TRACK TENSION) - CHECK is the only gas approved for use in the
accumulator. Charging the accumulator with
oxygen will cause an explosion. This danger
will
not happen if nitrogen cylinders with standard
CGA (Compressed Gas Association, Inc.)
Number 580 connections are used. When
ordering nitrogen gas, be sure that the
cylinders are equipped with CGA Number 580
connections. Do not use color codes or other
methods of identification to tell the difference
between nitrogen and oxygen cylinders Never
use an adapter to connect your nitrogen
charging group to a valve outlet used on both
nitrogen, oxygen, or other gas cylinders. BE
The track tension accumulator can be inspected SURE YOU USE DRY NITROGEN (99.8%
through the cut-out in the track roller frame. purity).
Visually
inspect track tension accumulator (1) for leaks.
Make any necessary repairs. If the accumulator
requires any service work, see, “Accumulator
(Track Tension) - Test and Charge”. Repeat this
procedure for the other track tension accumulator.
ACCUMULATOR (TRACK TENSION) - TEST

Preparation
AND CHARGE
BI6522035-11
Note: The temperature of the accumulator may

change as the accumulator is being charged due
to the expansion or compression of the nitrogen
charge. It may be necessary to charge the
accumulator in several steps in order to ensure a
correct charge. Use table 2 to determine the
correct amount of gas pressure to use..
Track Tension Accumulator

(1) Cap for valve assembly
(2) Bleed screw
Track Tension Accumulator

(1) Cap for valve assembly
1. Stop the engine. Release the pressure

from the hydraulic system.
2. Turn bleed screw (2) in a counterclockwise
direction for 1 to 2 turns in order to release
the pressure in the track tension cylinder.
Gas pressure is variable with temperature.
Check the temperature of the air around the
accumulator.In order to check the amount of
charge in an accumulator, the accumulator Use the 7S-5437 Nitrogen Charging Group in
must be at the same temperature as the order to test and charge the track tension
surrounding air. accumulator
5-12 BI652203
Charging the Tack Tension

Accumulator
1. Rotate valve handle (9) on chuck (10)
counterclockwise until the valve is completely
closed.
2. Ensure that the valve on the nitrogen cylinder
is shut off.
3. Connect the 7S-5437 Nitrogen Charging Group
to the nitrogen cylinder with connection (4).
4. Open the valve on the nitrogen cylinder. Make
an adjustment to screw (8) on the regulator
assembly until gauge (3) indicates the proper
7S-5437 Nitrogen Charging Group precharge pressure for the accumulator. Use
(3) Pressure gauge
(4) Connection to nitrogen cylinder valve
table 2 as a reference for the correct charging
(5) Regulator assembly pressure.
(6) Valve 5. Open valve (6). Loosen chuck (10) slightly.
(7) Pressure gauge Allow the nitrogen to purge the air from the hose.
(8) Pressure regulating screw
Tighten chuck (10).
(9) Valve handle
(10) Chuck 6. Rotate valve handle (9) on chuck (10)
. clockwise until the valve is completely opened
and put a charge into the accumulator. Turn off
valve (6). The accumulator has the correct charge
Checking the Nitrogen Chrge of a Tack Tension
if the pressure on gauge (7) and the pressure on
Accumulator gauge (3) are equal and the gauge readings do
not change. If there is a decrease in pressure on
gauge (7), open valve (6) and allow more
counterclockwise until the valve handle reaches the
nitrogen to go into the accumulator.
full out position. Close valve (6).
7. Repeat steps 4 through 6 until the following
2. Remove cap (1) from the valve assembly on the
items occur:
accumulator.
• The pressure on gauge (7) is equal to the
3. Install chuck (10) on the valve assembly of the
pressure on gauge (3).
accumulator.
• There is no pressure change when valve (6) is
4. Rotate valve handle (9) on chuck (10) clockwise
closed.
until the valve assembly is completely opened.
8. Close valve (6). Turn off the valve on the
5. Use pressure gauge (7) to check the amount of
nitrogen cylinder.
nitrogen charge in the accumulator. Check the
9. Turn valve handle (9) on chuck (10)
temperature of the air around the accumulator. The
counterclockwise until the valve is completely
pressure on the gauge must be within the values that
closed.
are shown in table 2.
10. Remove the test equipment. Replace cap (1).
6. If the pressure reading on the gauge is too high,
Tighten bleed screw (2).
lower the pressure by slowly opening valve (6). Allow
the pressure to bleed until the pressure reading is
within the specification. Close valve (6).
7. If the pressure reading on the gauge is too low,
follow the procedure given in “Charging the Track
Tension Accumulator”.
counterclockwise until the valve is completely closed.
9. If the pressure reading is within the specification,
remove the test equipment. Replace cap (1). Tighten
bleed screw (2).
BI6522035-13
TRACK ADJUSTMENT – INSPECT
Check the track adjustment. Check the track for wear and for excessive dirt buildup.If the track
appears to be too tight or too loose, see Operation and Maintenance Manual, “Track Adjustment -
Adjust”.
5-14 BI652203
UNDERCARRIAGE – CHECK
1. Check the carrier rollers, the track rollers, and the idler wheels for possible leakage.
2. Check the surface of the track, the carrier rollers, the track rollers, the idler wheels, the track
shoes, and the drive sprockets. Look for signs of wear and loose mounting bolts.
3. Listen for any abnormal noises while you are moving slowly in an open area.
4. If abnormal wear exists or abnormal noises or leaks are found, consult your Caterpillar dealer.
BI6522035-15
LUBRICANT SPECIFICATIONS
Planetary Gearbox Lubrication Specifications
1. The oils shown in figure above contain phosphorous type extreme pressure additives. Other
oils of equivalent quality and properties may be used, provided they contain phosphorous
type extreme pressure additives.
Oil Change Intervals
2. Contamination depends on operating conditions and operating temperatures. Operating at

temperatures of 180° F or above for continuous service will require more frequent oil changes.
5-16 BI652203
AXLES
The crawler frames are attached to the machine by two axles. The front axle (equalizer axle) allows
the front of the crawlers to pivot, equalizing the load of the machine between the two crawlers.
Each end of the axle is pinned to the crawler frames while the middle of the axle is pinned to the
bottom of the drill mainframe.
The rear axle is the pivot axle in that as the front of the crawlers move up and down to equalize the
loads when propelling over rough terrain, the rear of the crawler pivots about the rear axle. This axle
is solidly attached to both sides of the mainframe and does not move during operation.
Inspect the axles and the attachment points frequently for loose bolts or hardware. Inspect the
axles for cracks or damage. Repair or replace the axles if worn or damaged. Inspect the pivot pins
and retainers for wear or damage and replace as necessary.
Equalizer Axle - Details

BI6522035-17
REPAIR
Normally the axles will not need repair during the life of the machine. Accidents or abnormal wear
situations do occur, however, that may make repair of the axles necessary.
Due to the inaccessibility of the axles, removal of the axles from the machine will most probably be
necessary.
To remove the axles from the machine, use the following the procedure listed under Crawler Frame
Repair.
Remove One Crawler From The Machine.
1. Position the crawler to allow removal of the axles from the machine. Be sure the machine and
the opposite crawler are solidly blocked.
Rear Axle - Details

5-18 BI652203
2. To remove the equalizer axle, first remove the remaining equalizer axle pin, then securely
block the axle to allow removal of the pivot pin.
3. Remove the axle pivot pin. The pivot bearing block may be removed to facilitate removal of
the pin.
4. Remove the axle from beneath the drill and repair or replace as necessary.
5. Reinstall the axle by first positioning the axle to allow installation of the pivot bearing block
and/or pivot pin. Install the bearing block and/or pivot pin.
6. Install the equalizer axle pin and retaining pins. Install the crawler frame if only the equalizer is
to be repaired.
7. To remove the rear axle, remove the remaining axle retainer or clamp collar.
8. Securely block the axle to allow it so slide out of the crawler frame.
9. Remove the bearing block bolts attaching the axle to the mainframe.
10. Slide the axle from the crawler frame and remove from beneath the drill.
11. Repair or replace the axle as necessary.
12. Position the axle to allow it to slide into the crawler frame.
13. Lubricate the axle bearing bores in the crawler frame.
14. Slide the axle into the crawler frame.
15. Align the axle with the mainframe.
16. Install the bearing block and bolts to attach the axle to the mainframe.
17. Install the crawler frame per topic Crawler Frame Repair.
18. Raise the machine slightly with the leveling jacks and remove the remaining blocking. Lower
the machine to the ground.
BI6522035-19
MAINFRAME
The mainframe consists basically of two I-beams tied together with bracing and covered on the top
surface with deck plates.
Inspect the drill mainframe for wear, damage or cracks. Pay particular attention to the following
critical areas:
Main Frame - Details
1. Cross bracing which ties the bottom flanges of the I-beams together.
2. Cross bracing and deck plates which tie the top flanges of the I-beams together.
3. Mast lock pin attachment areas.
4. Leveling jack attachment areas.
5. Areas where the mast A-frame is pinned to the mainframe.
6. Mast hoist cylinder attachment lugs and the immediate area surrounding these
lugs on the mainframe.
5-20 BI652203
REPAIR
Cracking, wear or damage to the critical areas listed above require immediate repair. The urgency
of repair to other areas of the mainframe is dictated by the area in which the repair must be done
and the severity of the damage. Minor damage may not require immediate attention but all damage
to the mainframe should be repaired at the first available opportunity.
Repair to the mainframe is limited to repair welding. Follow the recommended procedures detailed
in the Appendix to complete welding repairs. If damage is severe or unusual circumstances arise,
contact the Caterpillar Global Mining Service Department for specific recommendations.
BIT VIEWING HATCH
The bit viewing hatch is mounted in the mainframe in line with the drill pipe and the operator’s
station. When the hatch cover is lowered, the operator can view the bit as a new hole is started.
Bit Viewing Hatch - Details
The structure should be checked monthly for weld cracks. The cylinder and hydraulic lines should
be checked daily for leaks.
BI6522035-21
MAST A-FRAME
The mast A-frame is a welded structure that is pinned to the mast and the mainframe and helps
support the mast at it’s lower end. The rear leg anchor pins are hydraulically operated.
The structure should be checked monthly for weld cracks, structural bending and wear. The cylinders
and hydraulic lines should be checked daily.
REPAIR
Any cracking, wear, or damage to the A-frame must be repaired immediately. Repair to the A-frame
is limited to repair welding. Contact your local Caterpillar Global Mining representative for a specific
weld repair solution.
5-22 BI652203
LEVELING JACKS
Inspect the leveling jacks for structural damage, proper lubricant coating and proper operation.
Verify that all bolts are tight and all pins are in place.
Check the jack pads for cracks or damage. Clean excess material from the jack pads. Check the
jack spuds for wear or damage. Verify that the spuds are coated with lubricant.
Leveling Jack - Details
Proper operation of the jack dictates that the jacks do not settle either while the machine weight is
resting on the jacks or when the jacks are in the stored position. To check the jacks, raise the
machine on the leveling jacks until the machine is completely off of the ground. Scribe a line on the
jack spuds 1 foot below the jack housing. Allow the machine to remain idle for 1 hour. Measure the
distance between the scribe lines and the jack housings. If the jacks have drifted more than 1/4",
the jack(s) and/or other hydraulic components are leaking and should be repaired.
BI6522035-23
REPAIR
Repair of the leveling jacks is limited to repair welding of selected components and clean-out of
others. Repair welding of structural damage is allowable on the jack casing and jack pad. Follow
the recommended repair welding practices detailed in the Appendix to repair these items. Repair
welding of the jack spud is not recommended if the damage has caused the spud to be bent or
become out-of-round. The spud should be replaced if it is bent or no longer round.
Repair of the hydraulic cylinder is limited in this manual to clean-out of the cylinder. Repair of the
cylinder itself follows the basic procedures for repair of any hydraulic cylinder.
Repair of the jack casing is limited in this manual to repair of minor cracks or damages. Should any
serious damage occur, consult the Caterpillar Global Mining Service Department for repair details.
Note that bolts securing the rear jack casing to the mainframe are torqued to 390 ft. lbs. (snug-tight)
then turned an additional 1/2 turn. Refer to turn-of-the-nut torquing method later within this section.
There should be hardened washers under bolt heads and nuts.
To remove and replace a hydraulic cylinder and jack spud proceed as follows:
1. If the rear jack is to be worked on, lower that jack until the pad is 1 or 2 inches from the ground.
Raise the other three jacks not being worked on, to the full retracted position. If a front jack is
to be worked on, both front jacks should be lowered to 1 or 2 inches from the ground. Raise
the rear jacks to the full retracted position.
2. Stop the hydraulic pump and relieve any pressure in the system by loosening the reservoir
breather. When trapped air in the reservoir is relieved, immediately replace the breather.
3. Carefully disconnect the main hydraulic lines attached to the counterbalance valve at the jack
cylinder.
NOTE: Do not disturb the lines going from the counterbalance valve to the electric junction box.
4. With appropriate plugs, seal open holes in the main hoses that were removed in step 3.
CAUTION: If working on a rear jack, refer to steps 5 through 8 and 15 through

31. If working on the front jacks, refer to steps 9 through 31.
5. For rear jack repair, with an open-end wrench, remove the female half of the quick disconnect
from the male half that is attached to port PR of the counterbalance valve. Leave the 1/4"
hose attached to the female half of the quick disconnect.
6. When step 5 has been completed, disconnect the 1/4" hose at the electric junction box.
5-24 BI652203
CAUTION: Always maintain a firm grip on the hose while the oil is flowing from it.
Do not allow the stream of oil to contact your skin as injury can occur.
7. Point the open end of the 1/4" hose into an empty 5 gallon pail and reattach the female half of
the quick-disconnect to the male half that is still attached to port PR. When the quick disconnect
opens, a stream of oil from the rod side of the cylinder will exhaust from the 1/4" hose into the
pail. This will allow the jack pad to lower by gravity to the ground at which time the oil will stop
flowing.
8. Again remove the female quick-disconnect half with 1/4" hose as in step 5 and reconnect the
1/4" hose onto port of electric junction box.
9. For front jack repair, uncouple the quick-disconnect at both front jacks, using a 1 1/4" open-
end wrench. The male half of the quick-disconnect will remain attached to the valve.
10. At one front jack only, remove the other end of the quick-disconnect hose from the electrical
junction box on the jack.
11. Place the hose end, removed from the electrical junction box, into a clean five gallon container.
(Two additional 5 gallons will be required to handle the oil from both front jacks.)
12. Re-couple the quick-disconnect. As the connection nears completion, oil will run out of the
hose-end in the container and the jack pad will drop to the ground! This will relieve all
pressure on the piston rod and create a vacuum on the housing-end of the cylinder.
13. To remove the oil from the other front jack, a helper will be required. Have the helper continue
to hold the disconnected hose into a empty 5 gallon container while you re-couple the quick-
disconnect on the other front jack. The oil from this jack will now flow from the hose being held
by the helper.
14. When the oil flow has stopped and the jack pad is on the ground, the loose end of the hose
can be reconnected to the electrical junction box.
15. Remove male half of quick-disconnect from port PR and thread it loosely into female half.
Cover open end with protection cap.
16. Remove 3/8" hose at counterbalance valve and plug open end of hose.
17. Insert SAE-6 steel O-ring boss plug into ports PR and PH.
18. Remove the casing cover bolts.

BI6522035-25
NOTE: If one of the front jacks is to be repaired, the mast brace support must be removed and
an eyebolt installed in the cover for removal purposes.
19. Remove the capscrew securing the shoe retainer to the spud. Separate the shoe from the
spud and remove the retainer and split retainer from the shoe.
20. Attach a suitable lifting device to the lifting lug or eyebolt on the casing cover and carefully lift
the spud and cylinder from the casing.
21. To remove the cylinder from the spud, remove the pipe plugs securing the spud foot pin and
remove the pin.
22. Slide the cylinder from the spud. Remove the casing cover from the cylinder.
23. Repair or replace components as necessary.
24. Install the casing cover on the cylinder.
NOTE: The cylinder rod should be retracted fully into the cylinder body. If not, using hydraulic
pressure, retract the hydraulic cylinder to the fully retracted position. Note that hydraulic
pressure must be used and pressure be exerted at port VR before the counterbalance
valves will allow the cylinder to move. Use oil similar to what is used in the hydraulic
system.
25. Using a suitable lifting device, slide the cylinder, body end first, into the spud.
26. Align the foot pin holes and insert the foot pin. Secure with the square head pipe plugs.
27. Using a suitable lifting device, lower the spud and cylinder assembly into the jack casing.
28. Attach the casing cover to the casing. Note that the rear jack casing cover bolts must be
torqued to 480 ft. lbs. There should be no plating or lubrication on the bolts.
29. Install the fittings into the hydraulic cylinder and attach the hydraulic hoses.
30. Position the pad under the jack and slowly lower the spud end into the pad. Attach the jack
pad to the spud using the split retainer and solid retainer. Torque the retainer capscrews to
280 ft. lbs. (dry threads).
31. Cycle the jack 2-3 times to check the operation of the unit and to remove any air pockets
created during the repair procedures. The jack should be extended and retracted to the
maximum without lifting the machine.
5-26 BI652203
MACHINERY HOUSE
Frequently inspect all house panels and structural members for cracking. Include a close examination
of all roof structures and bracing. Always restore defective structural members to their original
state by repair welding.
Periodically inspect the hinges and latches on all doors and windows to insure they will remain
closed during machine operation. Verify the sealing of all doors and windows to prevent the entrance
of dust. Search thoroughly for all loose or missing bolts. The absence of these fasteners can result
in excessive vibration and wear of house components. Inspect the condition of the paint on both the
interior and exterior surfaces of the house. Prepare any paint any areas where the paint has been
damaged or any areas where repairs have been made.
REPAIR
Repair of the machinery house is usually limited to repair of individual structures within the house.
Repair welding should follow the guidelines detailed in the APPENDIX. Any repair procedure should be
undertaken with the object being to prevent the entrance of dust, dirt, or moisture into the house. All
joints in the house structure should be adequately sealed and openings in the machinery house
should be kept to a minimum.
The machinery house roof is removable, as well as the cross members over the main air compressor.
Verify that the cross members are securely fastened. Verify that the roof is sealed properly and that
the clamps are secured.
Machinery House - Exploded View

BI6522035-27
HOUSE VENTILATION FAN AND FILTER
The machinery house is equipped with a ventilation fan and inertial filter which provides clean
ventilation air to the main air compressor and machinery house. The machinery house is pressurized
slightly above the atmospheric pressure by the fan. This serves to keep dust and moisture from
entering the machinery house. The ventilation fan should be operating any time the machine is
being operated. Keep all machinery house doors closed at all times to prevent the entrance of dust.
Inspection of the ventilation fan itself is not required except as necessary to repair some malfunction.
Machinery House Ventilation Fan

The inertial filter cleans the air entering the machinery house. This filter is self-cleaning and
does not require routing service typical of other filters. Proper operation of the filter, however, is
dependent upon proper air flow. Restriction of the intake by leaves, rags and paper will lessen
the effectiveness of the filter and ventilation fan. A light coating of dust on the blades of the filter
is normal and will not impair the efficiency of the filter. To remove material which has
accumulated on the blade surfaces, it is necessary to remove the filter cell and steam clean the
blades.
5-28 BI652203
WALKWAYS AND LADDERS
Inspect all handrails, walkways, platforms, stairs and ladders on the machine daily. Verify that all
structural members are in good repair and that all fasteners and welds are intact. Repair or replace
components immediately to insure the integrity of the structures and ensure compliance with safety
regulations.
Retractable Boarding Stairway - Details
Keep all walkways, stairways and ladders clear of materials which could present slipping or tripping
hazards. Keep walkways clear of tools, supplies or other obstructions. Clean up all grease or oil
spills immediately.
BI6522035-29
OPERATOR’S CAB
Inspect the operator’s cab daily for cracks or structural damage to all side, roof and floor panels.
Check the doors and windows for proper operation and correct sealing. Keep the cab clear of all oil,
grease or water spills to help prevent slipping.
Operator’s Cab Location Mounting

5-30 BI652203
OPERATOR’S SEAT
The individual operator may adjust the operator’s seat as

desired with respect to height, tilt and travel. Periodically
lubricate all bearings and pivot points to maintain smooth
movement.
OPERATOR’S CONTROLS
Inspect all of the operator’s controls daily for wear or damage. Verify the correct operation of all
controls daily. Repair or replace malfunctioning controls immediately. Clean all nameplates and
markers and maintain all markers and signs in a legible condition including warning signs.
Operator’s Controls
BI6522035-31
AIR CONDITIONING UNIT WITH HEATER
Inspect the HVAC unit on the operator’s cab roof for proper operation, structural integrity and sealing.
All permanent side panels should be in place and adequately sealed and secured.
Operator’s Cab Heating/Air Conditioning Unit

5-32 BI652203
HYDRAULIC PUMP DRIVE
The hydraulic system pumps are driven by the main air compressor motor through a gearbox. The
gearbox is mounted to the compressor base.
The oil level in the gearbox should be checked weekly and oil added if required. Daily check the
gearbox for oil leaks and repair as required.
Hydraulic Pump Drive
To remove and disassemble the pump drive gearbox, proceed as follows:
1. Place the machine in a secure area to perform the repair. Shut off and tag the controls.
BI6522035-33
2. Drain the oil from the gearbox. There is approximately 7.75 qts. of oil in the gearbox.
3. Remove the pump mounting capscrews and remove the pumps and gaskets.
4. Separate the gearbox drive coupling. Remove the gearbox mounting bolts. Remove the gearbox
from the mounting pads. Note the thickness of shims.
5. On a clean surface, position the gearbox so that the hydraulic pump adapter plates are facing
up. Remove the plate mounting bolts and lift the adapter plates from the gearbox.
Hydraulic Pump Drive Gearbox - Details
6. Lift the driven gears and their bearings from the gearbox. This can be done by hand since the
bearings are slip fit to the gearbox and adapter pad bores. The bearings are press fit to the
gear hubs. It may be necessary to tip the gear slightly to clear the drive gear bearing pocket.
7. After the driven gears have been removed, turn the gearbox over so that the drive shaft and
gear can be removed.
8. Remove the shaft adapter mounting bolts and remove the adapter assembly and gasket from
the gearbox.
5-34 BI652203
9. Separate the drive shaft adapter assembly as follows:
a. Remove the large snap ring from the bore of the adapter.
b. Remove the small snap ring from the drive shaft and pull the shaft from the adapter.
Take care not to damage to oil seal.
c. Remove the bearing from the adapter. Remove the oil seal from the adapter.
10. Clean and inspect all parts. Repair or replace all damaged or worn parts and reassemble in
reverse of disassembly, noting the following:
a. When reassembling the gearbox, use new seals, gaskets and bolts.
b. Use Loctite® 262 on all bolts and torque all bolts to 200 ft. lbs.
c. When installing gearbox coupling, proceed as follows:
(1. Verify that the motor shaft is centered.
(2. Mount the coupling hubs on the motor and gearbox.
(3. Mount the gearbox so that a 0.63 inch gap exists between the ends
of the shafts.
(4. Check the coupling for angular and offset misalignment. Maximum
misalignment should not exceed 0.002 inch. Use shims under the
gearbox feet to correct misalignment.
(5. Torque coupling capscrews (dry threads) to 30 ft. lbs.

