49HR Manual SN 141218 Part1

Bucyrus International, Inc.
49HR Blast Hole Drill
Manual No. 10528 Sept. 2007


Maintenance and Operation Manual
Manual No. 105528
sn: 141218, Lot 86
–Table of Contents–
This manual is divided into major sections covering the various serviceable components and systems
of the 49HR Blast Hole Drill. These sections and their contents are organized as shown below.
Section 1 - INTRODUCTION
Section 2 - OPERATION
Section 3 - LUBRICATION
Section 4 - SCHEDULED MAINTENANCE
Section 5 - MAJOR MAINTENANCE
Section 6 - BRAKES AND COUPLINGS
Section 7 - COMPRESSED AIR SYSTEM
Section 8 - HEATING, VENTILATION AND AIR CONDITIONING
Section 9 - ENGINEERING DATA
IMPORTANT NOTE
This document is protected under applicable copyright laws to the extent available. Any
unauthorized and unlawful reproduction, distribution or other use shall be subject to liability.
© 2007 Bucyrus International, Inc. All Rights Reserved.
Sept. 2007 Manual No. 10528

Manual No. 10528 Sept.. 2007

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.
Sept. 2007 Manual No. 10528

Manual No. 10528 Sept.. 2007

Section 1
Introduction
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
TYPICAL MACHINE SPECIFICATIONS ....................................................................................... 27
GENERAL ESTIMATED COMPONENT WEIGHTS .................................................................... 29
DECK PLAN - Color ...................................................................................................... ( foldout )
Sept. 2007 1-1 Manual No. 10528

Manual No. 10528 1-2 Sept. 2007

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 quickly by the Bucyrus
International parts representative.
Periodic additions or revisions may be made to this manual. These can be ordered and will be
mailed directly from the factory. Should you require additional information or factory service
assistance contact your regional service representative or:

1100 Milwaukee Avenue
P.O. Box 500
South Milwaukee, Wisconsin, USA 53172-0500
Telephone (414)-768-4000
It is Bucyrus International’s policy to improve its products whenever possible and practical to do so.
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.
Sept. 2007 1-3 Manual No. 10528

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 Bucyrus 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.
Manual No. 10528 1-4 Sept. 2007

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.
Sept. 2007 1-5 Manual No. 10528

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.
Manual No. 10528 1-6 Sept. 2007

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.
Sept. 2007 1-7 Manual No. 10528

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.
Manual No. 10528 1-8 Sept. 2007

STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS
These signals are derived from ANSI-B30.5-1868 and are intended to provide standardization to
the signalling 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.
Sept. 2007 1-9 Manual No. 10528

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.)
Manual No. 10528 1 - 10 Sept. 2007

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.
Sept. 2007 1 - 11 Manual No. 10528

WARNING SIGNS AND DECALS
The placards depicted below are mounted on the machine as delivered from Bucyrus International,
Inc. 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.
Manual No. 10528 1 - 12 Sept. 2007

Stored Energy Signs
Sept. 2007 1 - 13 Manual No. 10528

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
Mast Machinery of
Guide Frame Mast Brace Machine
Pulldown
Gearcase
Mast Machinery House

Breakout Machinery Main
Wrench Air Hose
Air House Filter
Hydraulic Cylinder, Assembly
Conditioner Mast Hoist
Rear
Leveling Operator’s
Jack Cab Mast Hinge
A-Frame
Water
Tank
Rotary
Gearcase
R R
Shock
Coupling
Front
141218nm Main Frame Leveling
Pad, Jack
Crawler Assembly
Pad, Leveling Jack Leveling Jack Boarding Stairs
Crawler
Walkways, House
Drive Sprocket
Manual No. 10528 1 - 14 Sept. 2007

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 it’s 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.
Sept. 2007 1 - 15 Manual No. 10528

MAIN FRAME AND DECKS
The main frame is of welded box type construction with integrally placed mast supports and jack
towers.
Manual No. 10528 1 - 16 Sept. 2007

MACHINERY HOUSE
Sept. 2007 1 - 17 Manual No. 10528

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 (74.7 m3/min) and a maximum
operating pressure of 65 psi.
Air Compressor
Manual No. 10528 1 - 18 Sept. 2007

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.
Sept. 2007 1 - 19 Manual No. 10528

OPERATOR’S CAB
The sound insulated operator’s cab of the 49HR 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 swivel mounted chair provides easy access to all required controls.
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) 8.00 inch (203mm) hydraulic cylinders.
Manual No. 10528 1 - 20 Sept. 2007