BI6522035-35
CABLE REEL
CAUTION: The cable reel handles the trail cable during propelling. The trail
cable carries a high voltage which can cause serious or fatal injury.
Whenever work is to be done on the cable reel the trail cable must
be disconnected from its power source.
A routine inspection of the cable reel should be performed every 3 months to assure that it is
working properly and that the trail cable is being spooled on and off the reel correctly. Check that the
level wind mechanism works freely. Check that all drive chains are properly tensioned and well
lubricated. Lubricate every six months.
Check all structural components for cracking.

5-36 BI652203
The cable reel should only be lifted using the provided lift points shown below.
The sprocket that drives the guide head unit is interchangeable to allow for reeling of a wide range
of cables. Before installing any cable make sure the correct sprocket is installed and the chain is
properly tensioned, use of the incorrect sprocket will lead to incorrect cable spacing and potential
damage to the cable or reel. Refer to the manufacturer’s documentation for more information.
BI6522035-37
CHAIN TENSIONING
All chains must be properly tensioned to ensure smooth operation and prevent excessive wear of
chain and sprockets. All sprockets must be properly aligned to prevent excessive wear on chain.
The Motor-Spool chain should have 0.50-0.75 in.

(1.3-1.9 cm) of slack when tensioned.
The Spool-Encoder chain should have 0.313-0.625

in. (0.8-1.6 cm) of slack when tensioned.
The Spool-Reducer chain should have 1.75-2.25 in.

(4.5-5.7 cm) of slack when tensioned.
The Reducer-Guide chain should have

0.563-1.13 in. (1.4-2.9 cm) of slack when
tensioned.
5-38 BI652203
The Guide chain should have 0.50-1.0 in. (1.3-2.5 cm) of slack when tensioned.
HYDRAULIC ADJUSTMENTS
When properly adjusted, the cable reel will pick up cable when the drill moves toward its power
source. The reel will stall when the drill is stationary and the reel drive will be overpowered when the
drill moves away from the power source, allowing the cable to be unwound from the reel.
DANGER: The cable reel should not be used to pull the trail cable onto the reel.
Wind the cable onto the reel only as the drill moves toward the cable.
Attempting to pull 50 feet or more cable, laid in a straight line onto
the reel without moving the machine toward the cable, will damage or
possibly break the cable.
View A - Hydraulic Adjustment Locations
Line pull is proportional to operating pressure. The correct line pull occurs when there is sufficient
pull on the cable to wind it on the reel, but not too great to put unnecessary strain on the cable.
BI6522035-39
Line speed is dependent on the volume of hydraulic oil flowing through the system. The correct line
speed is slightly faster than the travel speed of the drill.
Line pull when propelling away from the cable reel is set by the counter-balance valve. The cable
pull on the cable reel and builds pressure against the counter-balance valve. If cable is being
dragged, lower the counter-balance setting.
HYDRAULIC DRIVE START UP INSTRUCTIONS
1. Start the main compressor motor and allow the hydraulics system to run for 5 minutes to
ensure proper operating temperature.
2. Place a 3000 PSI gauges on test port 49 and 50; both located on station 3 manifold - VB4.
PRESSURE SETTING - REEL FORCE
1. With the trail cable installed on the cable reel, move the cable reel switch to the reel in position.
2. Set the pressure relief valve (refer to View A) to 800 PSI. Test port 49; located on station 3
manifold - VB4.
3. Return the cable reel switch to the neutral position.
4. Have the operator move the machine toward the cable allowing the cable reel to pick up
cable.
5. If the machine drags the cable, lower the pressure on the pressure relief valve.
6. If the machine can not reel on the cable, raise the pressure on the pressure relief valve.
7. Repeat Steps 4 to 6 until proper tension on the cable reel is achieved.
FLOW SETTING - REEL SPEED
1. With the trail cable installed on the cable reel and the pressure set.
2. Have the operator move the machine toward the cable allowing the cable reel to pick up
cable.
3. The cable reel should pick up cable slightly faster than the machine propel speed.
5-40 BI652203
4. If the cable reel does not pick up cable fast enough, adjust the flow control shown in View A.
5. Once the cable reel speed seems to be set, have the operator stop propelling the machine.
6. Place the cable reel switch to the unwind position, reel out cable and verify the speed is not
excessive.
7. Adjust the flow control as required and verify wind in speed with the machine propelling in
Step 2.
COUNTERBALANCE SETTING - PULL-OUT FORCE
1. With the trail cable installed on the cable reel, the pressure set, and the flow set.
2. Have the operator drive away from the cable.
3. The cable is set properly will pull off the cable reel with out dragging the cable.
4. If the cable is dragging, lower the counter balance setting. Refer to View A for location.
5. If the cable spool out cable under the weight of the cable, increase the counterbalance pressure
setting.
Now that the cable reel is set, operate the machine and observe the machine to ensure the cable is
being layed out and reeled up properly.
• If cable drags when machine propels toward the cable, lower the pressure setting.
• If cable drags when machine propels away from cable, lower the counter balance setting.
• If cable does not pick up the cable off the ground, raise the pressure setting.
• If cable spools out on the ground when machine is at rest, raise the counter pressure setting.
• If cable reel pick ups cable too slow, increase flow setting.
• If cable reel operates too fast, lower the flow setting.

BI6522035-41
LUBRICATION
Lubricate the guide rollers monthly using MPG lubricant. Ensure the rollers turn freely and all mounting
hardware is tight.
The chains should be lubricated every six months using a good chain lube. Diamond Chain
Company’s Chain Lube, which is a foam-type aerosol lube, is recommended. Check chain for
corrosion and tension. Re-adjust chain tension as needed.
Grease the main spool bearings and encoder jack-shaft bearings semi-annually.
The recommended lubricant for the gear reducer is Mobil Delvac Synthetic Gear Oil 75W-90 or
equivalent.
REPAIR
Repairs of cable reel will consist mainly of replacing worn or damaged parts
5-42 BI652203
MAST STRUCTURE
The mast is a fabricated structure made of

steel tubes and formed plates. The structure
is formed by four vertical tubes tied together
on three sides with tubular lacing. The fourth
side is open to allow the rotary drive unit to be
raised and lowered the length of the mast.
Inspect the structure daily for wear or damage.

Inspect all mast ladders and platforms for
loose hardware and structural integrity. Inspect
the racking on the outside of the rear mast
tubes for proper lubrication and any wear or
damage. Inspect the mast hinge pins and the
structure surrounding the pins for wear or
damage. Verify that the hinge pin keepers are
in place and tight. Inspect the mast hoist
cylinder attachments for wear or damage.
Lubricate the pins weekly with the appropriate
lubricant. Inspect the mast lock pins for wear
and damage. Verify that the lock pin hydraulic
cylinders and hydraulic line are not leaking.
Every 80 operating shifts lower the mast and

inspect all welds thoroughly for cracks or
damage. Clean the racking on the outside of
the two rear mast tubes and check the welds
securing the racking to the tubes.
BI6522035-43
REPAIR
Repair of the mast structure is limited to repair welding of cracked or broken welds or components
or replacement of severely damaged structures. Contact your local Caterpillar Global Mining
representative for a specific weld repair solution.
When repairing mast structures by welding it is important to keep in mind that the repair should
return the structure to its original condition. All welds should be smooth and any notches or undercuts
should be welded and ground. Do not add reinforcing material or change the geometry of the
structure. Replace any damaged components with material of the same strength and cross section.
For mast lock pins see Mast A-Frame.
MAST SAFETY SLINGS
The mast safety slings are used to help prevent drill pipe coming loose from the rotary unit and
falling off the machine or onto the operator’s cab. The slings should be checked weekly to verify
that all pipe supports are properly adjusted and all yoke end pins are secured in place.
Upper Safety Sling

5-44 BI652203
REPAIR
Lower Safety Sling - Optional
Repair of the safety slings consists mainly of replacing worn or damaged components. Repair
welding may be used to repair cracks. Contact your local Caterpillar Global Mining representative
for a specific weld repair solution.
BI6522035-45
ROTARY GEARCASE
CAUTION: Unexpected operation or movement of the pulldown unit and/or

rotary gearcase during service or inspection procedures can cause
severe personal injury or death. Lower the pulldown unit to its lowest
possible position or secure it in place. Lockout and tag controls to
prevent unexpected operation.
Inspect the rotary gearcase every shift for loose or missing hardware. Check the gearcase for
lubricant leaks and repair as necessary. Verify the operation of the automatic lube system or manually
lubricate all points as necessary. Check the lubricant level in the gearcase and add the proper
lubricant to the required level. If water has accumulated in the gearcase remove the drain plug and
completely drain the case. Refill the gearcase to the required level with an approved lubricant.
Check the air swivel for leaks and repair as necessary.
Rotary Machinery/Gearcase
5-46 BI652203
Every 80 operating shifts partially drain the gearcase and remove the inspection cover. Inspect the
gear teeth for wear or damage. Check the rotary drive shaft bearing pre-load. If any clearance
exists in the drive shaft bearings it will be necessary to adjust the pre-load by removing shims from
the lower retainer.
DRIVE SHAFT ADJUSTMENT
The drive shaft must be adjusted to give 0.003"

- 0.005" pre-load on the bearings. To adjust
the bearing preload proceed as follows:
1. Remove the capscrews which secure

the lower bearing retainer to the
gearcase. Remove the retainer shims.
NOTE: Cut shims in half for ease of

removal and installation.
2. With the shims removed, reinstall the

capscrews and torque to 60 ft.-lbs. to
insure proper bearing seating.
3. Remove all the capscrews except two

180° apart. Re-torque the remaining two
capscrews to 50 ft.-lbs., in 10 ft.-lb.,
increments so that the retainer remains
square to the case. Turn the shaft and
recheck the capscrew torque.
4. Measure the gap between the retainer

and gearcase at both capscrews. Obtain
the average gap by dividing the sum of
the measurement by 2.
1. Lower Bearing Carrier 7. Bearing Retainer

2. Center Bearing 8. Retainer Bolt
3. Rotary Drive Shaft 9. Oil Seal
4. Lower Bearing 10. Spacer
5. Retainer O Ring 11. Seal Retainer
6. Shims 12. Retainer Bolt
BI6522035-47
Rotary Machinery Intermediate Shaft

1. Upper Bearing Cover 10. Intermediate Shaft
2. Cover Bolt 11. Lower Bearing
3. O Ring 12. Retainer
4. Retainer 13. Retainer Bolt
5. Retainer Bolt 14. Lower Cover
6. Upper Bearing 15. Cover Bolt
7. Oil Seal 16. O Ring
8. Seal Sleeve 17. Gearcase
9. Intermediate Gear
5. The average gap minus 0.003" to 0.005" is the total shim pack thickness required to provide
0.003" to 0.005" pre-load on the bearings.
6. Remove the two remaining capscrews and install the required shim pack and capscrews.
Torque the capscrews to 200 ft.-lbs.
5-48 BI652203
REPAIR
There are three areas on the rotary gearcase where repair is possible. This topic deals only with
the repair of the internal components of the unit. Repairs of the rotary motor and the rotary coupling
are covered under separate topics.
Repair of the rotary gearcase is limited to replacement of worn or damaged components. The unit
may be repaired in place on the machine or may be removed from the machine and repaired
elsewhere. Refer to the Rotary/Pulldown Guide Frame topic for the procedure necessary to remove
the assembly from the machine.
To repair the gearcase either on or off of the machine use the following procedure:
1. Securely block the gearcase in the upright position. Remove the rotary motor form the
gearcase. Refer to the topic Rotary Motor. Drain the oil from the gearcase. Remove the motor
adapter ring. Remove the motor O-ring from the gearcase.
NOTE: If the drive unit is left in the machine, lower it to the bottom of the mast and rest it on the
lower stops. Shut off and tag the controls.
2. Remove the air pipe and gasket from the swivel housing.
3. Remove the gearcase front cover and gasket.
4. Remove the intermediate shaft upper bearing cover and cover O-ring.
REMOVE THE UPPER BEARING RETAINER.
5. Screw an eyebolt into one of the tapped holes in the top of the intermediate shaft. Support the
shaft with rigging and a crane.
6. Support the intermediate gear with blocking so that when the shaft is removed the gear will
not fall.
7. Remove the capscrews securing the lower bearing retainer to the gearcase. Remove the
bearing retainer. Remove the O-ring from the retainer.
8. Slowly lower the intermediate shaft out of the gearcase. Remove the lower bearing, retainer,
and spacer from the shaft. The lower bearing has an interference fit of 0.0005" - 0.0025" to
the shaft.
BI6522035-49
NOTE: The inner race of the upper bearing has an interference fit of 0.0006" - 0.0017" to the
shaft and may require a slight force to separate it from the shaft.
9. Position the intermediate gear to be removed through the front opening of the gearcase.
Remove the gear and upper bearing inner race and seal sleeve.
10. Remove the upper bearing cage and oil seal from the upper bore in the gearcase.
11. Support the drive shaft with blocking under the rotary coupling.
12. Remove the lockwire and capscrews securing the swivel housing to the gearcase. Remove
the housing.
13. Remove the seals, spacers and wave spring from the housing.
14. Remove the locknut, lockwasher and spacer at the top of the drive shaft.
NOTE: The locknut has left hand threads.
15. Remove the capscrews attaching the lower bearing retainer to the gearcase.
16. Slowly lift the gearcase until the vertical shaft gear is resting on the bottom of the gearcase. If
the weight of the vertical shaft will not free itself from the upper bearing inner race, additional
force will have to be placed on the top of the shaft to force the race off the shaft as the
gearcase is raised. The race has an interference fit of 0.0001"-0.0021" to the shaft.
17. When the upper race is removed from the shaft, continue raising the gearcase until it clears
the shaft. Remove the shaft and lower the gearcase back onto its blocking.
18. Remove the upper bearing inner race, seal sleeve, gear spacer and gear from the gearcase
through the front opening.
19. Remove the upper bearing cage, oil seal and O-ring from the upper bearing carrier. Remove
the upper lower bearing cup from the lower bearing carrier. The cup has an interference fit of
0.0004"-0.0050" to the carrier.
NOTE: The upper and lower bearing carriers are press fit to the gearcase and should be
removed only if damaged or worn.
20. Unbolt and remove the drive shaft clamp collars.
21. Unbolt and remove the rotary coupling lower half from the upper half of the coupling.
5-50 BI652203
CAUTION: In the following step a torch is used to heat the upper coupling half.
When using the torch be sure to take all safety precautions. Also use
suitable protective equipment when handling the heated item.
22. Use a torch to heat the upper coupling half and separate the two sections of the drive shaft.
Remove the O-ring from the drive shaft.
23. Slide the lower bearing retainer assembly from the shaft upper section and disassemble as
follows:
a. Remove the O-ring and shims.
b. Remove the seal retainer capscrews and retainer.
c. Remove the seals and spacer.
d. Remove the lower bearing cup from the retainer. The cup has an interference fit of
0.0010"-0.0050" to the retainer.
24. With a bearing puller, remove the lower bearing cage and the upper lower bearing cage from
the shaft.
NOTE: The lower bearing cage has an interference fit of 0.0005" - 0.0025" to the shaft. The
upper lower bearing cage has an interference fit of 0.0028" - 0.0048" to the shaft.
25. Inspect all components. Repair of replace all components as necessary.
CAUTION: There are a number of steps in the following procedure which

require heating of certain items prior to assembly. Use suitable
protective equipment when handling the heated items.
26. To reassemble the gearcase first clean all components thoroughly. Inspect all bores and
shaft surfaces, and remove any nicks or burrs. Lightly oil all parts. Apply LocTite® #271 to all
clean threads at assembly. Be sure to follow manufacturer’s instructions when using Loctite.
27. Install the upper lower bearing cup in the bearing carrier. This cup is interference fit to the
carrier and will have to be pressed in. Be sure the cup is tight against the shoulder in the
carrier.
28. Install the lower bearing cages on the drive shaft upper section. These cages are interference
fit and will require heating in an oil bath to 250° F prior to assembly. Be sure the cages are
tight against the shoulders of the shaft.
BI6522035-51
29. Assemble the lower bearing retainer assembly as follows:
a. Install the lower bearing cup in the retainer. This cup is interference fit and will have
to be pressed in. Be sure the cup is tight against the should of the retainer.
b. Install the oil seals and spacer in the retainer. Be sure the lips of the seals face
toward the bearing cup.
c. Install the seal retainer and capscrews. Tighten and lockwire the capscrews.
d. Install the O-ring on the retainer.
30. Install the retainer assembly on the drive shaft upper section. Do not install the shims on the
retainer.
31. Install the O-ring in the bottom of the shaft upper section.
32. Heat the upper shock coupling half in an oven or oil bath to 250° - 300° F maximum. Install the
rotary drive collar on the coupling. Insert coupling half on the half drive shaft and install clamp
collars and bolts. Allow shaft to cool to ambient temperature.
33. Remove the clamp collars and install the rotary coupling upper cushion seal strip. Re-install
the shaft clamp collars, tighten bolts and lockwire. The splits in the collars should be offset
90° from each other.
34. Re-install remaining parts of shock coupling per topic, Shock Coupling.
35. Install the drive gear in the gearcase. Make sure the gear is aligned to the shaft bore. Slowly
raise the gearcase so that the shaft can be positioned for installation.
5-52 BI652203
Rotary Machine Driveshaft - Details