Mast/Machinery
Sept. 2007 1 - 21 Manual No. 10528

ROTARY GEARCASE
Manual No. 10528 1 - 22 Sept. 2007

PULLDOWN GEARCASE
Sept. 2007 1 - 23 Manual No. 10528

DRILL TOOL STRING ASSEMBLY
Manual No. 10528 1 - 24 Sept. 2007

BREAKOUT WRENCH
CABLE REEL
Sept. 2007 1 - 25 Manual No. 10528

Manual No. 10528 1 - 26 Sept. 2007

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
A Overall Height with 65 Ft. (19.81m) mast 102' 5” 31.22m
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) 103’ 4" 31.50m
U Overall Machine Height with 65’ Mast at Rest (19.81m) 29’ 10" 9.09m
Sept. 2007 1 - 27 Manual No. 10528

Manual No. 10528 1 - 28 Sept. 2007

GENERAL ESTIMATED COMPONENT WEIGHTS
CAUTION: These are estimated weights only. Contact your Bucyrus

International 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 ................ 8,500
Frame, L.H. Crawler ................................................................. 1 ................ 8,500
Axle, Crawler Front Equalizer ................................................... 1 ................ 3,420
Axle, Crawler Rear ................................................................... 1 ................ 6,480
Tumbler, Crawler Drive ............................................................ 2 ................ 1,160
Gearcase, Planetary Propel ..................................................... 2 ................ 2,750
Link, Crawler .......................................................................... 110 ................. 240
Motor Assy., Hyd ....................................................................... 2 ................... 200
A-Frame
Leg, Front A-Frame .................................................................. 2 ................... 570
Leg, Rear A-Frame ................................................................... 1 ................ 2,860
Cylinder, Mast Latch ................................................................. 1 ..................... 20
Pin, A-Frame Lock .................................................................... 2 ..................... 40
Pin, Mast Latch Lock ................................................................ 6 ..................... 20
Pin, A-Frame ............................................................................ 8 ..................... 40
Ladder, A-Frame ....................................................................... 1 ..................... 80
Main Frame
Main frame ................................................................................ 1 ...............44,420
Casing Assembly, Left Rear Jack ............................................ 1 ................ 2,260
Casing Assembly, Right Rear Jack .......................................... 1 ................ 5,740
Cylinder, Leveling Jack Hydraulic ......................................... 4 ................... 850
Spud, Jack ............................................................................ 4 ................... 660
Shoe, Spud ........................................................................... 4 ................... 510
Module, Power Unit .................................................................. 1 ...............12,160

Base, Power Unit ..................................................................... 1 ................ 1,050
Motor, Module Power Unit ..................................................... 1 ................ 5,400
Pump Drive Assembly .......................................................... 1 ................... 980
Bracket, RH, Hydraulic Pump Drive ................................. 1 ................... 160
Bracket, LH, Hydraulic Pump Drive .................................. 1 ................... 160
Pump, Gear, Tandem, ...................................................... 1 ..................... 50
Pump Assy, 2 Pump ......................................................... 1 ................... 180
Filter, Oil w/Bypass Valve ..................................................... 1 ................... 770
Air End Assembly ................................................................. 1 ................ 4,160
Separator, Plumbing Assembly ............................................ 1 ................ 3,250
Reservior, Hydraulic ................................................................. 1 ................... 710
Reservior, Lube ........................................................................ 1 ................... 460
Sept. 2007 1 - 29 Manual No. 10528


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

Guard, Oil Cooler ................................................................. 1 ................... 360
Cooler Assy .............................................................................. 1 ................ 1,910
Cooler, Compressor, AC-Fan ................................................... 1 ................ 1,800
MCC. Low Voltage .................................................................... 1 ................... 830

MCC, Main Compressor........................................................... 1 ................... 600
Cabinet, Hoist/Pulldown ........................................................... 1 ................... 600
Control Panel, Static DC Drive ................................................. 1 ................... 210
Cabinet, Rotary ........................................................................ 1 ................... 600
Cabinet, PLC ............................................................................ 1 ................... 800
Tank, Water .............................................................................. 1 ................ 5,540

Valve Assembly, 7-Station ......................................................... 1 ..................... 80
Jack Valve Stand Assembly ...................................................... 1 ................... 500
Valve Stand Assy, 4-Spool Monobody ....................................... 1 ................... 190
Valve Assembly, 5-Station ......................................................... 1 ..................... 60
Operator Cab Structure ............................................................ 1 ................ 5,000

Console, R.H. Base Module ................................................. 1 ..................... 60
Console, L.H. Base Module .................................................. 1 ..................... 60
Console, Panelview Module ................................................. 1 ..................... 60
Hatch, Bit View ......................................................................... 1 ................... 230