BI6522035-53
36. Securely block the drive shaft in an upright position. Slowly lower the gearcase down onto the
shaft being careful not to damage the shaft threads. It may be necessary to rotate the gear
slightly to align the splines of the gear and shaft.
37. Insert and snug up the lower bearing retainer capscrews.
38. Install the gear spacer, seal sleeve and upper bearing oil seal. Be sure the lip of the seal faces
upward. Heat the upper bearing inner race in an oil bath to 250° F maximum and install on the
shaft tight against the sleeve, Install the bearing spacer, lockwasher and locknut, then tighten
the locknut firmly. Allow the race to cool to ambient temperature.
39. When the race has cooled remove the locknut and lockwasher, and install the upper bearing
cage. Re-install and tighten the lockwasher and locknut.
40. Preload the lower bearings as follows:
a. Torque the lower bearing retainer capscrews to 60 ft.-lbs. to insure proper bearing
seating.
b. Remove the capscrews except two 180° apart. Re-torque the remaining capscrews
to 50 ft.-lbs., in 10 ft.-lb. increments, so that the retainer remains square to the
gearcase. Turn the shaft and re-check the capscrew torque.
c. Measure the gap between the retainer and gearcase at both capscrews. Obtain
the average gap by dividing the sum of the measurements by 2.
d. The average gap minus 0.003" to 0.005" is the total shim pack thickness required
to provide 0.003" to 0.005" preload on the lower bearings
e. Remove the two remaining capscrews and install the required shim pack and
capscrews. Torque the capscrews to 200 ft.-lbs. and lockwire.
NOTE: If the shims are complete circles, cut in half for ease of installation.
41. Install the seals and spacers in the swivel housing as shown on figure 1-4-6. Be sure the seal
lips are facing upward. Install the O-ring in the bearing carrier.
42. Install the swivel house and secure with the capscrews. Tighten and lockwire the capscrews.
43. Install the intermediate gear and block in place. Set the seal sleeve on top of the gear. Align
the bore of the gear with the bore of the shaft.
5-54 BI652203
44. Heat the lower bearing in an oil bath to 250° F maximum and install the bearing on the shaft.
Secure the bearing with the retainer and lockwire the capscrews.
45. Install the O-ring in the lower cover. Insert the shaft assembly into the gearcase. Install the
lower cover and secure it with the cover capscrews. Tighten and lockwire the capscrews.
46. Install the upper oil seal. Heat the inner race of the upper bearing in an oil bath to 250° F
maximum and install on the shaft. Be sure the race is tight against the spacer, then secure
the race with the bearing retainer. Tighten and lockwire the retainer capscrews. Allow the race
to cool to ambient temperature.
47. Install the upper bearing cage in the gearcase. Install the O-ring on the upper cover and install
the cover on the gearcase. Tighten and lockwire the cover capscrews.
48. Install the motor per topic, Rotary Motor and fill the gearcase with an approved lubricant.
Lubricate all lube points with an approved lubricant.
BI6522035-55
ROTARY MOTOR
Inspection, lubrication and maintenance instructions for the rotary motor are described in the
manufacturer’s Motor Manual. To remove the rotary motor proceed as follows:
1. Lower the rotary drive unit to the bottom of the mast and rest it on the lower stops.
CAUTION: Open and tag the auxiliary power and control breakers in the
machinery house. Do not attempt to disconnect the motor leads with
these breakers closed. A voltage hazard is present and electrocution
is possible if these breakers are left closed.
Rotary Drive Motor - Details
2. Have an electrician identify and disconnect the electrical leads to the rotary motor. Remove
the cable from the junction box on the motor.
3. Remove the motor attachment stud nuts and washers.
4. Using a suitable crane and rigging, lift the motor from the rotary gearcase.
5-56 BI652203
5. Repair or replace the motor as necessary.
6. The motor pinion is press fit to the motor shaft. Refer to the Appendix for instructions regarding
replacement or installation of the motor pinion.
7. Prior to installation of the motor clean the mounting surfaces on both the gearcase and the
motor.
8. Install the rotary motor in reverse order of removal. Torque the attachment stud nuts using
turn-of-the-nut method. Tighten nuts snug, and then an additional 1/3 turn.
BI6522035-57
ROTARY SHOCK COUPLING
The rotary shock coupling is an optional assembly that replaces the standard lower rotary coupling
half. The shock coupling is used to reduce the shock loading transmitted to the rotary drive unit.
NOTE: The procedures detailed in this topic are

for a standard oem shock coupling.
Since shock couplings manufactured by
differing companies may be furnished
with the machine, be sure to verify that
the shock coupling being repaired is as
described before using the procedure
listed below.
Inspect the shock coupling monthly for loose or

missing nuts or other wear or damage or air leaks.
When the cushions have worn to a point that the
0.375" pre-load can no longer be obtained, the
cushions must be replaced. If the bailing air is
escaping from the shock coupling, the seals should
be replaced. At this time, also check the seal tube
for wear and replace if required.
REPAIR

severe personal injury or death. Lower the pulldown unit to its
lowest possible position or secure it in place. Lockout and tag
controls to prevent unexpected operation.
Repair of the shock coupling is limited to replacement of worn or damaged components.

Replacement of any of the components will require disassembly of the unit.
5-58 BI652203
To disassemble the shock sub proceed as follows:
1. Place secure blocking under the shock coupling and lower it onto blocking. Shut off and tag
the controls.
2. Remove the lock wire and slotted nuts from the shock coupling bolts. Remove the bolts and
washers.
3. Be sure the coupling lower half is securely blocked then slowly raise the rotary machinery
until the drive shaft lower section clears the shock coupling lower half. Shut off and tag the
controls.
4. Separate the upper cushion, lower cushion, cushion retainer, seal tube and seals from the
lower half of the shock coupling.
5. If the drive shaft lower section is to be removed, use the procedure as outlined in steps 20
and 22 of the topic Rotary Gearcase - Repair.
6. Clean and inspect all components of the assembly. Replace worn or damaged components
as necessary.
7. If removed, reinstall the drive shaft lower section per steps 31 and 32 under the topic Rotary
Gearcase - Repair.
8. Assemble the upper cushion, lower cushion, cushion retainer, seal tube and seals to the
coupling section.
9. Securely block the assembly in line with the drive shaft lower section. Lower the rotary unit
slowly until the shaft is seated in the coupling. Do not compress the cushions. Be careful not
to damage seals.
10. Install the shock sub bolts, apply LocTite to the threads and hand tighten the slotted nuts to
establish a free height. Refer to preload chart for nut tightening.
11. Progressively tighten the nuts no more than 1/2 turn at a time until tightening is completed.
Install lockwire.
BI6522035-59
ROTARY/PULLDOWN GUIDE FRAME
Rotary Pulldown Guide Frame - Details

The rotary guide frame consists of the two frames that support the rotary machinery and the pulldown
machinery. The guide frames also include the guide rollers which are used to align and secure the
unit to the mast.
5-60 BI652203
Inspect the entire guide frame daily for loose or missing hardware. Inspect the bumper blocks for
wear or damage and replace if necessary. Inspect the rack pinions for wear or damage. Check the
adjustment of the guide rollers and adjust if necessary. Inspect the alignment of the guide frame in
the mast. Check the main air pipe connections for leaks. Verify that the chock bars securing the
rotary gearcase are in place and that the welds on the chocks are intact. Check the lubrication of
the rack pinion.
GUIDE ROLLER ADJUSTMENT
The guide rollers on the rotary/pulldown guide frame keep the assembly aligned to the mast and the
rack pinions in contact with the mast rack. As the guide rollers wear, it is necessary to periodically
adjust the clearance between the rollers and the mast rack mounting tee. To adjust the guide rollers
proceed as follows:
Rack Pinion and Upper Guide Roller - Details
1. Position the rotary/pulldown unit so that the upper guide rollers and rack pinions are accessible.
Shutdown and tag the controls.
2. Using a suitable jack or pulling device, pull or push the rack pinion retainer snug against the
mast on both sides of the mast. This assures that the backlash of the pinions is correct.
NOTE: Also measure the distance from the face of the mast tee column to the center of the
bearing house mounting bolt. This measurement will be used later to determine if the
unit is parallel to the mast. This distance should be approximately 16.785 inches.
BI6522035-61
Lower Guide Rollers - Details
3. Remove the capscrew, nut and washer from the upper front guide roller eccentric pin handle.
Move the handle until a gap of 0.040 inch exists between the roller and the mast tee column.
Secure the handle with the capscrew, nut and washer.
4. Remove the nut, washer and capscrew that secures the lower rear guide roller eccentric pin
handle. Move the handle to position roller against the mast, then measure the distance from
face of the mast to the center of the rotary gearcase mounting bolts. This distance should be
approximately 16.035 inches. If it is not, continue moving the pin handle until the specified
distance is reached. Secure the handle with the capscrew, nut and washer.
5. With a suitable jack or pull device, pull or push the roller snug against the mast.
6. Remove the capscrew, nut and washer from the lower front guide roller eccentric pin handle.
Move the handle until 0.06 inch gap exist between the roller and the mast tee column:
7. Secure the handle with the capscrew, nut and washer.

5-62 BI652203
REPAIR
Repair of the rotary/pulldown guide frame is limited to replacement of worn or damaged components.
Repair welding of any of the components is not recommended. Since only limited repairs to the
guide frame are possible with the unit installed on the machine, it is assumed for the purposes of
this manual that the entire rotary/pulldown unit will be removed from the machine prior to repairs.
Replacement of the rack pinions and guide rollers is possible without removal of the entire guide
frame from the machine. The repair procedures for these components are included in the following
procedures.
To remove the guide frame assembly complete with the rotary gearcase and pulldown machinery
form the machine, proceed as follows:
1. Lower the rotary drive unit to its lowest position and rest it on the lower mast stops. Open the
auxiliary power and control breakers and tag all controls to prevent unauthorized operation.
2. Remove the upper air pipe from the swivel housing and from the guide angle. Discard the
gasket. Use new gaskets at reassembly.
3. Disconnect the electrical leads to the rotary and pulldown motor and remove the cable from
the drive unit.
4. Disconnect and remove the lubrication hoses leading to rotary drive unit, if so equipped.
5. Using a suitable crane and rigging, support the entire rotary/pulldown unit.
6. Remove the upper and lower front guide roller eccentric pin handle anchor bolts and turn
handles to back off on the tension on the rollers to the mast.
7. Remove the capscrews that secure wear plate.
8. Remove the capscrews that secure bearing to the eccentric pins.
NOTE: To remove the retainer capscrews it may be necessary to rotate the eccentric pin to
gain access to the capscrews.
9. Support the upper bogie rollers and lower front roller, then using the pin handles, pull the
upper and lower front eccentric pins from the rollers, bearing housings and guide frames.
10. With the crane and rigging installed in Step 5, lift the rotary/pulldown unit from the mast and
place it on secure blocking.
BI6522035-63
11. Completely disassemble the front upper and lower guide rollers and eccentric pins which
were removed in Steps 7 and 8. The bearings have an interference fit of 0.0010-0.0030 to the
roller and will require a puller to remove them.
12. Remove the shipper shaft pinion retainers and remove the pinions.
13. Refer to figure and remove the rear guide roller retainer capscrews and remove retainers,
shims, rollers and spacers from pin. Remove the bearings from the rollers. The bearings
have an interference fit to the roller and will require a puller for removal.
14. Using the eccentric pin handles, pull the rear guide roller eccentric pins from the frame.
Separate the handle from the eccentric pins.
15. Separate the pulldown motor coupling. Remove the motor hold-down bolts, chocks and shims.
With a crane and suitable rigging remove the motor.
16. Remove the two spreaders at the top of the guide frame. Remove the pulldown unit guard.
17. Remove the bolts that secure the shipper shaft end bearing housings to the guide frames.
Slide the housings toward the pulldown gearcase.
NOTE: The shipper shaft end bearing outer labyrinth seal is press fit to the bearing housing
and will require a certain amount of force to separate it from the bearing housing.
Remove the outer labyrinth seals.
18. Remove the pulldown gearcase hold-down bolts, chocks and shims. With a crane and suitable
rigging maneuver the gearcase out of the guide frame and place it on secure blocking.
19. Unbolt and remove the pulldown unit base.
20. Verify that the rotary gearcase is securely blocked and supported.
21. Using a suitable crane and rigging, support one side of the guide frame.
22. Remove the bolts securing the guide frame to the rotary gearcase and remove the guide
frame from the rotary gearcase.
NOTE: It may be necessary to remove the upper chock bar from the guide frame in order to
remove the guide frame from the rotary gearcase.
23. Repeat Steps 21 and 22 for the opposite guide frame.

5-64 BI652203
24. Clean and inspect all components and replace as necessary.
25. Reassemble the guide frames and install on the machine in reverse order of disassembly
noting the following.
a. Locate and assemble the shipper shaft bearing housings to the guide frames. Bolt and
chock complete.
b. Assemble the upper and lower guide rollers and handles to the guide frames. Shim the
rollers to achieve 0.003" roller bearing end play. Torque the retainer capscrews to 55 ft.
lbs.
NOTE: The upper and lower front rollers will have to be removed when the rotary/pulldown unit
is installed in the mast.
c. Install the R.H. and L.H. guide frames loosely to the rotary gearcase so that the guide
frames tip outward to allow the pulldown base to be installed.
d. Install the pulldown base with dowels and clearance bolts. Install dowels and clearance
bolts in rotary gearcase and tighten all bolts.
NOTE: All dowels are to be removed after chock bars are in place and replaced with bolts.
COUPLING ALIGNMENT
BI6522035-65
e. Install pulldown gearcase and align to center of shipper shaft bearing housings. Shim
case as required to center shaft to housings. Insure that inboard retainers are loose on
shipper shaft when installing case.
f. Install bearings to shipper shaft bearingeings and install all retainers and rack pinions.
Chock gearcase in place.
g. Install pulldown motor and align motor and coupling as follows:
1. Verify that the motor armature is centered and then position the motor so that there is a gap of
.19" between shafts (approx. 1.44" between coupling hub faces).
2. The coupling should be aligned within 0.002" offset and 0.002" angular misalignment. To find
angular misalignment, measure the gap (“L”) between the coupling hubs along the
circumference. The point 180° from the minimum measurement should be within 0.002 inch
(.0508 mm).
3. Use shims under motor mounting feet to achieve proper alignment.
4. When properly aligned tighten motor hold-down bolts and weld chocks to motor base.
CAUTION: In the following steps when welding chocks, be sure to follow all
safety precautions. Also use suitable protection equipment when
handling heated items.
5. Pack coupling with lubricant.
a. Lay rotary/pulldown unit down and install all lower chocks.
b. Remove front upper and lower guide rollers and install rotary/pulldown unit in mast.
Install front upper and lower guide rollers and adjust per topic Guide Roller Adjustment
c. Install air pipe and lube line; have an electrician reconnect motors.
6. Lubricate all points and verify correct operation of the rotary/pulldown unit.
5-66 BI652203
PULLDOWN GEARCASE

Inspect the pulldown gearcase every shift for loose or missing hardware. Check the gearcase for
lubricant leaks and repair as necessary. Verify the operation of the automatic lube system or manually
lubricate all points as necessary. Check the lubricant level in the gearcase and add the proper
lubricant to the required level. If water has accumulated in the gearcase, remove the drain plug and
completely drain the case. Refill the gearcase to the required level with an approved lubricant.
Pulldown Machinery - Overview

BI6522035-67
REPAIR
Repair of the pulldown gearcase is limited to replacement of worn or damaged components. The
unit may be repaired in place on the machine or may be removed from the machine and repaired
elsewhere. Refer to the topic Rotary/Pulldown Guide Frame for the procedure necessary to remove
the assembly from the machine.
To repair the pulldown gearcase proceed as follows:
NOTE: For this procedure we will consider the pulldown gearcase has been removed from the
machine per Steps 17 through 20 of the topic Rotary/Pulldown Guide Frame - Repair.
CAUTION: Be sure the rotary/pulldown guide frame is secured to the mast by

cable or other means. Since the rack pinions and upper guide rollers
have been removed.
Pulldown/Machinery Gearcase and Base

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Pulldown/Machinery First Intermediate and Shipper Shaft

1. Shipper Shaft 12. Shims
2. Bearing 13. 1st Intermediate Gear
3. Locknut 14. Key
4. Lockwasher 15. 1st Intermediate Pinion
5. Seal Retainer 16. Pinion Spacer
6. O Ring 17. Bearing
7. Oil Seal 18. Spacer
8. Labyrinth Seal 19. Spacer
9. Bearing Spacer 20. Shipper Shaft Gear
10. Bearing Spacer 21. Gearcase
11. Bearing Retainer
1. Remove bearing spacer from the ends of the shipper shaft. Use a puller to remove the end
bearing from the shaft. The bearings have an interference fit to the shaft.
2. Slide the bearing housing from the shaft and separate the inner labyrinth seal from the housing.
BI6522035-69
3. If not previously done, drain the gearcase.
4. Remove bearing cover from the pinion end of the second intermediate shaft. Remove O-ring
from the cover.
Pulldown Machinery Second Intermediate Shaft

1. 2nd Intermediate Shaft 11. Seal Retainer
2. Bearing 12. Oil Seal
3. Bearing Retainer 13. O Ring
4. Cover 14. Encoder Coupling
5. O Ring 15. Coupling pin
6. 2nd Intermediate Gear 16. Encoder
7. Key 17. Housing
8. Gear Spacer 18. Cover
9. Bearing 19. Gasket
10. Retainer 20. Gearcase
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5. Remove encoder housing cover, gasket and housing from the opposite end of the second
intermediate shaft.
6. Remove encoder coupling spring pins, then unbolt and remove encoder and coupling. Remove
retainer/encoder support from the gearcase. Remove the O-ring and oil seal from the retainer.
7. Remove the bearing retainer from each end of shipper shaft. Separate O-ring, oil seal and
labyrinth seal from each retainer.
8. Remove the rod bolts, tapered pins and capscrews securing the gearcase cover to the
gearcase. With a crane lift the cover from the gearcase.
9. Lift the shipper shaft from the gearcase. Remove the bearing spacer from the long end of the
shipper shaft.
10. Remove bearing retaining nut, lockwasher, bearing and bearing spacers from each end of
the shaft.
11. Slide shipper shaft gear from the shaft.
12. Remove first intermediate pinion bearing retainer and shims.
13. Press the pinion assembly from the shaft. The bearings have an interference fit to the shaft.
Remove pinion spacer from the shaft.
14. Separate bearings and spacer from pinion. The cup of the brake end bearing has an interference
fit to the pinion and will require a puller for removal.
15. The first intermediate gear is interference fit to the pinion and should only be removed if
required. If the pinion and gear are to be separated the lube fittings must first be removed.
16. Lift the second intermediate shaft from the gearcase. Remove pinion end bearing retainer
and bearing. The bearing has an interference fit to the shaft and will require a puller for removal.
17. Remove encoder end bearing retainer and bearing. The bearing has an interference to the
shaft and will require a slight force for removal.
18. Remove the gear spacer. The gear is interference fit to the shaft and will require a puller for
removal. Remove the gear end key.
BI6522035-71
Pulldown Machinery Input Shaft

1. Input Shaft 14. Bearing
2. Bearing 15. Bearing Spacer
3. Bearing Carrier 16. Oil seal
4. Gasket 17. Seal Retainer
5. Oil Seal 18. Gasket
6. Spacer 19. Oil Slinger
7. Retainer 20. Hub Spacer
8. O Ring 21. Brake Drive Hub
9. Coupling Spacer 22. Hub Retainer
10. Coupling 23. Brake Assembly
11. Key 24. Bearing Spacer
12. Nut 25. Key
13. Lock Plate 26. Shims
19. Remove the brake housing and cage mounting capscrews. Slide the brake assembly from
the brake drive hub. Disassemble the brake as covered under the topic Hoist Brake.
20. Remove the brake drive hub retainer capscrew and retainer. Remove hub, hub spacer and oil
slinger.
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21. At the coupling end of the shaft remove the bearing carrier capscrews. Slide the shaft assembly
from the gearcase. Remove the carrier gasket.
22. Remove spacer and bearing from the brake end of the shaft. The spacer and bearing are
interference fit to the shaft and will require a slight force for removal.
23. Use a puller to remove half coupling from the end of the shaft.
24. Remove seal retainer from bearing carrier. Remove O-ring, oil seals and seal spacer from
the retainer.
25. Remove bearing spacer and coupling spacer. The coupling and bearing have an interference
fit to the shaft and will require a slight force for removal. Remove the carrier and bearing as an
assembly, then separate them.
26. Remove seal retainer from the brake side of the gearcase. Remove gasket and oil seal from
the retainer.
27. Clean and inspect all parts and repair or replace all damaged or worn parts. Reassemble in
reverse of disassembly noting the following:
CAUTION: During reassembly of the pulldown gearcase certain items must be

heated or cooled for assembly purpose. When heating or cooling the
items take all necessary precautions and use suitable protective
equipment when handling the heating or cooled items.
a. The input shaft bearings, bearing spacer and coupling half are interference fit to the
shaft and will require heating to install.
b. Use thread locking compound on the brake hub retainer capscrews, the coupling end
bearing oil seal retainer capscrews and the brake drive ring mounting capscrews. Torque
drive ring mounting capscrews to 140-150 ft-lbs.
c. Fill the cavity between seals with lubricant at assembly.
d. The second intermediate shaft bearing and gear are interference fit to the shaft and will
require heating to install.
e. Use thread locking compound on the encoder end bearing retainer socket head
capscrews.
f. The first intermediate shaft should be assembled as follows:

BI6522035-73
1. Install pinion inner spacer on the shaft.
2. If removed during disassembly, reinstall gear on pinion. The gear is interference fit to
the pinion and will require heat to install. Be sure key is installed in gear.
3. Install inner bearing outer race in pinion. Race is interference fit to pinion and will require
cooling to install. Slide pinion assembly over shipper shaft as far as it will go.
4. Heat inner races of pinion bearing and install with spacer between them. Then use
special spacer supplied with tools to clamp bearing races. Secure the assembly with
the bearing lock nut.
5. Assemble the remaining outer race and retainer. Install three capscrews equally spaced
and torque to 50 ft-lbs. Measure the gap at all three unused holes and calculate average.
Install shim pack equal to average gap and install and tighten all retainer capscrews.
6. Remove the special spacer and install the remaining material.

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HOIST BRAKE

The hoist brake is a spring-set electric release brake.
INSPECTION
Inspect the brake periodically (every 2000 hours min.) for wear by measuring air gap through slots
in cage. One indication of brake wear is a brake release fault signal. When air gap becomes
excessive, the brake will not release. When the air gap reaches .065", the gap should be adjusted.
Normal operating gap is .050". When the friction disc pack is worn to 1/2 its original thickness, the
disc pack should be replaced.
Brake Wear Adjustment

BI6522035-75
Hoist Brake - Details

1. Magnet Body 10. Adjusting Rod
2. Pressure Spring Assembly 11. Feeler Gauge
3. Cage 12. Nut Plate
4. Cage O Ring 13. Manual Release Bolt
5. Armature 14. Limit Switch
6. Intermediate Disc 15. Switch Bracket
7. Friction Disc 16. Housing
8. Wear Adjusting Ring 17. Conduit Box
9. Hub 18. Terminal Block
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BRAKE WEAR ADJUSTMENT
1. Make sure the mast machinery is blocked or manually locked in the lowered position as the
brake needs to be released to perform the adjustment.
2. Remove the housing screws and brake housing using care to keep from damaging the
switches located on the circumference of the coil housing.
3. Insert brass feeler gages (0.050 supplied with brake) into air gap at the three slots and release
the brake electrically or with the manual release bolts.
4. Remove the locking screws from the wear adjusting ring in the slots of the cage.
5. Insert the adjusting rod into one of the holes in the wear adjusting ring and rotate CCW to the
end of slot. Repeat until resistance is felt.
6. Remove gages and turn the adjusting ring to the nearest end of the slot. Remove rod and re-
install locking screws.
7. Make sure the brake release switches are clean and actuate freely.
8. Set the brake and re-install the housing. Apply a bead of silicon sealant to all exterior joints.
REPLACEMENT OF FRICTION DISCS
1. Energize magnet and clamp armature to magnet body with four manual release bolts. De-
energize magnet and remove leads.
2. Remove cage mounting bolts and magnet body and armature assembly. Back-off wear
adjusting ring slightly to allow space for new friction disc pack.
3. The friction disc pack may now be slid from the hub and cage. Note the order of the pack so
that the new parts can be installed correctly.
4. Re-install new friction disc’s in the correct order with the intermediate discs as shown in
figure.
5. Replace magnet body and armature assembly. (Arrows metal stamped on each part must be
in line).
6. Re-connect lead wires, energize brake and remove four manual release bolts.
7. Set air gap to 0.050" per Brake Wear Adjustment.

BI6522035-77
DISASSEMBLY OF MAGNET BODY AND ARMATURE
1. Place assembly in press with spacer.
2. Press armature against magnet body and remove manual release bolts from armature. (6500
lbs press force required).
3. Slowly release pressure from press until spring pressure is relieved. Remove armature.
Pressure spring assemblies may now be removed.
RE-ASSEMBLY OF MAGNET BODY AND ARMATURE
1. Place magnet body with flange side up on spacer on press base.
2. Insert pressure spring assemblies and set armature in place being sure to align arrows on
armature and magnet body. Insert temporary pins into release bolt holes for aligning.
3. Press armature against magnet body (6500 lbs press force), remove temporary pins and
install four manual release bolts. Tighten bolt to hold armature against magnet body. Remove
assembly from press.
5-78 BI652203
PIPE RACKS
The pipe racks on the machine are used to store drill pipe in a position from where they can be
easily inserted into the drill string. The pipe racks are operated by a hydraulic cylinder which swings
the rack into position to accept or deliver drill pipe.
Inspect the pipe racks daily for loose or missing hardware or any wear or damage. Inspect the
racks each shift for proper operation. Verify that the pipe is held securely by the upper gate. Check
the operating cylinder for proper operation and any oil leaks. Check the bushings on both the pipe
racks for wear and replace as necessary. Check the pawls in the pocket on the lower end of the
pipe rack for proper operation. Remove any dirt, ice or other debris from the pipe pocket and verify
the operation of the gate operating system if no pipe is stored in the rack. Lubricate all points with
the required lubricant.
RH Pipe Rack - Details

BI6522035-79
LH Pipe Rack - Details
REPAIR
There are no wear items on the pipe racks with the exception of the bushings. All major components
of the pipe racks should last through the lifetime of the machine. Repair of the pipe racks is limited
to replacement of bushings and thrust washers.
To replace the bushings and thrust washer, proceed as follows:
1. Raise the rotary drive unit to its highest position and set the hoist brake.
2. Disconnect, plug and tag all hydraulic lines to the pipe racks.
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3. Secure the pipe rack to prevent movement.
4. Remove the bolts attaching upper pivot bracket to bracket support. Remove the bracket and
then remove bushing from the bracket.
5. Remove bushing retainer. Remove the half of split bushing from the bushing retainer.
6. Secure a suitable crane and rigging to the pipe rack. Separate and remove the rack positioning
cylinder. With the crane, lift the pipe rack from the mast bottom plate.
7. Remove bushing and thrust washer from the mast bottom plate and the half of split bushing
from bushing retaining block.
8. Clean and inspect all components. Replace worn or damaged components as necessary.
9. Reinstall in reverse of disassembly, lubricate all lubrication points and check for proper
operation.
BI6522035-81
Pipe Rack Variable Equipment

5-82 BI652203
TOOL WRENCH
The tool wrenches consist of the Tool Wrench and the Breakout Wrench. They are used to clamp
the drill pipe in order to break a pipe joint. The tool wrenches are two specially built hydraulic
cylinders operating inside a square casing. A spring loaded pawl engages a pocket in the drill pipe
to prevent rotation of the pipe.
Tool Wrench - Details
Inspect the tool wrenches daily for loose or missing hardware, or any wear or damage. Inspect the
wrenches each shift for proper operation. Check each wrench and associated hydraulic lines for oil
leaks and repair any leaks found immediately. Verify that the pawls are fully extended and secured
with dowel rod. Verify that the wrenches can pivot about the rear pin. Clean any accumulation of
cuttings from beneath the wrenches. Verify that the top blocks are in place and intact. Verify that the
BI6522035-83
rear pin bearing blocks are secured firmly to the drill deck and that the piston rod anchor bolts are
secure. Lubricate the assembly with an approved lubricant at the recommended intervals.
REPAIR
Repair of the tool wrenches is essentially limited to replacement of the pawl insert. Replacement of
the entire tool wrench is accomplished by removing the two hydraulic lines from the piston rod and
then removing the four bolts securing the bearing blocks. Repair of the tool wrench itself follows
standard procedures for repair of hydraulic cylinders.
To replace the pawl insert, proceed as follows:
1. Remove the defective tool wrench from the drill deck by removing the hydraulic lines leading
to the piston rod and removing the 4 bolts securing the bearing blocks to the drill deck.
2. Using suitable equipment compress the pawl springs slightly to remove pressure from the
pawl retaining pin.
3. Using suitable equipment remove the pawl retaining pin.
CAUTION: The pawl is spring loaded. Be sure to adequately restrain the pawl
before removing the retaining pin. Failure to restrain the pawl will
result in it being forcibly ejected from the cylinder body, possibly
causing death or serious injury to personnel in the area.
4. Completely relax the tension on the pawl springs. When tension is completely removed,
remove the pawl and pawl springs from the cylinder body.
5. Inspect the springs and pawl and replace as required.
6. Lubricate the springs and pawl with an approved lubricant and reassemble the components
in reverse order of disassembly.
REPAIR
CAUTION: The tool wrench is very heavy and removal without proper
preparation and precaution can cause serious bodily injury and/or
damage to the machine.
Repair of the tool wrench follows standard procedures for repair of hydraulic cylinders and is
essentially limited to replacement of main components. Replacement of the entire tool wrench is
accomplished by removing the two hydraulic lines from the tool wrench “T” fittings and then removing
the fourteen bolts from the two ring plates that secure the tool wrench base to the deck bushing.
BREAKOUT WRENCH
The breakout wrench is used to break pipe joints that will not break using the rotary drive.
With the pipe secured by the tool wrenches, the breakout wrench switch is turned to and held in the
EXTEND position. The breakout wrench extends, grips the pipe, then turns, breaking the pipe joint.
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REPAIR
he breakout wrench should be inspected daily for wear or damage, loose or missing hardware, and
proper operation. Repair of the breakout wrench is limited to the replacement of worn or damaged
components.
GENERAL GUIDELINES FOR DISASSEMBLY
1. Remove attachment pins to remove hydraulic cylinders.
2. Remove pin to dismount lever.
3. Remove pins to dismount jaws.
4. Remove pins to sidemount arm. Check for excessive wear on brass washers.
5. If jaw replacement is necessary, teeth or jaw inserts must be removed. Softly strike the tooth
to take it out.
6. Reinstall in reverse order, except for cotter pin.

BI6522035-85
7. Check the operation of the wrench. If the inserts contact the pipe, wrench is ready for use. If
inserts do not contact the pipe, repeat steps.
AUXILIARY WINCH
The auxiliary winch is used to lift tools on and off the drilling deck. The winch consists of a hydraulically
driven reel mounted at the bottom of the mast, a cable with hook, and cable guide sheaves at the
top of the mast.
The oil level in the winch should be checked monthly. The sheaves at the top of the mast should be
checked monthly for wear or damage. Once a year the sheave bearings should be re-packed with
lubricant.
For repair of the hydraulic winch refer to the Hydraulic System chapter of this manual.
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MAST BRACES
The purpose of the mast braces are to provide support to the mast while angle drilling.
Mast Braces - Details
Inspect the mast braces daily for loose or missing hardware or any wear or damage. Replace any
missing hardware and repair any damage immediately. Inspect the upper anchor pins, washers,
retainer pins daily, making sure that the retainer pins are in place. Inspect the mast brace structure
for cracks and any other damage. Repair the mast brace structure using the repair welding techniques
listed in the appendix. Inspect the telescoping lock pins for wear. The telescoping lock pin cylinders
and hydraulic lines should be checked daily for leaks. Verify that the adjustment bolt lock nuts are
tight and that the mast braces are adjusted properly.
Inspect the mast braces sleeves and supports for wear, damage or loose or missing hardware.
Lubricate all pins with an approved lubricant at the recommended intervals. Lubricate the adjustment
bolt with a rust inhibiting oil as required.
BI6522035-87
REPAIR
The mast braces are not normally considered wear items; therefore any repairs required will have
to be handled on an individual basis.
CAUTION: The mast braces are critical components especially on angle drilling
machines. Consult the Caterpillar Global Mining Service Department
before attempting major repair or modifications.
ADJUSTMENT
Normally the mast braces are adjusted during the machine erection and further adjustment is not
necessary. Special circumstances may require the readjustment of the mast braces to original
condition. To readjust the mast braces proceed as follows:
1. Remove the telescoping lock pins form the mast braces.
2. Accurately level the machine. Be certain that all four corners of the machine are at the same
elevation and that the mast is positioned vertically.
3. Loosen the adjustment bolt lock nut.
4. Turn the adjustment bolts until the telescoping lock pins can be freely inserted (approx. 14.25"
±2.50" from centerline of adjustment bolt pin to end of brace).
5. Lock the adjustment bolt in place with the lock nut.
CAUTION: Once the mast braces are adjusted, it is not necessary to alter the
adjustment unless the mast brace is replaced. Difficulty in pinning
the mast braces usually results from the machine not being level or
the mast not being vertical. Arbitrary adjustment of the mast braces
without accurately leveling the machine may cause serious damage
to the mast and should be avoided.
NOTE: Proper adjustment of the mast braces is made with machine leveled and supported on
jacks. Difficulty will later be encountered in removal or re-assembly of the telescoping
lock pin if the machine is resting on the crawlers.
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HYDRAULIC SYSTEM
SYSTEM OPERATION
The following description is intended to help field personnel understand hydraulic systems and
their operation. The explanation consists of an overview of the systems and the relationship of the
schematics to the actual components on the drill.
The two separate though not independent major hydraulic systems: Propel circuit and Cylinder
circuit. Both systems draw their oil from a common 108 gal. capacity reservoir. The pumps for the
circuits are driven through a gear drive box by the main compressor motor. The gear drive box will
increase, decrease or maintain the same speed ratio between the motor speed and the pump
speed. The main compressor motor determines the gear ratio of the gear box.
The propel circuit consists of two hydraulic pump/motor drives, one for each crawler. Piggy-backed
to the left propel pump is a single gear pump which supplies oil under pressure to leveling jacks and
mast raising cylinders and actuators. Piggy-backed to the right propel pump is a two-section gear
pump. The cover end pump supplies control pressure for the propel pumps as well as pilot pressure
for the mast hoist, auxiliary winch and pipe rack valves. This pump also supplies oil to actuate the
bit viewing hatch cylinder, boarding stair cylinder, and the lube system.
Hydraulic Components Overview

BI6522035-89
The propel circuit includes brake controls for each crawler. For towing purposes, the system is
equipped with a hand pump for manual release of the crawler brakes.
The shaft end pump of the two-section gear pump supplies oil under pressure to the remaining
hydraulic cylinders and actuators of the machine.
If the machine is equipped with a cable reel, the complete hydraulic system, including reservoir,
pump and motor are part of the cable reel unit.
The systems are totally sealed and filtered so as to keep the oil as clean as possible.
The gear box with pumps is mounted to the rear drive shaft of the main air compressor motor. The
reservoir, oil cooler and main frame manifold valves are located at the rear of the machinery house
and the various cylinders are mounted at various points around the machine.
CYLINDER CIRCUIT HYDRAULIC SYSTEM
Fluid for this system is supplied from the common 108 gallon reservoir. The single gear pump and
two-section gear pump supply oil to the actuators at the following rates:
2704 RPM @ 60 HZ
Single Pump 65 GPM
Shaft end Pump 17 GPM
Cover End Pump 18 GPM
2253 RPM @ 50 HZ
Single Pump 54 GPM
Shaft end Pump 14 GPM
Cover End Pump 15 GPM
The multiple station manifold valve assemblies contain control valves for the various actuators.
Usually the control valves will be assembled in stacks – one stack for each actuator. A typical valve
stack could include a relief valve, a flow control valve, a check valve, a quick disconnect valve for
pressure testing and a solenoid valve.
Most hydraulic lines run from the manifold valve to bulkheads, then from the bulkheads to the
actuators. All oil returning to the reservoir passes through 10 micron filters before entering the
reservoir.
5-90 BI652203
PROPEL CIRCUIT HYDRAULIC SYSTEM
Fluid for the propel system is also supplied from the 108 gallon reservoir. Most hydraulic control
valves of the propel circuit are modules bolted directly to the pumps. The pilot pressure valve and
brake valves are separate from the pumps. The oil for each pump control circuit is directed through
a 10 micron filter equipped with a 25 PSID by-pass valve.
The pilot pressure is controlled to 1000 PSI by the sum of the 850 PSI relief valve and the 150 PSI
supercharge relief.
The pumps are equipped with two main relief/pressure override assemblies referred to as a
combination valve; one for the forward propel side, and the other for the reverse propel side.
The pressure override portion of the assembly is set at 4500 PSI.
The pressure override valve prevents continuous dumping of excessive flow, at load pressure,
through the main relief valves. This eliminates unnecessary heating of the oil and protects the
pump and motor from damage.
GENERAL MAINTENANCE
HYDRAULIC SYSTEM CLEANLINESS
It is extremely important to use the correct oil in the system. It is equally important to keep the oil
clean. Whenever a repair procedure requires a connection to be broken or a part to be replaced,
first clean the immediate area around the joint and/or part to be replaced. This step is required to
assure no contaminates enter the system through the hydraulic lines or replacement parts.
While performing the repair keep everything clean and also keep openings covered or plugged until
they are re-connected. Contamination is the most common cause of trouble in a hydraulic system.
It causes excessive wear of parts, interferes with the close clearances, and hinders normal operation.
NOTE: Never add oil to the system by removing the reservoir breather and pouring it in through
the funnel. Even new drum oil is dirty and can cause sticking valves.
When hydraulic oil is added to the system, it should always be pumped into the system. The pump
discharge line should be attached to the quick-disconnect coupling at the top of the tank. This
connection insures that the new oil will pass through the tank return filters before entering the
system.
BI6522035-91
If the pump used to add the oil is equipped with a filter buggy and the pump has been used for other
fluids, the pump system and filter buggy must be purged of the other fluid prior to connecting the
pump unit to the quick-disconnect coupling. This purging can be accomplished by flushing the
pump unit and filter buggy with at least one gallon of the specified hydraulic oil.
OIL REQUIREMENTS
For hydraulic oil benchmarks refer to Section 3 of this manual – (Hydo) Hydraulic Oil.
OIL AND FILTER CHANGES
During normal operation change the element when indicated by the filter condition indicator with the
oil at normal operating temperature and whenever oil is changed.
NOTE: Before changing the element, open the circuit breaker for the hydraulic pump motor. Be
sure there is no pressure on the system to prevent possible oil leakage.
The change frequency for hydraulic oil depends on the type of oil used in your machine. This cycle
can range from 2,000 hrs. for standard grade petroleum base type oil as determined by the lube
bench marks, to 8,000 hrs. for certain synthesized hydrocarbon hydraulic oils as noted in the lube
bench marks. These change frequencies can be shortened or lengthened depending on the condition
of the oils. To determine the condition of the oils, samples should be taken periodically (i.e. 200
hrs.) and analyzed by a reputable manufacturer. When taking oil samples, never take the sample
from the tank drain system. If possible, the sample should be taken from a point near the return
manifold just before the return filters.
CAUTION: To minimize fire hazard, no open flames or other ignition sources are
allowed when changing oil.
Water should be drained from the bottom of the hydraulic oil reservoir once a day, after a period of
shutdown and when the oil is cold.
The hydraulic oil reservoir holds 108 gallons of oil.