Cylinder, Bit Viewing Hatch ................................................... 1 ................... 120
Retainer, Plate .......................................................................... 1 ..................... 40
Cylinder, Dust Seal ................................................................... 1 ..................... 90
Carrier, Dust Seal ..................................................................... 1 ................... 300
Gate, Front ............................................................................... 1 ................... 380
Gate, Rear ................................................................................ 1 ................... 630
Frame, Dust Seal ..................................................................... 1 ................... 700
Stairway, Boarding .................................................................... 1 ................... 210
Machinery House
Wall, Machinery House R.H. ..................................................... 1 ................ 1,750
Wall, Machinery House Front ................................................... 1 ................ 1,050
Wall, Machinery House L.H. ..................................................... 1 ................ 1,190
Door Assembly, L.H. ................................................................. 1 ................... 140
Cover, Hydraulic ....................................................................... 1 ................ 1,250
Panel, Center Roof ................................................................... 1 ................... 580
Manual No. 10528 1 - 30 Sept. 2007


(U.S. Pounds)
Weldment, L.H. Front Extension .............................................. 1 ................ 8,270

Panel, Rear Roof ...................................................................... 1 ................... 600
Roof, Machinery House Removable ......................................... 1 ................... 430
Roof Section, Machinery House ............................................... 1 ................ 2,030
Hatch, Pressurization Unit Roof ............................................... 1 ................... 350
Enclosure, Dynavane Bleed Fan .............................................. 1 ................... 380
Duct, Pressurization Unit Transition ......................................... 1 ................... 280
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 ................... 150
Hatch, Roof .............................................................................. 1 ................... 350
Blower and Blower Motor ......................................................... 1 ................... 250
Mast Braces
Brace, Mast .............................................................................. 2 ................ 1,560
Sleeve, Mast Brace .................................................................. 2 ................... 710
Support, L.H. Mast Brace ......................................................... 2 ................... 780
Support Arm, R.H. Safety Sling (lower) .................................... 1 .................... 110
Eyebolt ...................................................................................... 2 ................... 150
Pin, Lock ................................................................................... 2 ..................... 20
Cylinder, Brace Lock ................................................................ 2 ..................... 20
Pin, Pivot .................................................................................. 2 ..................... 40
Cylinder, Mast Hoist Hydraulic .................................................. 2 ................ 1,300
Mast Assembly
Mast Assembly with Racks ...................................................... 1 ...............30,610
Mast Structure ...................................................................... 1 ...............26,000
Rack, Pulldown Pinion......................................................... 42 ................... 110
Plate, Mast Bottom ............................................................... 1 ................ 2,000
Gearcase, Pulldown ................................................................. 1 ................ 1,170

Shaft, Pulldown Input ............................................................ 1 ..................... 80
Coupling, Pulldown Input ...................................................... 1 ..................... 60
Shaft, 2nd Intermediate Pulldown ......................................... 1 ................... 150
Gear, 2nd Intermediate Pulldown ......................................... 1 ................... 390
Housing, Encoder ................................................................. 1 ..................... 30
Pinion, First Intermediate ...................................................... 1 ................... 160
Gear, First Intermediate ........................................................ 1 ................... 370
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 ................ 1,020
Sept. 2007 1 - 31 Manual No. 10528


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

Shaft, Intermediate Rotary .................................................... 1 ..................... 80
Gear, Intermediate Rotary .................................................... 1 ................... 100
Gear, Rotary Drive ................................................................ 1 ................... 590
Shaft, Rotary Drive ............................................................... 1 ................... 360
Bearing, Shaft Center ........................................................... 1 ................... 130
Carrier, Lower Bearing ......................................................... 1 ................... 220
Retainer, Bearing .................................................................. 1 ................... 210
Housing, Upper Seal ............................................................ 1 ..................... 40
Carrier, Upper Bearing.......................................................... 1 ..................... 30
Bearing, Shaft Lower ............................................................ 1 ..................... 40
Pinion, Rotary Motor ............................................................. 1 ..................... 60
Motor, Rotary ........................................................................ 1 ................ 2,550
Coupling, Upper Rotary Shock ................................................. 1 ................... 320

Coupling, Lower Rotary Shock ................................................. 1 ................... 670
Retainer, Rotary Shock Coupling ............................................. 1 ..................... 80
Guide Frame (LH) .................................................................... 1 ................ 1,130