5-92 BI652203
WEEKLY MAINTENANCE CHECKS
Check for correct operation of all components of the system. Valves, cylinders, and motors and
pumps should operate smoothly, with no jerking or binding. Check the oil level in the reservoir. The
reservoir should be almost full (108 gal.) when the mast is horizontal and all other cylinders are
retracted. With the mast vertical and all other cylinders retracted, the reservoir should be slightly
below 7/8 full.
CAUTION: Before topping off the fluid in the hydraulic tank, verify that the mast
cylinders are extended and all other cylinders are retracted. Failure
to comply with the above (i.e. jack cylinders extended) will overfill the
tank when the jack cylinders are retracted and will cause the tank to
rupture.
CAUTION: Do not operate with low oil level. Operating with low oil level can
cause cavitation and air pockets. This will cause faulty operation and
can also cause damage to the system components.
Inspect all components and lines to be sure they are in good operating condition. Check for obstructed
or distorted cylinders. Inspect the system for leaks. If a leak is found, tighten the screws or fittings
around the leaking area before beginning major repairs. If that does not stop the leak, it may then be
necessary to repair or replace the leaking part.
OIL RESERVOIR REPAIRS
The hydraulic oil reservoir is epoxy coated on the inside to prevent scale and oxidation.
CAUTION: DO NOT weld on the reservoir; it will damage the coating.
LEVELING JACK COUNTERBALANCE VALVE PRESSURE RELIEVING PROCEDURE
If it becomes necessary to work on the leveling jack counterbalance valve for any reason, relieve
pressure in the cylinder using the following procedure:
1. Position the machine with crawlers on the ground and jacks retracted so that the jack pads
are approximately one inch off the ground.
2. Turn off the hydraulic pump and relieve any pressure in the system by loosening the reservoir
breather. When trapped air in the reservoir is relieved, immediately replace the breather.
BI6522035-93
REAR JACKS
1. Uncouple the quick disconnect using a 1 1/4" open end wrench. The male half of the quick
disconnect will remain attached to the valve.
2. Remove the other end of the quick disconnect hose from the electrical junction box on the
jack.
4. Re-couple the quick disconnect. As the connection nears completion, oil will run out of the
hose end in the container and the jack pad will drop to the ground! This will relieve all
pressure on the piston rod and create a vacuum on the housing end of the cylinder.
Do not allow the stream of oil to contact your skin as injury can
occur.
6. With the pressure relieved, the counterbalance valve or jack cylinder can now be safely worked
on.
FRONT JACK
1. Uncouple the quick disconnect at both front jacks, using a 1 1/4" open end wrench. The male
half of the quick disconnect will remain attached to the valve.
2. At one front jack only, remove the other end of the quick disconnect hose from the electrical
junction box on the jack.
(Two additional 5 gallons will be required to handle the oil from both front jacks.)
4. Re-couple the quick disconnect. As the connection nears completion, oil will run out of the
hose end in the container and the jack pad will drop to the ground! This will relieve all pressure
on the piston rod and create a vacuum on the housing end of the cylinder.
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5. To remove the oil from the other front jack, a helper will be required. Have the helper continue
to hold the disconnected hose into a empty 5 gallon container while you re-couple the quick
disconnect on the other front jack. The oil from this jack will now flow from the hose being held
by the helper.
7. With the pressure relieved, the counterbalance valve or jack cylinder can now be safely worked
on.
PRE-START INSPECTION
If the machine hydraulic systems have had a major overhaul, the following presort inspection should
be completed before start-up of the machine.
CAUTION: Before starting pumps, establish a safe walking perimeter around

machine to reduce possible injury to ground personnel due to
automatic operation of boarding stair, dust curtain, or cable reel.
NOTE: Read all instructions before starting any individual test. Initial each step after its
completion or record the requested information.
1. Check all lines and fittings for tightness and plumbing accuracy.
2. Visually check that no open port exists on any valve.
3. If the crawlers or mast have been removed from the machine, be sure that all ports have
been plugged or capped and all loose lines terminated in a quick disconnect or plugged with
a steel fitting.
NOTE: Make note of the oil manufacturer and type of oil being used in this hydraulic system
(e.g. Conoco Syncom AW22).
4. Verify that the hydraulic reservoir is filled to the correct level with the required hydraulic oil.
5. Check the suction plumbing and the reservoir for external leaks.
6. From the test kit install 0-1500 PSI gauges to test ports 14 and 15 at the left and right propel
pump charge filter outlet, respectively, as shown on the gauge port location table at the end of
this section of this manual.
BI6522035-95
NOTE: All pressure gauges must be calibrated before using.
7. Verify that pump drive gear box is filled with 7.75 quarts of S.A.E. 80 - 90W oil.
8. Check the pump drive motor for correct rotation by jogging the main compressor start/stop
pushbuttons, or PTO clutch, if diesel driven. Pump drive gearbox input shaft rotation is opposite
pump shaft rotation.
9. When item 8 is complete, continue to jog electric motor until pressure on gauges at test ports
14 and 15 is 100 PSI.
10. When pressure rise is verified, turn on the hydraulic pumps and visually check all plumbing
for leaks.
HYDRAULIC SYSTEMS TESTS
The hydraulic systems are equipped with quick disconnect test ports for checking the operation of
the systems. The test ports are shown in the figures. The test ports are identified by the circled
numbers on the illustrations.
These tests are designed to assure that the specified units are operating correctly and, if they are
adjustable, they are adjusted to the correct pressure setting. The results of each of the following
tests should be noted in a log book so that on future checks and in case of system failure, pressure
readings can be compared to help locate the failure.
NOTE: For location of test points on the machine see the gauge port location table at the end
of this section of this manual.
CAUTION: Before attaching or disconnecting pressure gauges to test ports, be

sure that the hydraulic pumps are turned OFF.
PROPEL PUMP CHARGE PRESSURE CHECK
NOTE: Charge pump relief adjustment is on right side of pump.
1. With pump controls at NEUTRAL and pumps running, check pressure at test port 14 on a
1500 PSI gauge. Set charge pump relief pressure of left propel pump as required to obtain
350 PSI ±10 PSI (use 1-1/16" hex wrench and screwdriver).
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2. With pump controls in neutral and pumps running, check pressure at test port 15 on a 1500
PSI gauge. Set charge pump relief pressure of right propel pump as required to obtain 350
PSI ±10 PSI (use 1-1/16" hex wrench and screwdriver).
3. Turn off pumps.
CONTROL PRESSURE CHECK
1. With Pilot Pressure Valve (PPV) disconnected electrically at station 6 of 6 station manifold
located immediately above and to the rear of the jack valve stand, and with a 1500 PSI gauge
at test ports 7 and 17, turn pumps on. Record pressure at test ports 7 and 17 (approx. 150
PSI). Pressure at test port 17 should be greater than port 7.
NOTE: Before performing step 2, warm-up hydraulic system so that oil cooler motor has
cycled ON at least once.
2. With solenoid wires re-connected to pilot pressure valve (PPV), start pumps and after 10
seconds, with PPV energized, observe pressure at test port 17. Adjust relief valve at station 6
as required to see: 1000 ±10 PSI. Adjustment is facing wall, opposite the electrical solenoid.
3. Record pressure at test port 7 (approx. 150 PSI).
PROPEL ENABLE VALVE AND LOW SPEED SELECT CHECK
1. With drill/propel select switch in PROPEL NORMAL, in on-board propel, with a 1500 PSI
gauge at test ports 8 and 18, start the pumps and press the drill/propel ON pushbutton.
Record the pressure at test ports 8 and 18. Test port 18 should be the same as pressures
noted in step 2 of CONTROL PRESSURE CHECK. Test port 8 reading should be zero (0)
2. With pump still running, first lift one propel joystick out of the DETENT position and then
release it. Do the same with the other joystick.
NOTE: There is no need to move joysticks out of NEUTRAL. Just lift the joystick clutch straight
up to engage solenoid Propel Active Valve (PAV).
Accomplishing step 2 will cause PAV to energize which should cause pressure at test port 18 to go
from 650 PSI to 0 and test port 8 should go from 0 to 650 PSI.
3. With a 1500 PSI gauge at test port 9 and the pumps running, rotate Propel Selector Switch to
SLOW speed and record pressure.
BI6522035-97
4. Pressure in step 3 should be 1000 ±10 PSI .
5. With Propel Selector in NORMAL, record pressure at test port 9. (Should read zero.)
JACK CYLINDER CHECK IN MANUAL MODE
NOTE: Under no circumstances must either 3-spool valve or relief valve adjustments be
allowed to bottom-out. The spool valve is located on the back wall of the machinery
house to the left of the hydraulic oil tank and slightly below the top of the tank. The main
relief is near the inlet port.
1. With a 7,500 PSI gauge at test port 16 and pumps running, energize auto level in RETRACT
mode. With all cylinders fully retracted, adjust 3-spool valve relief to show exactly 3,300 PSI
on the gauge.
2. Check all jacks for operation versus manual lever movement (i.e. moving the right front jack
control to EXTEND, extends the right front jack. Check both directions with all 4 jacks).
NOTE: Re-check hydraulic oil level and add oil as required. Set flow controls per FLOW
CONTROL CHECK before continuing with step 3.
3. Back-out adjustment of relief valve 1/8th of a turn and then tighten the jam nut.
4. Install a 0-1,500 PSI gauge at test port 70, located at inlet to back pressure valve underneath
and slightly to the left (rear) of the 3-spool valve.
5. With the right front jack manually extending from full RETRACT position, adjust back pressure
relief as necessary to see 400 PSI.
6. With step 5 complete, install a 7,500 PSI gauge at test port 16 and with right front jack extending
from full RETRACT towards the ground, adjust relief valve located at inlet of jack spool valve
on jack stand. Adjust to see 3,200 PSI.
NOTE: Do not bottom any relief valve adjustments.
7. Re-check all jacks for operation versus manual lever movement.
8. Install all four jack pads.

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FLOW CONTROL CHECK
1. Remove hose nearest wall from 3rd flow control (counting from left to right) on jack valve
stand and install a -10 ORS steel plug into the open hose.
2. Install a 20 GPM Hedland flow meter #700-020 (inlet side) into the open port of flow control.
3. Disconnect hose coming from the spool valve to the 7th flow control. Install a steel -10 ORS
cap onto the flow control’s open port.
4. Connect the outlet side of the flow meter to the hose just removed from the 7th flow control.
5. With pumps running and with the aid of a helper, energize left rear jack, in either UP or DOWN
mode, to show flow in the meter. Adjust flow regulator, as required. Set all 8 flow controls to 15
GPM for 60 Hz machines as well as for 50 Hz machines running at 3,000 RPM input speed.
All other 50 Hz machines are to be set at 12.5 GPM.
6. After first flow regulator is tested, substitute the remaining untested regulators into the 3rd
position until all eight flow regulators have been checked. All flow regulators MUST end up in
their proper position when test is complete.
NOTE: During calibration of flow controls, as well as anytime jacks are being operated in
MANUAL or AUTO-LEVEL mode, the flow control should not exhibit any chattering or
screaming noise.
7. With step 6 complete, re-assemble hoses to proper ports.
8. Now complete Jack Cylinder Check In Manual Mode starting with step 3.
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JACK CYLINDER DRIFT TEST
NOTE: Read items 1 through 5 of this test before continuing.
1. Lower all jacks to ground such that the jack pads are firmly on the ground but are not lifting the
machine.
NOTE: If in steps 2 and 3 the crawlers are not mounted and the machine is resting on blocks,
only lift the machine a few inches.
2. Manually extend left and right front jacks simultaneously to lift the front of the machine.
3. Manually extend left and right rear jacks simultaneously to lift the rear of the machine.
4. Continue to lift the machine by alternating front to rear until the crawler tracks have cleared
the ground by 3 or more inches. If crawlers are not mounted, lift the machine approx. 6 inches
off the blocks.
5. With machine approximately level, position all manual jack controls to NEUTRAL and check
for jack cylinder drift. Drift should not exceed 1/8" in 30 minutes.
BRAKE RELEASE PRESSURE CHECK
NOTE: Crawlers must be mounted to mainframe for this test.
1. With 0-1500 PSI gauges at test ports 5 and 6 and with pump running, the pressure should be
at or near zero with hands removed from the propel joysticks and drill/propel select switch in
PROPEL NORMAL mode.
2. With pump still running, first lift one propel joystick and then release it and then lift and release
the other propel joystick. Anytime either or both joysticks are lifted full up out of the DETENT
position, the propel active valve (PAV) will energize and the pressure at test ports 5 and 6
should be the same as pressures noted in step 2 of CONTROL PRESSURE
CHECK.
3. With drill/propel select rotated to DRILL mode, pressure at test ports 5 and 6 should be zero
regardless of whether the joysticks are in or out of the DETENT position.
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BI652203
PROPEL BRAKE EMERGENCY RELEASE CHECK
NOTE: This test must be performed with the pumps OFF.
1. With 0-1500 PSI gauges at test ports 5 and 6, the bypass valve handle (located on the left
side surface of left front jack housing) rotated fully CW, and with hand pump bypass valve
CLOSED, manually operate pump handle to raise pressure on the gauge until the operator’s
display terminal screen displays: PROPEL BRAKE TOW RELEASE. Record the pressure
that causes the operator’s display terminal screen display to appear. (Pressure should be
500 PSI.)
2. With step 1 complete, continue to operate the pump until the gauge shows 1,000 PSI. Record
the amount of pressure drop in 5 minutes (should not be more than 500 PSI).
NOTE: Pressures in step 1 and step 2 should also appear at test ports 5 and 6 on 0-1500 PSI
gauges.
PROPEL PUMP MAIN RELIEF PRESSURE CHECK
NOTE: Crawlers must be mounted and there should be no crawler movement during this test.
Main relief valves are on the top of the pump, as mounted on machine.
1. With machine still raised on jacks and with a 7,500 PSI gauge at test ports 1 and 2 and a 0-
1,500 PSI gauge at test port 59, disconnect the propel brake release line at the brakes and
plug the hoses with a -6 O-ring seal plug. Leave the port on the brakes open; do not cap or
plug the fittings.
NOTE: Use a 5 mm Allen wrench and a 3/4" open end wrench to adjust main relief valves.
2. With the pumps running, energize the propel active valve (PAV). Note the presence of 600 PSI at
test port 59. Operate the left crawler control in the FORWARD direction by manually pressing coil
PLV-FWD. Adjust relief as required to see 4,500 PSI on gauge at test port 1.
3. Maintain step 1. Place the left crawler control in the REVERSE direction by manually pressing
coil PLV-REV. Adjust pressure as required to see 4,500 PSI at test port 2.
4. With machine still raised on jacks and with a 7,500 PSI gauge at test ports 3 and 4, check
main relief pressures on right crawler pump.
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5. With the pumps running, operate the right crawler control in the FORWARD direction by
manually pressing coil PRV-FWD. Adjust main relief valve as required to see 4,500 PSI on
gauge at test port 4.
6. Repeat step 5 but place the right crawler control in the REVERSE direction by manually
pressing coil PRV-REV. Adjust pressure as required to see 4,500 PSI at test port 3.
7. Reconnect the propel brake release hoses disconnected in step 1.
8. De-energize propel active valve (PAV).
CRAWLER FUNCTION CHECK
NOTE: Check that the crawler boxes have each been filled with 7.5 gallons of 80W-90W oil.
1. With propel selector in SLOW SPEED, check the left crawler function in FORWARD and
REVERSE. Record time for 3 revolutions of crawler sprocket:
60 Hz should be 3 revolutions in 56 seconds.
2. Repeat step 1 with propel selector in NORMAL SPEED. Record time for 10 revolutions of
crawler sprocket:
3. Repeat step 1 for right crawler.
4. Repeat step 2 for right crawler.

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BIT VIEWING HATCH CHECK
Check function of bit viewing hatch with switch in operator’s cab. Hatch should open and close
smoothly with no chattering action.
BOARDING STAIR CHECK
Check function of boarding stair with switch in operator’s cab. Stairway should raise and lower
smoothly with no chattering action.
MAIN FLOW VALVE CHECK
1. With 0-1,500 PSI gauge at test port 26 and with pumps running, set backpressure relief to
see 300 PSI.
2. With 0-1,500 PSI gauge at test port 23 and with pumps running and all valves de-energized,
record pressure observed.
3. With 0-7,500 PSI gauge at test port 23 and with 0-1,500 PSI gauge at test port 26, start pump
and energize main flow valve (MFV) via hydraulic test function. Adjust relief valve of center
sandwich valve at station 1 to see 3,000 PSI at test port 23. Record pressure at ports 23 and
26.
BREAKOUT WRENCH AND TOOL WRENCH CHECK
Check function of breakout wrench and tool wrench with switches in operator’s cab.
DUST CURTAIN CYLINDERS
1. Check function versus switch position.
NOTE: After 3 - 5 cycles, operation should be smooth with no jerkiness or chattering.
2. Adjust door stops.