Guide Frame (RH) .................................................................... 1 ................ 1,130
Housing, L.H. Mast Guide Roller .......................................... 1 ................... 420
Guide Roller Assembly, Upper .................................................. 2 ................... 150
Guide Roller, Upper .............................................................. 4 ..................... 40
Roller, Guide ..................................................................... 8 ..................... 10
Guide Roller, Lower .................................................................. 2 ..................... 50
Roller, Guide ..................................................................... 4 ..................... 10
Extender, Drill Pipe ................................................................... 1 ................ 1,040

Bushing, Drill Pipe Guide .......................................................... 1 ................... 320
Bushing, Drill Pipe Guide .......................................................... 1 ................... 260
Wrench, Bit .............................................................................. 1 ................... 130
Wrench, Bit .............................................................................. 1 ................... 140
Adapter, 8 in. to 6 in. BECO ..................................................... 1 ................... 140
Tool Wrench ............................................................................. 2 ................... 470
Winch, Hydraulic Driven ........................................................... 1 ................... 420
Hydraulic Cylinder, Rack Position ............................................ 2 ..................... 90
Ladder, Mast ............................................................................. 5 ................... 100
Ladder, Mast Lower .................................................................. 1 ..................... 90
Manual No. 10528 1 - 32 Sept. 2007

Hi-Voltage Auxiliary Main
Disconnect Transformer Transformer Compressor Oil Cooler and Radiator
Water Injection Tank
Leveling Jack,
Left Rear
Service
Jack Pad Ladder
Hydraulic
Oil Cooler
Leveling Jack,
Pipe Rack Hi Voltage
Left Front
Compressor Programmable Rotary Drive Hoist/Pulldown
Deck Start Low Voltage Controller Control Drive Control
Bushing Cabinet Cabinet Cabinet Cabinet Cabinet Jack Pad
Main Air Compressor House Ventilation
C Main Loadcenter
L Machine & Filter Assembly Main Air Filter & Fan
and Air Electro/Hydraulic Butterfly Valve
Deck Bushing Pipe Valves
Tool Wrench Bit

Lubricator
A-Frame Jack Pad
Hydraulic Pumps Main Drive

Panelview Mast and Gearcase Motor Separator
Propel Leveling Jack,
Hydraulic Right Front
Control Main Oil Tank
Panels Walkway, Right Boarding Stairs Auto Lube
Leveling Reservoir
Leveling Jack,
Jack Pad Right Rear
Operator’s Operator’s Front of Machine
Cab Seat
C
L Deck Bushing BUCYRUS R
49HR Deck Plan

Lot 86, sn: 141218
141218_D.cdr
Section 2
Operation
Always refer to the safety information in Section 1 of this manual before
starting any maintenance procedure on this machine.
Table of Contents
GENERAL INFORMATION ............................................................................................................ 5

OPERATION NEAR ELECTRICAL TRANSMISSION LINES ................................................... 5
CONTROLS - LOCATION AND FUNCTION ................................................................................ 6
OPERATOR’S CONTROL CONSOLE ......................................................................................... 7
OPERATOR’S CONTROL CONSOLE - OVERVIEW ................................................................... 7
MAIN CONTROL PANEL ......................................................................................................... 8
MAIN CONTROL PANEL - OVERVIEW ...................................................................................... 8
HOIST/PULLDOWN RHEOSTAT ...................................................................................... 8
ROTARY RHEOSTAT ....................................................................................................... 9
DRILL/PROPEL CONTROLS ON AND OFF PUSH-BUTTON ......................................... 9
HOIST/PULLDOWN SPEED SELECTOR SWITCH ...................................................... 10
ROTARY SPEED SELECTOR SWITCH ........................................................................ 10
HOIST BRAKE SWITCH ................................................................................................. 11
PIPE RACK SELECTOR SWITCH ................................................................................. 11
PIPE RACK JOYSTICK (LEFT CRAWLER PROPEL) ................................................... 11
WINCH/MAST SELECTOR SWITCH .............................................................................. 12
MAST/WINCH JOYSTICK (RIGHT CRAWLER PROPEL) .............................................. 12
TOOL WRENCH SWITCH .............................................................................................. 13
DUST CURTAIN SWITCH ............................................................................................... 13
BIT VIEW HATCH SWITCH ............................................................................................. 13
PROPEL CONTROL PANEL ................................................................................................ 14
PROPEL CONTROL PANEL - OVERVIEW ............................................................................... 14
EMERGENCY STOP PUSH-BUTTON (OPTIONAL) ...................................................... 14
PROPEL SPEED SELECTOR SWITCH ........................................................................ 15
COMPRESSOR STOP PUSH-BUTTON ........................................................................ 15
COMPRESSOR VENT/DRILL SWITCH ......................................................................... 15
HEATER/VENT/AIR CONDITIONER CONTROLS .......................................................... 15
OPERATING MODE SELECTOR SWITCH .................................................................... 15
PROPEL JOYSTICKS ..................................................................................................... 16
SELECTOR SWITCH PANEL ............................................................................................... 16
SELECTOR SWITCH PANEL - OVERVIEW ............................................................................. 16
BREAKOUT WRENCH SWITCH .................................................................................... 17
PIPE POSITIONER SWITCH (OPTIONAL) .................................................................... 17
DUST SEAL SWITCH (OPTIONAL) ................................................................................ 17
A-FRAME LOCK SWITCH (OPTIONAL) ......................................................................... 17
MAST BRACE LOCK SWITCH ....................................................................................... 17
MAST LOCK SWITCH .................................................................................................... 18
Sept. 2007 2-1 Manual No. 10528

BOARDING STAIRS SWITCH ......................................................................................... 18

PEDESTAL HEATER SWITCH (OPTIONAL) .................................................................. 18
FIRE SUPPRESSION SYSTEM INDICATORS (OPTIONAL) .......................................... 18
RADIO (OPTIONAL) ........................................................................................................ 18
LEVELING CONTROL PANEL .............................................................................................. 19
LEVELING CONTROL PANEL ................................................................................................... 19
MANUAL LEVELING JOYSTICKS .................................................................................... 20
AUTOMATIC LEVELING SWITCH ................................................................................... 20
WATER INJECTION ON/OFF SWITCH (OPTIONAL)..................................................... 20
WATER INJECTION FLOW CONTROL (OPTIONAL) .................................................... 20
HORN PUSH-BUTTON ................................................................................................... 21
DEPTH INDICATOR RESET PUSH-BUTTON ................................................................ 21
PROGRAMMED DRILL CONTROL SWITCH ................................................................. 21
EMERGENCY STOP PUSH-BUTTON (OPTIONAL) ...................................................... 21
OPERATOR’S DISPLAY TERMINAL ..................................................................................... 22
OPERATOR’S DISPLAY PANEL ................................................................................................ 22
MACHINERY HOUSE CONTROLS ...................................................................................... 23
LIGHTING LOAD CENTER .............................................................................................. 23
LIGHTING LOAD CENTER ........................................................................................................ 23
CONTROLS LOCATED ON LOW VOLTAGE START CABINET .................................... 24
TYPICAL LOW VOLTAGE START CABINET ............................................................................ 24
CONTROLS LOCATED ON LOW VOLTAGE CABINET ................................................. 24
TYPICAL LOW VOLTAGE CABINET ......................................................................................... 24
CONTROL LOCATED ON PROGRAMMABLE CONTROLLER CABINET ..................... 25
TYPICAL PROGRAMMABLE CONTROL CABINET ................................................................... 25
HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS ............................... 25
TYPICAL HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS ........................... 25
MISCELLANEOUS CONTROLS ..................................................................................... 26
PORTABLE REMOTE PROPEL STATION (OPTIONAL) ................................................ 26
PORTABLE REMOTE PROPEL STATION ................................................................................. 26
HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL ...................................... 27
HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL ................................................... 27
LUBE CONTROL PANEL ................................................................................................ 27
LUBE CONTROL PANEL ........................................................................................................... 27
PRESTART CHECKS ................................................................................................................. 28
EXTERNAL INSPECTION ..................................................................................................... 28
ONBOARD INSPECTION ..................................................................................................... 30
PRESTART LUBRICATION ......................................................................................................... 32
START-UP ................................................................................................................................... 33
MACHINE START UP ............................................................................................................ 33
MACHINERY CHECK ...................................................................................................... 34
BREAK-IN OF NEW COMPONENTS ............................................................................. 34
ROTARY DRIVE UNIT BREAK-IN ............................................................................. 34
HOIST/PULLDOWN GEARCASE BREAK-IN ........................................................... 34
ELECTRIC MOTOR BREAK-IN ................................................................................ 34
Manual No. 10528 2-2 Sept. 2007