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DUST SEAL SLIDER
Operate in forward and reverse to check function. Record pressure observed at test port 24 on a 0-
7,500 PSI gauge.
MAST LOCK
1. With 0-7,500 PSI gauge at test port 21, energize mast lock latch solenoid and check function.
2. Adjust relief, as required, to see 1,000 PSI.
NOTE: Adjustment is facing away from left wall.
3. With gauge still at test port 21, energize mast lock unlatch solenoid. Observed pressure
should be 3000 PSI.
4. Repeat steps 1 and 2 except with a 0-1,500 PSI gauge at test port 21.
MAST BRACE LOCK CYLINDERS
1. With 0-7,500 PSI gauge at test port 23, energize Mast Brace Lock (MBLV) solenoid and
check function.
2. Adjust relief, as required, to see 1,000 PSI while mast brace lock (MBLV) is energized.
3. Energize mast brace unlock (MBLV) solenoid. Observed pressure should be 3,000 PSI.
A-FRAME LOCK CYLINDERS
NOTE: This test should not be run unless the mast is fully up or unless the mast is off the
machine. Mast lock cylinder pins MUST be extended before conducting this test.
1. With 0-7,500 PSI gauge at test port 22, energize A-Frame Lock (AFLV) solenoid and check
function.
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BI652203
2. Adjust relief, as required, to see 1,000 PSI. Adjustment is facing away from left wall.
3. Energize A-frame unlock (AFLV) solenoid. Observed pressure at port 22 should be 3,000
PSI.
MAST LOCK CONSTANT PRESSURE CHECK
1. With a 0-1,500 PSI gauge at test port 61, start pump.
2. Rotate mast lock switch to UNLOCK and then return switch to NEUTRAL.
3. With switch at NEUTRAL, pressure at test port 61 should be 0.
4. Rotate mast lock switch to LOCK and then return switch to NEUTRAL.
5. With switch at NEUTRAL, pressure at test port 61 should be the same as pressures noted in
step 2 of CONTROL PRESSURE CHECK.
MAST BRACE CONSTANT PRESSURE CHECK
1. With a 0-1,500 PSI gauge at test port 60, start pump.
2. Rotate mast brace switch to UNLOCK and then return switch to NEUTRAL.
3. With switch at NEUTRAL, pressure at test port 60 should be 0.
4. Rotate mast brace switch to LOCK and then return switch to NEUTRAL.
5. With switch at NEUTRAL, pressure at test port 60 should be the same as pressures noted in
step 2 of CONTROL PRESSURE CHECK.
A-FRAME LOCK CONSTANT PRESSURE CHECK
1. With a 1,500 PSI gauge at test port 65, start pumps.
2. Rotate A-frame lock switch to UNLOCK and then return switch to NEUTRAL.
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3. With the switch in NEUTRAL, pressure at test port 65 should be 600 PSI.
4. Rotate A-frame lock switch to LOCK and then return switch to NEUTRAL.
5. With the switch at NEUTRAL, pressure at test port 65 should be the same as pressures
noted in step 2 of CONTROL PRESSURE CHECK.
MAST RAISE/LOWER
NOTE: This adjustment limits the maximum lowering speed of the mast.
1. With the pumps shut down, adjust the Hoist Flow Control located under the deck just forward
of the rear torque tube. Loosen the setscrew and turn the adjustment in all the way.
2. With step 1 complete, back out the adjustment 6 full turns and tighten setscrew.
3. Install a 0-7,500 PSI gauge at test port 16 and proceed as follows:
a. If mast is not mounted to machine, position mast/winch selector to MAST HOIST and
operate master switch in MAST RAISE mode. If cylinders are connected, the cylinder
rods should both be extending.
b. When rods have fully extended, the pressure gauge reading will be 2,500 PSI.
c. With master switch in LOWER mode, the cylinder rods will retract. The pressure gauge
reading should then be 2,500 PSI.
d. If mast hoist cylinders are not mounted, then pressures at step 3b and step 3c will be
seen almost as soon as master switch is moved from NEUTRAL.
NOTE: Step 3e is to be done with jacks FIRMLY on the floor.
e. If mast is mounted, check function carefully by raising mast 6 - 12 inches out of the
rack while observing pressure on the 0-7,500 PSI gauge at test port 16. If more than
2,500 PSI is needed to lift mast from rack, adjust port relief on hoist side as necessary.
f. With step 3e complete, carefully position master switch to LOWER mode and observe
“inching” capability of control.
g. Raise mast to full vertical (with the deck level and on jacks).
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BI652203
h. With a 0-7,500 PSI gauge at test port 16, observe pressure needed to pull mast out of
vertical. Adjust lower mode port relief as necessary to generate enough pressure.
i. With 0-7,500 PSI gauge still at test port 16, with mast in vertical position and with mast
brace and mast lock pins engaged, operate mast hoist in raise and lower to set port
relief valves to 200 PSI greater than pressures observed at steps e and h respectively.
NOTE: An alternate way to accomplish step 3i is to disconnect hoses at both mast hoist
cylinders and then plug hoses with steel ORS plugs. With hoses plugged, start pumps
and operate mast hoist in RAISE and LOWER mode to set port reliefs to 200 PSI
greater than observed at 3e and 3h respectively. When reliefs are set, reconnect hoses
and check function of mast hoist.
AUXILIARY WINCH
With a 7,500 PSI gauge at test port 16, proceed as follows:
NOTE: If the mast is not mounted, skip to step 4.
1. With the mast mounted and in the rack (fully down), operate the winch with no rope on the
drum to check function verses master switch position.
2. Check the ability to smoothly start in the HOIST and LOWER mode.
3. Check drum RPM in the HOIST and LOWER mode and record. Drum speed should be:
10 revolutions in 17 seconds (36 RPM).
4. If mast is not mounted, set port relief so pressure gauge shows 3,000 PSI in the HOIST
position when moving the master switch out of NEUTRAL. Moving hoist lever to full LOWER
position will show 3,300 PSI on gauge.
NOTE: If mast is mounted, port relief setting may be observed by first disabling WACV
electrically and then proceeding per step 4.
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HYDRAULIC CENTRAL LUBE DRIVE PRESSURE CHECK
NOTE: Steps 1 through 3 apply to LINCOLN lube system with LINCOLN lube pump only.
1. With the pumps running, energize Lube Enable Valve (LEV) solenoid.
2. Adjust pressure reducing valve attached to lube pump manifold, as required, to see 450 PSI
on gauge attached to manifold.
3. With Lube Enable Valve (LEV) energized and the pumps running, observe that the lube pump
is functioning.
NOTE: If grease is not pumped during test, then don’t run test step 3 any longer than
necessary to see that the pump is cycling.
NOTE: There should be NO external hydraulic oil leakage during test.
WINDOW GUARD FUNCTION CHECK - OPTION
CAUTION: Before starting test, make sure there is nothing laying on window
guard that could fall off to cause injury to personnel or damage to
machinery. Keep personnel away from window guard area during test.
1. With a 0-1500 PSI gauge at test port 75 and with Window Guard Valve (WGV) de-energized,
energize Main Flow Increase Valve (MFV) via hydraulic test function on operator’s display
terminal screen.
2. Adjust pressure reducing valve (same valve that test port 75 is attached to) see 900 PSI.
3. De-energize Main Flow Increase Valve (MFV) and energize Window Guard Valve (WGV) to
check function. After 3 or 4 cycles, window guard should operate smoothly, without chatter.
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BI652203
CHECK JACKS IN AUTO LEVEL MODE
1. Manually position all jacks such that they are midway between the ground and fully up.
2. Position auto level switch to RETRACT mode and observe that all 4 jacks simultaneously
retract.
3. Maintain step 2 until all 4 jacks are fully up, at which time the operator’s display terminal
screen WILL SHOW THE JACKS TO BE FULLY UP and the retract solenoids at the jack
valve control manifold have each turned off. Jack Loader Valve (JLV) will stay energized so
long as the switch position is maintained in RETRACT. When the auto level switch is returned
to NEUTRAL, solenoid JLV should turn off.
4. With all jacks fully extracted, position the auto level switch to extend and observe that all 4
jacks extend simultaneously. Do not extend jacks all the way to the ground.
NOTE: If the crawlers are not mounted, use extreme care during step 5 through step 8.
5. With step 3 and step 4 complete, run each jack down individually and manually check that
each ground pressure switch activates and is shown on the operator’s display terminal screen.
6. With step 5 complete, repeat step 2 and step 3.
7. With step 6 complete, position the auto level switch to EXTEND and observe the following
actions of auto level while maintaining switch position:
a. Starting from full retract into extend, all cylinders will extend at once.
b. As each cylinder pad is lowered enough to generate ground pressure, it will stop moving,
until all four cylinder ground pressure indications are shown on the operator’s display
terminal.
c. If the machine is out of level, it will level itself (first side to side and then front to back).
d. The machine will raise up straight and level on all four jacks.
NOTE: Step 5, step 6, and step 7 must be done with EXTREME care if crawlers are not
mounted to machine.
8. With step 7 complete, position auto level switch to RETRACT to check function.
NOTE: If crawlers are unmounted, step 8 should not be run unless AT LEAST one observer is
present outside the machine.
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PIPE RACK POSITION CHECK
With 0-7,500 PSI gauge at test port 16, with selector switches in operator’s cab set to DRILL mode,
and at PIPE RACK/JOINTS, proceed as follows:
1. Raise left joystick out of detent, without leaving NEUTRAL, until one second has passed.
NOTE: Step 1 is intended to allow sufficient time for the pipe rack lock pin to unlock the rack,
before rack is allowed to be moved.
2. With step 1 accomplished, move joystick to full stroke, first in one direction and then the
other. Pressure should increase smoothly with increasing stick travel. Pressure should be
2,500 PSI at maximum stroke in STORE position. Adjust port relief, as required. Pressure
should be 3,200 to 3,300 PSI at maximum stroke in OVER-THE-HOLE position.
3. Re-check with selector rotated to all four positions.
PIPE RACK LOCK AND GATE CYLINDER PORT RELIEF SETTING
With the mast in the vertical position, attach a 1,500 PSI gauge to test port 52. With pumps running,
set the relief valve at station 3 of 8 station valve located directly above auxiliary winch, as required
to see 600 PSI.
PIPE THREAD LUBRICATOR CHECK
NOTE: Station 1 of 4-station manifold is located on right side wall of machinery house.
1. With pumps running and Lubrication Timing Screen showing on the operator’s display terminal,
press F7 to energize Pipe Thread Lubricator Valve (PTLV) solenoid.
2. With step 1 complete, adjust reducing valve on the lube pump assembly to 450 PSI on the
gauge located on the grease pump.
3. With step 2 complete, press F7 again to de-energize (PTLV) solenoid.
CAUTION: Advise personnel to stay away from grease discharge during testing
or adjustment.
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4. With hydraulic pumps running, press F8 on the operator’s display terminal to energize the
Pipe Thread Lube Pump and observe that pump runs.
NOTE: Pump will time-out at anywhere between 1 and 10 seconds with initial time-out being
set at 2 seconds. Time-out is set on Lubrication Timing Screen on the operator’s
display terminal.
PIPE POSITIONER FUNCTION CHECK
Check function as follows:
1. When positioning switch to OVER-THE-HOLE, the clamp stays open until the position cylinders
are fully retracted, after which time the clamp should close.
NOTE: The clamp must NOT close until after the position cylinders are fully retracted.
2. When positioning the switch to STORE (i.e. moving away from Over-The-Hole), the clamp
must open first, then the position cylinders will extend the clamp away from the drill steel to
the STORED position.
NOTE: The position cylinders must not move until the clamp is fully open.
CENTER GUIDE FUNCTION CHECK
1. Attach a 7,500 PSI gauge to test port 55.
2. Activate the center guide switch to OVER-THE-HOLE position.
3. Observe the pressure at port 55.
4. The position cylinders should bottom out against the mast and the clamp cylinder should
close once 2000 PSI is reached on test port 55. Adjust the sequence valve to obtain about
2000 PSI at test port 55 - the bottom cartridge on station 1.
5. Activate the center guide switch to the STORE position. The clamp should start to open and
the positioning cylinder should only start to retract once the clamp is fully open and 2000 PSI
is seen on test port 55. Adjust the sequence valve if required to obtain about 2000 PSI at test
port 55 - the second cartridge on station 1.
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6. Repeat operation of the center guide to ensure sequencing operation is correct and repeatable.
Readjust sequence valves in step 4 or 5 as required.
AUTOMATIC BREAKOUT WRENCH CHECK
1. Attach a 0- 3000 PSI gauge to test port 55 on two station valve located on the side of the mast.
2. Retract the breakout wrench fully.
3. Verify 3000 PSI is at test port 55.
Activate the automatic breakout wrench switch to EXTEND and then RETRACT to check proper
function.
Refer to OEM documentation for sequence valve setup.
DUST CONTROL
GENERAL MAINTENANCE
The dust control system on this drill consists of 1) the drilling platform and 2) dust curtains which
trap the cuttings and dust in an area under the machine. Two methods of controlling the trapped
dust are available: water injection which dampens the dust before it leaves the drilling hole, and a
dry-type system which draws the dust laden air through filter elements which separates the dust
from the air.
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DRILLING PLATFORMS AND DUST CURTAINS
• Daily inspect the dust curtains for tears and other damage. Replace worn or damaged curtains.
• Check the curtain raising ropes for broken or frayed ropes. Replace broken or damaged
ropes.
• Check the dust deflector seal which fits around the drill pipe for damage. Replace if damaged.
• Check the curtain raising lever mechanism for proper operation. Lubricate all pins once a
week.
WATER INJECTION - OPTION
The maintenance of the water injection system consists mainly of keeping the water tank full of
clean water, checking weekly that the pump and valves are operating correctly, and that all hoses
and fittings are not leaking.
OPERATION
With the operating mode switch in the DRILL position, the main compressor operating, and butterfly
valve open, turn switch WIS on the operator’s console to the ON position. Close the air operated
drain valve located in the tank.
The water pump is a variable speed pump driven by an AC motor and controlled by a variable
frequency drive. The amount of water supplied is governed by the speed of the pump motor. Moving
switch WIR on the operator’s console CW will increase the amount of water. Full CW will supply
the maximum amount of water.
Because the pump is submerged below the water in the tank, the water will begin pumping
immediately. Water will flow from the pump through a flow control valve back to the tank. Once the
water pressure increases over 30 PSI [check-valve cracking pressure] and overcomes air pressure
from the mast air line, the water will begin to flow to the mast air line. Water will continue to flow until
the water injection system is turned OFF or the main butterfly valve starts to close.
When the water injection system shuts down for any reason, the WIC valve will de-energize and
the drain valve in the tank will open to drain the system by gravity.
5-114 BI652203
FILLING WATER TANK
The fill line of the water tank includes a cam lock style fitting that fills the tank through a stand pipe.
When filling the water tank, connect the water supply hose to the cam lock fitting. Fill the tank until
water comes out the vent. When the tank is full, disconnect the water supply hose. Allow the water
in the fill line and tank standpipe to drain out.
BI652203 6-1
Brakes and Couplings Section
Section 6
Brakes And Couplings
Table of Contents
BRAKE HUB INSTALLATION ........................................................................................................ 3

Hub Adapter Pre-Heat Advance Requirements Table .................................................................. 4
MOTOR COUPLING INSTALLATION ............................................................................................ 5
Motor Coupling Pre-Heat Advance Requirements Table ............................................................... 6
PARALLEL MISALIGNMENT .................................................................................................... 7
Checking for Parallel Misalignment ............................................................................................. 7
ANGULAR MISALIGNMENT ..................................................................................................... 8
Checking for Angular Misalignment ............................................................................................. 8
MISALIGNMENT EXAMPLES................................................................................................... 9
Parallel Misalignment Example .................................................................................................... 9
Angular Misalignment Example ................................................................................................... 9
Combination Misalignment Example ........................................................................................... 10
6-2 BI652203
BI652203 6-3
Section 6
Brakes and Couplings
BRAKE HUB INSTALLATION
Brake hubs must be shrunk onto tapered motor shafts in order to achieve the tension and lockup
required for the torque values involved. The procedure described below is intended to develop
sufficient frictional force to transmit the imposed torque without dependence on the keyway.
Clean and dress the bore and shaft to remove any deformity and foreign matter.
Mount the cold hub onto the shaft and measure the position of the hub on the shaft carefully.
Measure from the end of the shaft to the end of the hub. The dimension derived during this step will
be used later.
Remove the hub and pre-heat the item until the “estimated temperature difference” has been
reached. Refer to table below.
Example:
If the shaft temperature = 25° C (77°F) and the estimated temperature difference
derived from the table is 100°C (180°F), the hub must be heated to 125°C
(257°F) for mounting.
CAUTION: BRAKE HUB TEMPERATURE SHOULD NEVER EXCEED 190°C

(374°F) FOR INSTALLATION.
CAUTION: Pre-heated components temperatures will often be brought to

temperatures that can be extremely hazardous to the human body.
USE EXTREME CARE AND ALWAYS WEAR APPROPRIATE SAFETY
EQUIPMENT WHEN WORKING WITH PRE-HEATED COMPONENTS
AND AROUND THE PROCESSES.
Wipe all oil from both the shaft and the bore of the hub prior to installation.
Replace the heated hub on the shaft once again and take care to note the amount of advance
(further movement) onto the shaft that has been obtained. If the advance amount does not fall
within the limits called out in the table it will be necessary to remove the hub and re-heat it to the
specified temperature. IN ALL APPLICATIONS THE PROPER AMOUNT OF ADVANCE MUST
BE ACHIEVED!
6-4 BI652203
The taper fit between mating parts shall be checked at assembly with Dykem or Blueing to assure
a minimum of 80% bearing contact.
Hub Adapter Pre-Heat Advance Requirements Table
NOTE: This table makes reference to brake hubs only, motor coupling advance data appears in
a separate table later within this section.
BI652203 6-5
MOTOR COUPLING INSTALLATION
Motor couplings must be shrunk onto tapered motor shafts in order to transmit the torque values
involved without slippage. The procedure described below is intended to develop sufficient frictional
force to transmit the imposed torque without dependence on the keyway.
Clean and dress the bore and shaft to remove any deformity and foreign matter.
Mount the cold coupling onto the shaft and measure the position of the coupling on the shaft carefully.
Measure the distance from the end of the coupling to the end of the shaft. The dimension derived
during this step will be used later.
Remove the coupling and pre-heat the item until the “estimated temperature difference” has been
reached. Refer to table below.
Example:
If the shaft temperature = 25° C (77°F) and the estimated temperature difference
derived from the table is 100°C (180°F), the coupling must be heated to 125°C
(257°F) for mounting.
CAUTION: PINION OR BRAKE COUPLING TEMPERATURE SHOULD NEVER

EXCEED 190°C (374°F) FOR INSTALLATION.
CAUTION: Pre-heated components temperatures will often be brought to

temperatures that can be extremely hazardous to the human body.
USE EXTREME CARE AND ALWAYS WEAR APPROPRIATE SAFETY
EQUIPMENT WHEN WORKING WITH PRE-HEATED COMPONENTS
AND AROUND THE PROCESSES.
Wipe all oil from both the shaft and the bore of the coupling prior to installation.
Replace the heated coupling hubs on the shaft once again and take care to note the amount of
advance (further movement) onto the shaft that has been obtained. If the advance amount does
not fall within the limits called out in the table it will be necessary to remove the coupling and re-heat
it to the specified temperature. IN ALL APPLICATIONS THE PROPER AMOUNT OF ADVANCE
MUST BE ACHIEVED!
6-6 BI652203
The taper fit between mating parts shall be checked at assembly with Dykem or Blueing to assure
a minimum of 80% bearing contact by marking during initial fit-up and comparing to actual fit after
assembly.
Motor Coupling Pre-Heat Advance Requirements Table
MOTOR COUPLING ALIGNMENT
Final alignment of direct-driven units is made by moving or shimming the unit so that misalignment
of the unit and drive shafts is within required tolerance from the general arrangement drawing
received with your machine. Misalignment can be either offset, angular, or a combination of both.
Misalignment can occur in both the vertical and the horizontal plane. Refer to the following illustrations
to bring couplings within the maximum acceptable misalignment.
The following method of coupling alignment uses a dial indicator. Readings taken 180 degrees
apart will measure the runout in one plane. It is important to rotate both shafts to avoid errors due
to surface imperfections of the shafts or couplings.
BI652203 6-7
PARALLEL MISALIGNMENT
Checking for Parallel Misalignment
1. Mount the indicator on this coupling hub.
2. Take readings in the horizontal plane at 90 and 270 degree positions on the hub while turning
the shafts.
3. Correct offset misalignment in the horizontal plane by shifting inboard and outboard feet an
equal distance.
4. Take indicator readings in the vertical plane at 0 and 180 degree positions.
5. Correct offset misalignment in the vertical plane by adding or removing an equal thickness of
shims at each foot.
6-8 BI652203
ANGULAR MISALIGNMENT
Checking for Angular Misalignment
1. Mount the indicator between the coupling hubs.
2. Measure the gap between the hubs at 90 and 270 degree positions.
3. Shift the outboard feet until coupling faces are parallel in the horizontal plane.
4. Take coupling readings at 0 and 180 degree positions.
5. Raise or lower the outboard feet with shims to parallel coupling faces in the vertical plane.
BI652203 6-9
MISALIGNMENT EXAMPLES
Parallel Misalignment Example
Angular Misalignment Example

6-10 BI652203
The condition shown below is encountered often after major repairs have been made to a machine.
To remedy this condition, perform the alignment for either angular or parallel misalignment, get as
closes as possible, then perform the alignment for the other misalignment. Duplication of either, or
both processes may be required.
Combination Misalignment Example

BI652203 7-1
Compressed Air systems Section
Section 7
Compressed Air System
Table of Contents
COMPRESSED AIR SYSTEMS .................................................................................................... 3

AIR COMPRESSOR ..................................................................................................................... 4
AIR INTAKE FILTER ................................................................................................................ 5
OIL DRAIN VALVE ................................................................................................................... 6
VARIABLE VOLUME CONTROL — OPTION .......................................................................... 6
SEPARATOR MAINTENANCE ................................................................................................ 8
SEPARATOR COVER HARDWARE TIGHTENING PROCEDURE .................................. 9
ROTARY SCREW COMPRESSOR ..................................................................................... 10
Compressor Air End Assembly .................................................................................................. 10
OIL SYSTEM ......................................................................................................................... 12
START UP AND VENT MODE ............................................................................................... 12
DRILL MODE ......................................................................................................................... 13
VARIABLE VOLUME OPTION ............................................................................................... 13
COMPRESSOR START-UP ................................................................................................. 14
COMPRESSOR SHUTDOWN MODES ............................................................................... 15
COMPRESSOR FAILURE FAULT .................................................................................. 15
COMPRESSOR COOLING FAILURE FAULT ................................................................. 15
COMPRESSOR OVERHEAT WARNING ........................................................................ 15
COMPRESSOR AIR TEMPERATURE FAULT ................................................................ 15
THERMOSTATIC CONTROL VALVE .................................................................................... 15
INLET REGULATING VALVE.................................................................................................. 18
DISCHARGE AIR TEMPERATURE GAUGE ......................................................................... 18
SAFETY RELIEF VALVE ....................................................................................................... 18
SOLENOID BLOWDOWN VALVE ........................................................................................ 18
SCHEMATIC, COMPRESSED AIR .............................. LOCATED AT THE END OF THE MANUAL

7-2 BI652203
Compressed Air Systems Section
BI652203 7-3
Section 7
Compressed Air System
COMPRESSED AIR SYSTEMS
The main air system supplies compressed air

for bailing the hole during drilling. The air also
cleans and cools the bearings in the bit. The
air is compressed by a rotary oil flooded screw
air compressor. Inlet air passes through a filter
before entering the compressor.
Inside the air end the air stream will pass

through a butterfly valve used to control the
amount of air in the compressor. Oil is then
injected into the air stream to lubricate, cool
and seal the screws of the air end. The
compressed air/oil mixture leaves the air end
and enters the separator tank. The separator
tank removes the oil from the air stream. The
separator uses swirling action in combination
with 4 filter elements to remove the oil from
the air. The air is then passed through a
butterfly valve into the mast air pipe.
When the main air valve is activated, a butterfly

valve in the mast air pipe is opened and the
air flows through the main air piping to the
rotary head. A passage in the rotary shaft
allows air to flow into the drill pipe, through the
bit and out of the hole, carrying out the cuttings.
When the compressor is unloaded by the operator switching into vent mode, the butterfly valve at
the inlet of the compressor closes, the main air valve closes in the discharge pipe, the blowdown
valve opens allowing the air in the tank to go to atmospheric and the horsepower drawn from the
motor will be greatly reduced.
The general maintenance required for the main air system consists mainly of inspection of the
components of the system to see that they are working properly and that all liquids are at their
proper levels.
7-4 BI652203
AIR COMPRESSOR
The air compressor assembly is composed of the air end, separator tank and associated piping,
valves, gauges and filters. The compressor is located on the right side of the machine at the front of
the power module.
BI652203 7-5
AIR INTAKE FILTER
CAUTION: Take care to not allow

dust, dirt or any foreign
objects to fall into the
compressor inlet during
filter servicing.
This machine uses a manifold type air intake filter

assembly, located on the air compressor intake.
Should the air intake assembly require removal,

remove the 12 hex head capscrews that fasten
the intake to the machine, then lift the intake
assembly off the machine. Remove and replace
the mounting gasket if required. Reinstallation is
the opposite of removal.
An air flow clog indicator is located at the base of

the intake filter. Flow through the system will draw
the indicator in toward the component during
operation. If air flow is indicated while the system
is off, push the reset pushbutton to restore the
indicator.
Each of the three air cleaners located on top of the

manifold consists of 1) a filter precleaner, and 2)
the air cleaner. The precleaner filter should be
inspected frequently and cleaned whenever
necessary. The air cleaner medium should also be
inspected at regular intervals (at least every two
months), or more often as conditions warrant. The
Primary Air Cleaner Medium should be replaced
annually, or whenever a tear, hole or rupture is
found during inspection.
7-6 BI652203
OIL DRAIN VALVE
A drain valve is located beneath the main frame immediately below the separator tank. Use this
valve to drain oil from the tank. Also a quick fill port with a check valve is located on the outer
walkway. The check valve is used in line to prevent oil backflow.
VARIABLE VOLUME CONTROL — OPTION
The variable volume feature is used to decrease the bailing velocity to reduce or eliminate
sandblasting of the drill pipe and bit. This will result in increased life of these components. To
reduce the bailing velocities, reduce the air flow rate or “CFM” of the compressor. Turning the
variable volume control switch on the operator’s display will activate the air end spiral valve, reducing
in three steps (Level 1, Level 2, Level 3 - Between 100% and 68%) the amount of air produced by
the compressor.
With the compressor CFM reduced, the operator can inspect the size of the chips produced from
drilling and keep track of the life of the bit and drill tool. From this information, the optimum air
volume can be determined.
Many bit manufacturers have instructional literature available with bit pressure tables. These tables
will show what the bit pressure should be based on the size of orifices in the bit and the CFM
produced by the compressor. Once the desired bailing velocity has been determined, adjust the
variable volume switch to obtain the desired bit pressure.
BI652203 7-7
NOTE: After adjusting the variable volume control, especially when reducing the compressor
CFM by a large amount, make sure the tank pressure while drilling is greater than 30
PSIG. This will avoid excessive oil carryover.
Refer to the figure below for variable volume component locations.