OPERATION ............................................................................................................................... 35
PROPELLING ....................................................................................................................... 35
DEFINITIONS .................................................................................................................. 35
PROPEL PROCEDURE ................................................................................................. 36
PROPEL CONTROLS - OVERVIEW ......................................................................................... 37
STRAIGHT PROPEL ................................................................................................................. 38
GRADUAL RIGHT HAND TURN ................................................................................................. 38
GRADUAL LEFT HAND TURN ................................................................................................... 39
COUNTER-ROTATION LEFT HAND TURN ................................................................................ 40
ENSURE GRADUAL TURNS ARE MADE - 15O INCREMENTS ............................................... 40
TOWING PROCEDURE ................................................................................................. 42
TOWING PROCEDURE ............................................................................................................. 42
CABLE REEL OPERATION .................................................................................................. 44
CABLE REEL ............................................................................................................................ 44
LEVELING ............................................................................................................................. 45
LEVELING CONTROLS ............................................................................................................. 46
MAST RAISING AND LOWERING ......................................................................................... 47
MAST RAISING ................................................................................................................ 47
MAST RAISING/LOWERING CONTROLS ................................................................................. 48
MAST LOWERING .......................................................................................................... 49
MAST CONTROLS TO ADJUST FOR ANGLE DRILLING .......................................................... 49
PULLDOWN MACHINERY OPERATION .............................................................................. 51
HOIST/PULLDOWN CONTROLS ............................................................................................... 51
AUXILIARY WINCH OPERATION .......................................................................................... 52
WINCH OPERATION CONTROLS ............................................................................................. 52
PIPE RACK OPERATION ............................................................................................... 53
PIPE RACK OPERATING CONTROLS ...................................................................................... 53
PIPE RACK OPERATION .......................................................................................................... 54
TOOL HANDLING .................................................................................................................. 56
PIPE LOADING AND UNLOADING .................................................................................. 56
DRILL TOOL STRING ASSEMBLY .................................................................................. 58
TOOL STRING .......................................................................................................................... 58
STABILIZER INSTALLATION ..................................................................................................... 59
DRILL PIPE INSTALLATION CONTROLS .................................................................................. 59
BREAKOUT WRENCH OPERATION ................................................................................... 62
DRILL TOOL STRING DISASSEMBLY .................................................................................. 64
ADDING ADDITIONAL DRILL PIPE .................................................................................. 66
REMOVAL OF MULTIPLE SECTION DRILL PIPE ........................................................... 67
ANGLE DRILLING ................................................................................................................. 68
ANGLE DRILLING EQUIPMENT ................................................................................................ 68
PIPE POSITIONER ................................................................................................................... 69
JIB CRANE ................................................................................................................................ 70
DUST SUPPRESSION SYSTEM OPERATION .................................................................... 71
WATER INJECTION SYSTEM .................................................................................................. 72
Sept. 2007 2-3 Manual No. 10528

DRILLING .............................................................................................................................. 73
VERTICAL DRILLING ...................................................................................................... 73
CONTROLS UTILIZED WHILE DRILLING ................................................................................. 73
STARTING THE HOLE (COLLARING) ...................................................................... 74
NORMAL DRILLING ................................................................................................... 76
ENDING THE HOLE .................................................................................................. 77
ENDING THE HOLE (MULTIPLE PIPE SECTIONS) ................................................. 78
DRILLING DIFFICULT FORMATIONS ............................................................................. 78
UNCONSOLIDATED MATERIALS ................................................................................... 79
WET OR STICKY FORMATIONS ......................................................................................... 81
ANGLE DRILLING ................................................................................................................. 82
PROGRAMMED DRILL CONTROL DRILLING ..................................................................... 83
PROGRAMMED DRILL CONTROLS UTILIZED ......................................................................... 83
PREPARING TO MOVE .................................................................................................. 84
MACHINE SHUTDOWN ........................................................................................................ 86
SHUT DOWN PROCEDURE ................................................................................... 86
SHORT TERM STORAGE ........................................................................................ 87
LONG TERM STORAGE ........................................................................................... 88
ATTENDED LONG TERM STORAGE ...................................................................... 89
UNATTENDED LONG TERM STORAGE .................................................................. 89
TOOL RECOVERY ..................................................................................................................... 90
DRILL STABILITY CHARTS ................................................................................................... 92
Manual No. 10528 2-4 Sept. 2007

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.
Sept. 2007 2-5 Manual No. 10528

• 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 he can begin to operate the machine.
Since this manual covers all possible controls that could be used on this machine, he should
familiarize himself with both this manual and the particular machine being operated.
For the purpose of this manual, the operating controls have been divided into three groups,
depending upon their location. These three groups are:
1. Operator’s Console Controls

2. Machinery House Controls
3. Miscellaneous Controls
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.
Manual No. 10528 2-6 Sept. 2007

OPERATOR’S CONTROL CONSOLE
NOTE: The controls on the operators console are all electric. The switches operate electric
controls, electromechanical or electrohydraulic valves on the machine. For purpose of
describing the controls, the console will be broken down into panels and the controls
on each panel described. The panels of the console are: main controls, propel
controls, selector switches, leveling controls and Operator’s display terminal.
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.
Sept. 2007 2-7 Manual No. 10528