7-8 BI652203
SEPARATOR MAINTENANCE
The air compressor separator tank contains 4 air filter cartridges. These must be changed at 4000
hours or anytime more than 10 PSI pressure differential exists across the filters, or if the compressor
starts to bypass oil. To replace the separator filter cartridges:
1. Shut down the machine. Ensure that the electric motor and compressor are powered down.
Relieve any residual pressure in the main air line and the separator tank. Check pressure
gauge on the tank to verify.
2. Loosen the hex nuts that attach the separator cover to the tank. Loosen each nut enough to
allow the attaching bolt to be pulled away from the tank and lowered.
BI652203 7-9
3. With all bolts pulled away, use the installed hydraulic jack at the lower, left hand side of the
separator tank to raise the separator cover enough to clear the filter cartridges.
NOTE: Be sure that the cover seal is not damaged during cover seal removal.
4. Once lifted, rotate the cover out of the way.
5. Remove the hex nuts and the filter retainer which covers one of the filter cartridges.
6. Pull the filter cartridge out of the separator tank. Repeat for the remaining 3 cartridges.
Inspect all parts. Repair or replace as required. Reassembly is the opposite of disassembly. Note
the following:
SEPARATOR COVER HARDWARE TIGHTENING PROCEDURE
Refer to the label on the left side of the separator tank. If the label is not readable, use the following
tightening sequence.
Tighten all bolts hand-tight to begin. Then tighten all bolts in order. Start at any bolt
and continue in a diametrically opposed (star) pattern. Tighten the bolts incrementally
3 times as follows:
1. Tighten ALL bolts to 30 Ft. Lbs.

2. Tighten ALL bolts to 60 Ft.Lbs.
3. Tighten ALL bolts to 100 Ft.Lbs.
7-10 BI652203
ROTARY SCREW COMPRESSOR
Compressor Air End Assembly

BI652203 7-11
The air end of the compressor is an oil flooded, single-stage,

twin screw, rotary type. The suction (inlet) port is located on
the top, drive shaft (inboard) end of the compressor. The
discharge port is located on the bottom (outboard) end. The
air end is directly driven through a flexible coupling from the
main electric motor. The male rotor of the air end is driven by
a gear mounted on an independent input shaft and a mating
gear on the male rotor. The female rotor is driven by the male
rotor because the rotors are meshed.
Air circulates through the system beginning at the air intake filter, passes through the intake valve
and into the air end where it is compressed. As the male rotor is turned counterclockwise (by the
clockwise rotation of the gear shaft and gears - not shown), it drives the female rotor
counterclockwise. This action causes air to be drawn through the suction port completely filling the
uncovered channels or grooves between the spiral (helical) lobes in the male and female rotors.
As the rotors continue to turn, the lobes begin to inter-mesh at the bottom. This inter-meshing
causes the spiral grooves to become shorter, thus resulting in the compression of the air entrapped
in the grooves. Compression continues until the grooves are uncovered by the discharge port.
From the air end, compressed air is discharged at rated pressure into the air/oil receiver.
During the compression process, cool oil is injected into the entrapped air by a remotely located
gear-type oil pump. The oil is injected for the following reasons:
Cooling: The oil removes the heat of compression to maintain discharge air
temperatures below 225°F (107ºC).
Sealing: The oil seals the internal clearances between the rotor, cylinder, and
discharge end casing to prevent loss of air volume back to the inlet.
Lubrication: The oil lubricates the rotors, bearings, gears, and mechanical shaft
seal.
7-12 BI652203
Separation of the oil from the air which was injected into the air end during compression begins in
the separator. From 90% to 95% of the oil separation from the air is accomplished by a decrease in
air velocity, changes in flow direction, adequate baffling and proper location of the inlet port. Final
air/oil separation is obtained by forcing the flow through the separator elements to provide practically
oil-free air at the outlet. Oil collected by the separator elements is returned to the system by the
compressor scavenging line. To prevent tank over-pressurization, an air pressure relief valve is
installed downstream or on the dry-side of the separator elements.
OIL SYSTEM
The oil system consists of a separate and remote electric pump motor package. The pump suction
pulls oil from the bottom of the receiver tank. The relief valve pressure setting for this pump is 180
PSI (to protect the oil cooler) and can be checked at the test port G 9. The pressure from the pump
goes to the thermostatic valve, this will either divert the oil to the oil cooler when the oil temperature
reaches 140F and on to the compressor filters, or it will be directed to the filters on the compressor
if the oil temperature is below 140F. The filters have an internal bypass that opens at a differential
pressure of 25 PSID, in case the filters become plugged. Built into each filter is a filter clogged
indicator switch that will give a visual and a panel view alert.
Down stream of the filters are devices that provide system feedback; the first is the Main Compressor
Oil Temperature Sender - MCOTS and temperature gauge T2 located on the filter assembly, normal
operating range for the compressor is 140 F to 190 F. Second is the solenoid operated Air Compressor
Oil Stop Valve - ACOSV which when energized, sends oil through the filters to the compressor
injectors. Third is the Compressor Oil Pressure Switch COPS which will shut down the compressor
if there is a loss of pressure (pressure can be checked at test port G 11). On the outlet of the
compressor is the Main Compressor Air Temperature Sender MCATS and temperature gauge T1
which monitor the discharge air temperature from the receiver tank.
START UP AND VENT MODE
Start the Air Compressor Oil Circulation Pump, pressure at Test Port G1 on the control manifold
should be approximately 100 PSI. Pressure at test port G9, on the pump will be 110 - 180 PSI.
Solenoid operated Air Compressor Spiral Valve - ACSV on control manifold will be DE-ENERGIZED.
This sends oil to the compressor spiral valve which rotates the valve to MINIMUM. The Variable
Volume control valves (if equipped), ACVV1, ACVV2, and ACVV3 are all DE-ENERGIZED.
Solenoid operated Air Compressor Intake Valve - ACIV on control manifold will be DE-ENERGIZED.
The oil from ACSV communicates with the ACIV and opens both the recirculating valve (sending air
to the suction side of the compressor) and holds the compressor inlet butterfly valve shut.
The solenoid operated Drill Air Valve (DAV) will be DE-ENERGIZED. When the DAV is de-energized,
the blow down valve will be open resulting in maximum separator tank pressure of 30 to 50 PSI. The
Drill Air valve will be shut.
BI652203 7-13
DRILL MODE
Valve ACSV will be ENERGIZED, the spiral valve will rotate from MINIMUM to MAXIMUM.
Valve ACIV will be ENERGIZED; allowing the inlet butterfly valve to open and closes the recirculating
valve.
The solenoid operated Drill Air Valve will be ENERGIZED closing the blow down valve and opening
the drill air valve sending air to the drill bit.
Maximum tank pressure will be maintained through the Air Pressure Regulating Valve, any operating
pressure greater than 80 PSI will modulate the inlet valve to maintain the 80 PSI tank pressure.
VARIABLE VOLUME OPTION
The above Drill Mode is for 100% volume, the variable volume option gives the operator control for
3 Different volume outputs between 100% and 68%. The valve positions are as follows:
LEVEL 1
ACSV - DE-ENERGIZED
ACIV - ENERGIZED
Variable Volume manifold ACVV1 - ENERGIZED
Variable Volume manifold ACVV2 - DE-ENERGIZED
LEVEL 2
ACSV - DE-ENERGIZED
ACIV - ENERGIZED
LEVEL 3
ACSV - DE-ENERGIZED
ACIV - ENERGIZED
7-14 BI652203
COMPRESSOR START-UP
NOTE: For accurate readings, the machine must be level when checking the oil level.
1. COMPRESSOR OIL - The compressor air end, separator and cooler must be filled with the
recommended compressor oil.
NOTE: After initial start-up, the oil level in the separator will drop due to the oil filling the piping
system. Shut down the compressor after approximately 15 minutes of operation. Allow
the machine to sit for 10 to 15 minutes to allow air bubbles to settle out of the oil. Check
the oil level gauge. If the oil level is below the sight glass, refill to the top of the sight
glass.
CAUTION: The system contains hot oil under pressure. Always check the
pressure gauge to make certain the pressure is at zero before
opening the fill plug.
2. DRAIN THE CONDENSATE - Open the drain valve slightly to drain off any condensate into a
container. Close the valve securely when oil appears. Dispose of the oil and condensate
properly.
3. START THE UNIT - Start-up the compressor.
4. OBSERVE THE DISCHARGE AIR PRESSURE - During drilling operations, the main air valve
will maintain a minimum pressure of approximately 30 PSIG in the receiver. Pressure higher
than this minimum will be regulated by the drill bit orifice size or air pressure control valve
setting. The discharge air pressure must not operate above the maximum rating plate pressure
during the loaded cycle. However, momentary high pressures up to the 85 PSIG are permitted
(e.g. to blow out clogged drill bit orifices).
NOTE: The tank safety relief valve is set at 150 PSI and should be replaced or serviced anytime
it is opened.
5. OBSERVE THE DISCHARGE AIR TEMPERATURE - The maximum discharge air temperature
must not exceed 225°F (107ºC).
NOTE: The air temperature limit is factory set to shut down the unit at 225°F (107ºC).
6. OBSERVE THE OIL INJECTION TEMPERATURE - The oil injection temperature must not
exceed 185°F (85ºC).
7. PERFORM MAINTENANCE CHECKS - Refer to the proper area of this manual for
recommended maintenance checks.
BI652203 7-15
8. UNLOAD THE COMPRESSOR – To unload the compressor, the air compressor inlet valve
(ACIV) is energized, closing the inlet valve, and the drill air solenoid valve (DAV) is de-energized
to close the main air valve. The air pressure in the tank is bled down using the blow down
valve. Air pressure in the tank will drop to approximately 30 PSI, depending on the quality of
the seal on the inlet valve.
NOTE: The discharge air temperature must not exceed 225oF (107ºC). Oil injection
temperature must not exceed 185oF (85ºC).
COMPRESSOR SHUTDOWN MODES
COMPRESSOR FAILURE FAULT
The compressor will shut down if the air temperature is above 212oF (100oC) and oil temperature is
more than 72oF (22oC) less than air temperature.
COMPRESSOR COOLING FAILURE FAULT
The compressor will shut down if the air temperature is above 212oF (100oC) and oil temperature is
within 18oF (-8oC) of air temperature.
COMPRESSOR OVERHEAT WARNING
This fault occurs when the air temperature is above 212oF (100oC)
COMPRESSOR AIR TEMPERATURE FAULT
If the air temperature reaches 225oF (107oC), the compressor will shut down.
THERMOSTATIC CONTROL VALVE
The thermostatic (3-way) control valve controls the oil flow to maintain a 140°F (60°C) minimum oil
injection temperature.
7-16 BI652203
On start-up, with the unit cold, the thermal element is open to the bypass line. Oil flows from port B
through port A to the compressor, bypassing port C to the cooler. The element is factory set to open
at 140°F (60°C). As the receiver oil warms up to this temperature, the thermal element gradually
closes port B and opens port C. This allows the cool oil from the radiator cooler to mix with the
bypass oil. After the unit is warmed-up, the thermostatic control valve will normally be open to port
C. This produces an oil injection temperature above 140°F (60°C). The valve should be fully open
at 150°F (66°C) directing full flow to the cooler.
If the compressor shuts down under high air temperature conditions, the thermal element may be
stuck in the bypassed position from port B to port A. Let the unit cool down and then restart the
compressor. Check the temperature of the hose from the C port to the cooler. If the temperature is
above 150°F (66°C) and within 5°F of port A the element is functioning properly. If the oil injection
temperature continues to rise past the 150°F (65°C) and the temperature of the hose from port C
to the cooler is less than 5°F below port A hose temperature, shutdown the unit immediately. Remove,
clean, test, and replace the thermostatic element, if required.
BI652203 7-17
Removal, clean and test the thermostatic control valve as follows:
1. Shut down the compressor. Lockout and tag the compressor controls. Allow the system to
cool if at all possible. Drain the oil. Relieve the oil pressure in the lines to and from the
thermostatic valve.
2. It may be necessary to remove the thermostatic valve from the machine in order to separate
the components. However this is not required. At least disconnect the compressor supply
hose at valve port A.
DANGER: STORED ENERGY! At operating temperature, the hydraulic fluid is

hot and pressurized. Hot hydraulic fluid may cause burns. Hydraulic
fluid under pressure may cause injury or death if not released in a
controlled manner before the lines are disconnected.
3. Remove the four bolts and lockwashers attaching the adapter housing at port A.
4. Remove the adapter housing and O-Ring.
5. Remove the thermostatic element assembly and seal.
6. Clean the element and test as follows:
CAUTION: The valve housing and thermostat may be hot. Use suitable protective
equipment when handling any hot items.
7. Place the element in 150°F (65°C) water and stir the water vigorously with the element for 5
minutes. Immediately place the element in the housing. If the element is fully stroked, the
seating of the element against the upper housing can be felt. If the element is not fully
stroked and seated, replace with a new element, [140°F (60°C) setting].
CAUTION: Replacement element must be the same as the original. Do not

replace with other brands.
8. Clean the internal surfaces of the adapter housing and the main valve housing.
9. Lubricate a new O-Ring and slide it over the top of the element assembly and into position on
the element.
10. Place a new housing gasket in the recess of the main valve housing.
11. Insert the element into the adapter housing. Install the adapter housing over the element.
12. Install the housing capscrews and lockwashers and tighten. Refill the oil in the system. Remove
the compressor lockout and restart the compressor. Test for leaks and for proper operation.
7-18 BI652203
INLET REGULATING VALVE
The intake valve on the compressor is a butterfly valve with an air/oil cylinder operator. The intake
valve is closed for the compressor start up. This prevents air from entering the compressor causing
the screw to operate in a vacuum. Since the screws are not compressing air, this reduces the
horsepower required to drive the compressor.
The intake valve remains in the closed position until the operator want to drill a hole. The operator
will place the main air valve switch to the open position; this will cause the air inlet valve control
cylinder to retract opening the intake valve. Air will flow into the compressor and start to compress
air.
The intake valve is also used to regulate the maximum air pressure in the receiver tank. If the air
pressure in the tank becomes too high, the air control regulator will open and extend the air control
cylinder closing the intake valve and reducing the air flow into the compressor. Once the hole
clears and the air pressure reduced in the tank, the intake valve will return to the full open position.
DISCHARGE AIR TEMPERATURE GAUGE
This temperature gauge is a direct reading temperature gauge which indicates the air temperature
at the compressor discharge flange.
CAUTION: This reading must not exceed 225°F (107°C) at any time.
SAFETY RELIEF VALVE
The pressure safety relief valve is located on the side of the receiver and is set to relieve the
pressure at 150 PSIG. Periodic checks should be made to insure its proper operation.
CAUTION: Never operate the unit without a proper safety valve setting.
SOLENOID BLOWDOWN VALVE
The blowdown valve is installed on the receiver outlet and will automatically open and blowdown
the receiver, piping and compressor air end when the compressor is stopped. The blowdown time
is approximately five minutes to reduce the pressure down to 0 PSIG.
NOTE: Too rapid a blowdown would cause oil foaming and excessive oil carry-over past the oil
separator.
BI652203 8-1
Heating Ventilation and Air Conditioning Section
Section 8
Heating, Ventilation and Air Conditioning
Table of Contents
AIR CONDITIONING UNIT WITH HEATER .................................................................................... 3

DESCRIPTION ........................................................................................................................ 3
SPECIFICATIONS ................................................................................................................... 4
HOUSE FANS ............................................................................................................................... 4
INSPECTION ........................................................................................................................... 4
LUBRICATION ......................................................................................................................... 5
8-2 BI652203
BI652203 8-3
Section 8
Heating, Ventilation and Air Conditioning
AIR CONDITIONING UNIT WITH HEATER
DESCRIPTION
SIGMA climate control units are heavy duty systems designed to be roof mounted on the cabs of
industrial and mining equipment.
This unit will provide superior performance in a variety of climate conditions and under the most
harsh environment.
8-4 BI652203
SPECIFICATIONS
Nominal Cooling Capacity 25,000 Btu/hr@460V/60Hz
22,500 Btu/hr@380V/50Hz
Refrigerant HFC 134a
HOUSE FANS
INSPECTION
Check the blades for grease and/or dirt accumulation. Clean if necessary. Blades should rotate
freely without binding.
If vibration is detected, check the following
1. Bearing and drive alignment
2. Shaft straightness
3. Wheel or sheaves loose on shaft
4. Loose or worn bearings
5. Loose mounting bolts
6. Motor out-of-balance
7. Sheaves out-of-balance
8. Nose cap loose on wheel
9. Worn or corroded wheel
10. Accumulation of material on the wheel
11. Cracks on blades and/or at the hub
12. Worn fan blades and hubs

BI652203 8-5
LUBRICATION
All bearings are pre-lubricated and sealed at the factory. Under normal temperature conditions
(-20° to +150°F), when the fans are circulating clean air, the bearings are considered lubricated for
life and additional lubrication is unnecessary.
If the fans are circulating contaminated air, or operating at elevated temperatures, periodic lubrication
is required.
For normal temperatures, a high quality, light neutral mineral grease is used. It is free of abrasive
fillers and highly resistant to oxidation.
When fans are operating at elevated temperatures (166°F or higher), silicone or lithium soap base
grease should be used. This high temperature grease should have a breakdown point above 350°F.
Use a low pressure grease gun for fan bearings. It is preferable that either the gun or the fitting be
vented. To prevent overfilling apply only a small amount of grease.
This is especially important when extended lubrication piping is used and the bearing cannot be
observed.
8-6 BI652203
BI652203 9-1
Engineering Data Section
Section 9
Engineering Data
Table of Contents
CAPSCREW (BOLT) GRADE ...................................................................................................... 3

BOLT TIGHTENING ....................................................................................................................... 4
TORQUE WRENCH METHOD ............................................................................................... 4
Table 1 - Lubricated or Plated Threads or with Hardened Washers .............................................. 4
Table 2 - Dry Threads .................................................................................................................. 4
TURN-OF-NUT METHOD ....................................................................................................... 5
Table of Snug Tight Torque Values ............................................................................................. 5
WIRE LOCKING CAPSCREWS ................................................................................................... 6
Patterns for Wirelocking Capscrews ........................................................................................... 6
MAINTENANCE WELDING ........................................................................................................... 7
WELDING ELECTRODES ..................................................................................................... 8
REPAIR WELDING OF CRACKS ........................................................................................... 9
Joint Preparation for Repair of Cracks ........................................................................................ 9
PREHEAT ........................................................................................................................ 10
WELDING TECHNIQUE .................................................................................................. 10
REPAIR WELDING OF BROKEN PARTS ............................................................................ 11
WELDING AND CUTTING EQUIPMENT ..................................................................................... 12
STRESS RELIEVING & TEMPERATURE MEASURING EQUIPMENT ....................................... 12
GEAR INSPECTION ................................................................................................................... 14
Gear Tooth Surface Failures ..................................................................................................... 15
AEROQUIP ORS CONNECTIONS ............................................................................................. 16
ORS Connection Assembly ....................................................................................................... 16
9-2 BI652203
BI652203 9-3
Section 9
Engineering Data
CAPSCREW (BOLT) GRADE
The grade classification of a capscrew (bolt) is identified by the marks on the head as shown
below:
Use the SAME GRADE washer and nut as the capscrew. NEVER SUBSTITUTE A LESSER GRADE
CAPSCREW IN PLACE OF THAT WHICH IS SPECIFIED.
9-4 BI652203
BOLT TIGHTENING
TORQUE WRENCH METHOD
The following tables show torque values for bolt grades 2, 5 and 8 with UNC threads only. Table 1
lists torque values for lubricated or plated threads and for using hardened washers. Table 2 lists
those for dry threads.
The bolts should be tightened to the

specified total value in increments,
alternating from bolt to bolt to assure
gradual, even pull-up of mating parts.
Tightening should progress
systematically from the most rigid part of
a joint to its free edges.
Circular bolt patterns should be

tightened in a diametric crosshatch
pattern while applying torque in
increasing values to ensure proper pull-
up of parts.
Table 1 - Lubricated or Plated Threads or with Hardened Washers
Table 2 - Dry Threads

BI652203 9-5
TURN-OF-NUT METHOD
CAUTION: THIS TIGHTENING PROCEDURE IS ONLY APPLICABLE FOR BOLT

GRADES 5 AND 8 WITH UNC THREADS. For bolts with other than UNC
threads, contact the Caterpillar Global Mining Service Department.
NOTE: When using this procedure the bolt threads and the surfaces under the bolt head and
nut must be lubricated. This procedure is applicable only if the joint and under head
surfaces for bolt and nut are machined for parallelism.
1. The bolts should be brought to a “snug tight” condition to insure that the parts of the joint
have good contact with each other. “Snug Tight” is defined as the tightness attained by
torquing a bolt to the value specified in the table on the following page. Snug tightening
should progress systematically from the most rigid part of the joint to its free edges while
alternating from bolt to bolt to assure gradual even pull up of the mating parts. After all bolts
have been snugged, the first bolts tightened at the most rigid part of the joint should be
rechecked for proper torque retention. If these bolts are loose due to pull up of the joint, the
snug tightening sequence should be repeated for all bolts in the connection. This rechecking
and re-torquing procedure should be repeated as many times as is required until the joint is
completely pulled up and all bolts are at the specified “snug tight” torque. Tightness of the
mating surfaces of the joint should then be verified by using feeler gauges.
Table of Snug Tight Torque Values
2. The nuts and bolts should then be matched marked by center punching the bolt end and nut.
On rod bolts match mark both rod ends and nuts. The bolts and nuts should then be tightened
additionally by the applicable amount of nut rotation as specified in Table 4. It is not necessary
to follow any particular bolt to bolt sequence during this portion of the “turn of the nut” tightening.
9-6 BI652203
NOTE: Nut rotation is read between the punch mark on the bolt and the punch mark on the nut.
For rod bolts, nut rotation is the cumulative total rotational movement between punch
marks on both ends of the rod bolt.
WIRE LOCKING CAPSCREWS
Wire locking of capscrews is used when maximum lock assurance is required when periodic visual
inspection is not possible.
The illustrations below show the recommended wire locking methods for various right hand thread
capscrew patterns. For patterns not shown, wire lock the screws “in pairs”. For odd numbered
patterns, wire lock the screws in pairs except the remaining 3 capscrews wire lock together
Patterns for Wirelocking Capscrews
Use 14 gauge soft annealed lockwire. Thread the wire through the capscrew head so that tightening
stress on the wire will exert a tightening torque on the direction of capscrew thread. (The illustrations
show lock wire threading for right hand threaded capscrews. Reverse the lock wire patterns shown
for left hand capscrews.)
BI652203 9-7
MAINTENANCE WELDING
These recommendations for repair welding apply to the major structural members of the machine.
The high cyclic loading characteristics of the machine are considered in the design and material
selected for the construction of the machine. However, due to unusual operational conditions that
may be encountered and to the great number of cyclic loadings that may be applied to the machine,
fatigue cracks or other abnormalities may occur. Early detection of these conditions through regular
machine inspection helps to avoid problems or emergency breakdowns.
Maintenance welding is applied to the repair of cracked or broken structural components.

Reconditioning of broken parts by the application of heating, cutting and welding processes requires
attention to a number of details, careful adherence to the repair procedure and observance of
federal, state and local safety regulations.
CAUTION: WELDING AND THERMAL-CUTTING OF METALS INVOLVE THE

GENERATION OF TEMPERATURES UP TO THOUSANDS OF DEGREES
AT WHICH METALS MELT AND VAPORIZE. When proper precautions
are taken to protect personnel and property against the heat, evolved
gases and fumes, electric shock and radiation, no harm will result
either to personnel or property. In gas heating and cutting, the
handling and storage of compressed gases present other hazards
that also must be protected against to provide a safe working
environment.
Safety precautions should conform to the latest edition of ANSI
standard Z49.1, Safety in Welding and Cutting, published by the
American Welding Society.
Reconditioning of failed members requires attention to a number of details and careful application
of the repair procedure. Only in certain cases is it necessary to strengthen members by added
reinforcement.
WARNING: REINFORCING STRUCTURAL MEMBERS SHOULD BE MADE ONLY

UPON RECOMMENDATION BY THE FACTORY. IMPROPERLY
APPLIED REINFORCEMENTS CAN HAVE AN ADVERSE EFFECT ON
THE PERFORMANCE AND LIFE OF THE STRUCTURE.
A broken member is best repaired by making a complete penetration weld, preferably by welding
from both sides, using the correct welding electrode and observing all precautions such as preheat,
back-gouging, etc. The complete penetration groove weld should be ground flush with the base
metal on both sides to remove all surface irregularities. An alternate procedure incorporates backup
bars to ensure sound, complete penetration welds in the repair area. Be sure to follow all applicable
safety measures and federal, state and local regulations.
A complete penetration weld repair conditioned by grinding instead of adding reinforcement is

favored to maintain the original pattern of stress flow designed into the structural members. Addition
of reinforcement which is not part of the design can reduce fatigue strength because of the change
in geometry from the original structure.
9-8 BI652203
Effective repair welding of cracked, broken or bent structural members of the machine involves
knowledge of the types of steel used, proper welding electrodes and recognized good welding
practice. The chemical composition, mechanical properties and thickness of the steel determine
the welding electrode to be used and the preheat temperature required.
WELDING ELECTRODES
With the exception of the boom, weld repairs on the various structures of the machine can be
made with two basic classifications of shielded metal arc electrodes: E7018 and E8018-C1. Both
are low hydrogen electrodes which deposit weld metal having excellent properties at strength
levels with 70,000 to 80,000 PSI, and impact properties from -20° to -75°F. These are all-position
electrodes which produce high quality welds for repairing the structural components of heavy
machinery.
NOTE: Although these electrodes are of superior quality, care must be exercised in their
application. Low hydrogen electrodes are highly susceptible to moisture pickup after
removal from sealed containers. To maintain low hydrogen, crack-resistant properties,
they must be stored in electrode ovens at 250°F up to the time of use. Small portable rod
ovens at the welder’s side are ideal. Use of dry low hydrogen electrodes cannot be
overemphasized.
Cracks caused by hydrogen are extremely fine and occur invisibly below the surface in the base
metal heat affected zone, as shown. Therefore, they are not detectable at the time of welding.
These cracks can propagate in service and lead

to ultimate failure of the part. It is necessary to
adhere strictly to recognized good welding
practice regarding the handling, storage and use
of low hydrogen electrodes. To avoid underbead
cracks, remove all oil or grease or other
contaminates from the surface and be sure the
steel is dry.
Preheat to the required temperature. Use only dry

electrodes taken from the electrode oven. After
exposure to the air, the electrodes must be
returned to the oven. Time limit outside the oven
is four hours for E7018 and two hours for E8018-
C1 electrodes.
BI652203 9-9
REPAIR WELDING OF CRACKS
Joint Preparation for Repair of Cracks
Remove the entire crack by arc air-gouging or grinding. Prepare a V-groove of approximately 45-
60° included angle for rewelding. If cracked through the full thickness and if it is possible to make
the repair from both sides, a double V preparation is preferred. When welding from both sides,
back-gouging for complete penetration is always recommended.
When it is not physically possible to back-gouge and weld the second side, an alternate approach
must be taken. Sometimes it is possible to gouge through to completely remove the crack, then fit
a backup bar on the underside to facilitate making a complete penetration weld.
NOTE: The backup bar must fit tightly to the underside otherwise poor welding conditions
conducive to cracking may occur.
When it is not possible to fit a backup due to limited accessibility to the underside, it is advisable to
remove a portion of the defective plate and weld in a new piece, using back up bars on all sides to
ensure complete penetration welds.
A further alternative is to gouge through, removing the crack, and then weld small stringer beads
to close the gap and prepare a groove for a repair weld. In this case, the repair weld will be
essentially full penetration, but will be less than perfect on the under side. The other methods are
preferred in the order described, that is, welding both sides, welding against a backup bar, or
completely replacing a section of plate.
9-10 BI652203
PREHEAT
When preheating, apply heat to a broad, general area surrounding the repair location. A soaking
heat which thoroughly penetrates the material through the full thickness is preferred to high surface
temperature quickly applied. Electrical resistance or radiant heating is suggested since the heat
source can be left operating during welding to maintain the minimum preheat temperature. Preheat
temperatures up to 400°F, depending upon the steel analysis, are adequate under most conditions
for major repairs. As previously stated, preheat temperatures are determined by the type of steel
in the structure. Temperatures should be measured with temperature indicating crayons.
WELDING TECHNIQUE
Maximum electrode sizes are 1/4 inch for flat

position, 3/16 inch for horizontal position and 5/
32 inch for vertical and overhead positions. Use a
split weave as soon as bead width is large enough
to accommodate beads side by side. Throughout
all welding be certain thorough fusion with the base
metal and adjacent weld beads is obtained on all
weld passes. Clean off all slag between passes
and all craters before starting the next electrode.
Inspect closely for cracks, undercut or overlap of

beads, and gouge out or grind flaws where they
occur before continuing. It is very important on
highly loaded parts, particularly members subject
to cyclic or dynamic stresses, to obtain sound
repair welds.
The presence of any stress risers on the surface

of a part is detrimental to fatigue life and can result
in future cracking. Therefore, it is essential that
the finished repair be smooth and well blended
into the base metal. Repair weld any undercuts,
grind off overlapped weld beads and blend out
any notches or gouges. The best condition in a
repair weld location is provided by grinding the
repair smooth and flush with the surface of the
base metal. Final grinding direction is to be
identical with the direction of applied load on the
structure. Refer to the figure.
BI6522039-11
REPAIR WELDING OF BROKEN PARTS
All recommendations given for repair of cracks apply to repair of broken parts, with additional
corrections. Depending on the size and cross-section of the part, a specific sequence of welding
procedures may be required in making the repair. These techniques include back-step welding
sequence, block welding sequence, alternating from side to side, welding simultaneously on opposite
sides, etc. All of these precautionary measures are intended to minimize shrinkage stresses and
subsequent distortion or cracking during welding. The method to follow should be determined after
a careful analysis of the situation and by approaching the problem with common sense. Generally
a procedure which has proven successful in previous experience could logically be applied in most
cases.
Use of doubling plates, stiffeners or other reinforcements to strengthen a member which has
cracked in service, must be carefully considered before that repair measure is decided upon.
Additional material added for strengthening alters the configuration and geometry of the member,
possibly with a pronounced effect on the fatigue life of that structure. Many times, such attempts at
strengthening by added plates only serves to “chase the crack someplace else.” The stress flow in
the part has been altered, creating a location for stress concentration. Attachments requiring fillet
welds across a tension member for example, are poor repair methods. A sound repair weld, carefully
made and smoothly blended into the base metal on all sides, is preferable to additional
reinforcements. Any application of reinforcements requires careful consideration regarding total
overall effect on the structure during service, and should be done only after consulting Catepillar
Global Mining.
9-12 BI652203
WELDING AND CUTTING EQUIPMENT
The welding and cutting equipment needed for general repair welding is listed below.
WELDING MACHINES, Arc - 600 ampere (for Welding and Air Arcing)
OXY ACETYLENE TORCHES with Gauges - 150' Long Hoses
HEATING TORCHES, Butane (for Boom Welding)
ARC AIR ATTACHMENTS (for use with 600 Ampere Welding Machines)
WELD RODS - E7018, E8018, E11018 - 1/8", 5/32". 3/16", 1/4"
C02 - Welding Grade - 45°F Max. Dew Point
OXYGEN - Cutting, and Heating
ACETYLENE
WELD FLUX CHIPPERS - Pneumatic with Chisels and Spare Parts
BLOWERS, Ventilating (for Compartment Welding,)
GRINDERS, Wheel - Air Powered w/Wheels
TARPAULINS - Fireproof (for Boom Welding Shelters)
ASBESTOS GLOVES
CUTTING GOGGLES, Dark
SOAPSTONE MARKERS
ANTI-SPATTER COMPOUND
TEMPILSTIKS - 200° and 200°
STRESS RELIEVING & TEMPERATURE MEASURING EQUIPMENT
The equipment recommended for stress relieving, after repair welding, is listed below.
TEMPERATURE MEASURING EQUIPMENT

SPEEDOMAX, “W” Multipoint, Potentiometer Recorder
POWER REQUIREMENT - 120 Volts, 60 or 50 Hz.
RANGE - 0 to 1500°F
CALIBRATION - Chromel-Alumel Thermocouple Wire
ACCURACY RATING - 0.3% of Electrical Span
CHART SPEED - 2" per Hour
THERMOCOUPLE SELECTION - Six (6) Points
FLUORESCENT LIGHTING
MANUFACTURER - Leeds & Northrup Company
BI6522039-13
THERMOCOUPLE EXTENSION WIRE

DUPLEX WIRES - Chromel-Alumel - Type K - 16 AWG Stranded
LENGTH - Total External Resistance for both Wires including Thermocouple not to exceed 2500
Ohms or 410 Feet.
WIRE RESISTANCE - Nominal Resistance, Ohm per Foot at 20°C 66°F, - Chromel - Ohms -
Alumel - .0683 Ohms.
WIRE INSULATION - each Conductor Enamel, Asbestos (Twisted Pair) Overall Asbestos Braid
WIRE CODE -Alumel, Negative Wire (Red); Chromel, Positive Wire (Yellow)
OVERALL COLOR - Yellow
CATALOG No. 16-59-17
POLARITY DISCONNECT
CHROMEL-ALUMEL COMPENSATED CONNECTION
JACK Color Code (Yellow) - Catalog No. 040419
PLUG Color Code (Yellow) - Catalog No. 040434
CABLE CLAMP - Catalog No. 072513
ADAPTER - Catalog No. 076794
THERMOCOUPLE ELEMENT
CHROMEL-ALUMEL - Type K - Swaged One (1) Inch Stripped
CHROMEL POSITIVE WIRE Color Code (None)
ALUMEL NEGATIVE WIRE Color Code (Red)
CATALOG No. 8784-K-1-3-12"-D
1. 588003 Kaopak Flex Heaters
2. 588004 Kaopak Collector Streamer Type
3. Kaopak Blankets 3, 5, or 6 Pocket Size as needed for Size Pipe being Stressed Relieved
Thermocouple Assembly, Complete
Catalog No. 8784-K-1-3-12"-Q
Temperature Heating Pellets
Range: 1050°F, 1100°F, 1200°F, 1250°F
Mean Accuracy: +/-1%
These Tempil Pellets will begin to melt at the temperature specified.
9-14 BI652203
GEAR INSPECTION
An important part of machine maintenance is regular inspection of gears. This should include the
gears and pinions of the pulldown, rotary and propel machinery.
Listen for any unusual noises or vibrations which would indicate excessive wear patterns of gears
and pinions. Usually this would necessitate prompt attention before complete failure occurs.
Of primary importance in proper gear operation is correct lubrication. Always check to see that all
the gears are adequately lubricated. See the Lubrication Section in this manual for further information
on correct lubricants and their application.
A condition of normal wear should result when gears do not operate at excessive loads or
temperatures and correct lubricants are used.
Gears are designed to function satisfactorily during the entire life of the machine. Their failure to do
this indicates some unusual conditions. Regardless of gear design, size or construction, correct
lubrication is essential to assure minimum wear, quiet operation and long service life. Gear tooth
shapes are very accurately manufactured, nevertheless there will always be microscopic surface
irregularities which cause frictional resistance. With the gears in proper mechanical condition and
with correct lubrication, friction is reduced, wear is practically eliminated and gears should operate
efficiently. However, even with correct lubricants properly applied, certain mechanical or operating
conditions can cause wear and destruction of teeth. Destruction seldom takes the form of tooth
breakage, but usually shows up as damage to the contact surfaces.
Such surface failure may rapidly destroy the original tooth contour, preventing smooth, quiet operation.
This failure may be directly attributable to overloading, overheating, shock, abrasives, chips, improper
alignment, loose bearings or deflection of shafts or housing.
Many terms are employed to graphically describe the appearance of damaged tooth surfaces. The
terms pitting, abrasion, scratching, spalling and galling are the major types of failures under which
all of the other failures can be grouped. These five types of failure have different basic causes.
From the lubrication point of view, the cause of the failure is of major interest rather than the
appearance of the surfaces. These gear-tooth failure classifications are shown in the figure.
Gears and pinions may show some minor pitting which is usually normal. However, any heavy
pitting or spalling or any abnormalities as shown will necessitate replacement.
BI6522039-15
Gear Tooth Surface Failures

9-16 BI652203
AEROQUIP ORS CONNECTIONS
The Aeroquip ORS type connection is used throughout the hydraulic system of this machine.
The ORS connection has an O-Ring groove machined into the flat male face. This flat face and O-
Ring mate with the connection’s other machined face to form a virtually leak-free seal.
The face-seal concept allows the components to be installed or replaced without moving mating
components or applying strain on tube and hose lines. The swivel nut can be retracted to inspect
seal placement and joint fit prior to assembly.
When using this connection, remove the O-Ring from the male face and fill the groove with a high
quality multi-purpose grease, then install the O-Ring in the groove. The grease will additionally seal
around the O-Ring while helping to retain the O-Ring in the groove. The grease will also lubricate
the connection while it is being assembled.
There is no need for special torque of the connection as the installer can “feel” when the fitting is
tight.
ORS Connection Assembly

BI652203 10-1
Schematics Section
Section 10
Schematics
Table of Contents
SCHEMATICS ............................................................................................................................... 2
SIDE VIEW .............................................................................................................................. 3
DECK PLAN ............................................................................................................................ 5
MAIN FRAME HYDRAULIC SCHEMATIC ................................................................................ 7
MAIN FRAME HYDRAULIC SCHEMATIC (CONT’D) ............................................................... 9
MAIN HYDRAULIC ................................................................................................................. 11
JACK HYDRAULIC SCHEMATIC ........................................................................................... 13
CRAWLER HYDRAULIC SCHEMATIC .................................................................................. 15
MAST HYDRAULIC SCHEMATIC .......................................................................................... 17
HYDRAULIC SOLENOID VALVE & GAGE PORT LOCATION .............................................. 19
AIR SCHEMATIC ................................................................................................................... 21
AIR SCHEMATIC, RECIRCULATING SYSTEM ..................................................................... 23
10-2 BI652203
Schematics Section
Section 10
Schematics
SCHEMATICS
The following pages contain a series of block diagrams depicting the schematic layout of the hydraulic
systems and air system.
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© 2014 Caterpillar All Rights Reserved. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,”
the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of
Caterpillar and may not be used without permission.
Printed in U.S.A.

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BI652203

MD6640 Blast Hole Drill

Section 4 - PREVENTIVE MAINTENANCE

Section 5 - SERVICE PROCEDURES

Section 6 - BRAKES AND COUPLINGS

Section 7 - COMPRESSED AIR SYSTEM

Section 8 - HEATING, VENTILATION AND AIR CONDITIONING

Section 9 - ENGINEERING DATA

Section 10- SCHEMATICS

DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE

DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE

GENERAL INFORMATION ............................................................................................................ 3

DECK PLAN.......................................................................LOCATED AT THE END OF THE MANUAL

Caterpillar Global Mining, LLC

CAUTION: This signal word serves as a reminder of safety practices or directs

DANGER: This signal word denotes an imminently dangerous electrical hazard

CAUTION: STORED ENERGY! Components on machine are heavy and

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

FIRE PREVENTION CONSIDERATIONS

DO NOT smoke while handling flammables or when near batteries.

DO NOT carry flammable fluids such as gasoline or solvents on board themachine.

NEVER weld, burn, or perform service on the machine alone.

STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS

HOIST Extend forearm upward, keeping forefinger extended and pointing

LOWER Extended arm downward, keeping forefinger extended and pointed

DOG EVERYTHING Clasp hands together in front of body.

SWING Extend arm horizontally with index finger extended in desired

EXTEND BOOM (Telescoping Booms) Place both hands in front of body

RETRACT BOOM (Telescoping Booms) Place both hands in front of body

EXTEND BOOM (Telescoping Booms) With fingers clenched and thumb

RETRACT BOOM (Telescoping Booms) With fingers clenched and thumb

WARNING SIGNS AND DECALS

Stored Energy Signs

Pipe Rack Front

Idler Roller Final Drive

MAIN FRAME AND DECKS

MAIN AIR SYSTEMS

DRILL TOOL STRING ASSEMBLY

65 OR 70 FOOT MAST - TYPICAL MACHINE SPECIFICATIONS

Refer to the images on the following page.

GENERAL ESTIMATED COMPONENT WEIGHTS

Quantity Weight Each

Power Module ........................................................................... 1 ...............13,600

Quantity Weight Each

Oil Cooler, Air Cooled ............................................................... 1 ................... 570

MCC. Low Voltage .................................................................... 1 ................... 900

Leveling Jack Stand .................................................................. 1 ................... 470

Operator Cab Assembly ........................................................... 1 ................ 8,400

Hatch, Bit View ......................................................................... 1 ................... 225

Quantity Weight Each

Duct, Pressurization Unit Transition ......................................... 1 ................... 275

Gearcase, Pulldown ................................................................. 1 ................ 1,170

Quantity Weight Each

Gearcase, Rotary ..................................................................... 1 ................ 2,950

Coupling, Shock ....................................................................... 1 ................ 2,500

Guide Frame (LH) .................................................................... 1 ................ 1,130

Extender, Drill Pipe ................................................................... 1 ................... 620

GENERAL INFORMATION ............................................................................................................ 5

AUTO LEVEL SWITCH ................................................................................................... 18

HOIST/PULLDOWN GEARCASE BREAK-IN ........................................................... 40

PROGRAMMED DRILL CONTROL DRILLING ..................................................................... 87

OPERATION NEAR ELECTRICAL TRANSMISSION LINES

DANGER: HIGH VOLTAGE! The following precautions shall be complied with