MAIN CONTROL PANEL
MAIN CONTROL PANEL - OVERVIEW
HOIST/PULLDOWN RHEOSTAT
The hoist/pulldown rheostat (1) 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.
Manual No. 10528 2-8 Sept. 2007

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.
ROTARY RHEOSTAT
The rotary rheostat (2) controls the speed and direction of the rotary motor which in turn drives the
machinery to rotate the tool string.
Turning the rheostat clockwise from the “0” position will turn the tool string in a clockwise direction.
Maximum rotary speed is achieved at full clockwise position.
Turning the rheostat counterclockwise from the “0” position will turn the tool string in the reverse
direction. Maximum rotary speed is achieved 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.
DRILL/PROPEL CONTROLS ON AND OFF PUSH-BUTTON
The drill/propel controls on (3) and off (4) push-buttons are used to energize or de-energize the
control levers and switches of the machine.
When the operating mode selector switch is in the DRILL position, pressing the ON push-button
will energize the hoist/pulldown and rotary drives if all appropriate circuit breakers are closed; no
drive or power system faults exist, and master switches are in NEUTRAL.
When the operating mode selector switch is in the PROPEL position, pressing the ON push-button
will enable the propel controls if all appropriate circuit breakers are closed, compressor motor is
operating normally, and no power system faults exist.
When the operating mode selector switch is in the REMOTE position the ON and OFF push-
buttons are not functional.
Sept. 2007 2-9 Manual No. 10528

HOIST/PULLDOWN SPEED SELECTOR SWITCH
The hoist/pulldown speed selector switch (5) is located above the hoist/pulldown rheostat and is
used to determine the speed range of the hoist/pulldown rheostat. The switch is a four-position
switch with the following designations: PULLDOWN, HOIST HIGH, HOIST LOW, 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 HIGH and HOIST LOW 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 65 FPM [19.8 MPM]).
In the HOIST HIGH position maximum head speed capability is allowed for both hoisting and
lowering. However, force capability in the lowering direction is limited to the weight of the rotary
head/pipe combination. No additional downforce is allowed to the drive which reduces the chance
of equipment damage during lowering operation.
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.
In the PIPE RACK/JOINT position, the hoisting and lowering force capabilities are the same as
those when the switch is in the HOIST HIGH position. However, the speed limit is reduced to 25-
35 FPM (7.62-10.67 MPM). 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.
ROTARY SPEED SELECTOR SWITCH
The rotary speed selector switch (6) 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.
Manual No. 10528 2 - 10 Sept. 2007

HOIST BRAKE SWITCH
The hoist brake switch (7) is a two-position switch. It is 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 rotary head assembly. Placing the switch into the SET position during machine operation
immediately disables hoist/pulldown drive operation.
Under normal operating conditions, the hoist/pulldown speed rheostat must be set to “0” before
setting the brake.
PIPE RACK SELECTOR SWITCH
The pipe rack selector switch (8) 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.
PIPE RACK JOYSTICK (Left Crawler Propel)
This joystick (9) will operate the pipe rack or the left crawler (secondary propel control). For the
joystick to control the pipe rack, the operating mode selector switch on the propel control panel
must be in the DRILL position and the hoist/pulldown speed selector switch (5) in the PIPE RACK/
JOINT position.
For the joystick to control the left crawler the operating mode selector switch on the propel control
panel must be in the SECONDARY PROPEL position.
Full forward or rearward movement of the joystick will supply the fastest motion.
This switch is equipped with a lock feature. To move the switch out of the NEUTRAL position the
switch knob must be lifted.
Sept. 2007 2 - 11 Manual No. 10528

WINCH/MAST SELECTOR SWITCH
The winch/mast selector switch (10) is a two-position switch. Turning the switch to the WINCH
position will activate the winch circuit. The joystick associated with this switch can then be used to
operate the winch. Turning the switch to the MAST position will activate the mast hoist cylinder
circuit and the associated joystick is used to raise or lower the drill mast.
When the machine is equipped with winch remote control, this switch has four positions. These
positions are OFF, REMOTE WINCH, CONSOLE WINCH, and MAST. The REMOTE WINCH and
CONSOLE WINCH positions determine whether winch is controlled at the remote station or the
operator’s console.
The switch is operational only when the operating mode selector switch on the propel control panel
is in the DRILL position, the air compressor motor is running, and NO leveling jacks are being
operated.
MAST/WINCH JOYSTICK (Right Crawler Propel)
This joystick (11) is used to raise or lower the mast, operate the auxiliary winch or right crawler.
For the joystick to control the mast raising and lowering operation, the operating mode selector
switch on the propel control panel must be in the DRILL position and the mast/winch selector
switch (10) must be in the MAST position.
For the joystick to control the auxiliary winch, the operating mode selector switch on the propel
control panel must be in the DRILL position and the mast/winch selector switch (10) must be in the
WINCH position.
For the joystick to control the right crawler, the operating mode selector switch on the propel
control panel must be in the SECONDARY PROPEL position.
Pushing the joystick lever forward will either raise the mast, raise the auxiliary winch line or propel
the right crawler in the forward direction.
Pulling the joystick lever to the rear will either lower the mast or auxiliary winch line or propel the
right crawler in the reverse direction.
Full forward or rearward movement of the joystick will supply the fastest motion.
This switch is equipped with a lock feature. To move the switch out of the NEUTRAL position the
Manual No. 10528 2 - 12 Sept. 2007

TOOL WRENCH SWITCH
The tool wrench switch (12) is a three-position spring return switch. Turning the switch to the
EXTEND position will cause the tool wrench to extend to clamp the drill pipe. Turning the switch to
the RETRACT position will retract the wrench, releasing the drill pipe. This switch is functional
whenever the hydraulic pumps are running.
DUST CURTAIN SWITCH
The dust curtain switch (13) is a three-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.
In the AUTO position, the curtains are raised automatically when the operating mode selector
switch on the propel control panel is in the PRIMARY PROPEL, SECONDARY PROPEL, or
REMOTE PROPEL position. The curtains are not lowered automatically, but must be lowered by
moving the switch to the LOWER position.
BIT VIEW HATCH SWITCH
This is a two-position switch (14) that 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.
Sept. 2007 2 - 13 Manual No. 10528

PROPEL CONTROL PANEL
1. Emergency Stop Pushbutton

2. Propel Speed Selector Switch
3. Compressor Stop Pushbutton
4. Compressor Vent/Drill Switch
5. HVAC Mode Selector Switch
6. HVAC Fan Speed Selector Switch
7. Operating Mode Selector Switch
8. Propel RH Crawler Joyswitch
9. Propel LH Crawler Joyswitch
PROPEL CONTROL PANEL - OVERVIEW
EMERGENCY STOP PUSH-BUTTON (Optional)
The emergency stop push-button (1) on the propel control panel 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 electrical and
immediate mechanical braking. This button should therefore only be used if the operator intends
the harshest braking for all motions.
CAUTION: PRESSING THIS BUTTON WHEN ANY DRIVE IS IN MOTION MAY

RESULT IN COMPONENT DAMAGE.
Manual No. 10528 2 - 14 Sept. 2007

PROPEL SPEED SELECTOR SWITCH
This two-position switch (2) is used to set the propel speed. In the SLOW position, the propel is in
the low speed range (about 30% 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.
COMPRESSOR STOP PUSH-BUTTON
This push-button (3) is used to shutdown the compressor motor. The compressor will have to be
restarted from the machinery house.
COMPRESSOR VENT/DRILL SWITCH
This switch (4) is used to open or close the butterfly valve in the compressor discharge line. In the
VENT position, the butterfly valve will close and the compressor will unload and vent air to the
atmosphere. In the DRILL position, the butterfly valve will be opened and the air will be routed to the
drill bit to bail the hole of cuttings.
HEATER/VENT/AIR CONDITIONER CONTROLS
The heater/vent/air conditioner controls consist of two (2) four-position switches (5 & 6).
One switch (5) selects the mode being used and has the following positions: OFF, FAN, HEAT, and
COOL.
The other switch (6) controls fan speed for vented air and circulated air. The four positions are:
VENT HIGH, VENT LOW, CIRCULATE HIGH, and CIRCULATE LOW.
OPERATING MODE SELECTOR SWITCH
The operating mode selector switch (7) is a four-position switch. Turning the switch to the DRILL
position will allow the drill controls of the machine to be operated. Turning the switch to the PRIMARY
PROPEL position will allow the propel joystick controls on this panel to control the propelling
motion of the machine. Turning the switch to the SECONDARY PROPEL position will allow the
propel joysticks on the Main Control Panel to control the propelling motion of the machine. Turning
the switch to the REMOTE PROPEL position enables the optional portable remote propel control
function.
Sept. 2007 2 - 15 Manual No. 10528

PROPEL JOYSTICKS
For the joysticks (8 & 9) to control the crawlers, the operating mode selector switch (7) must be in
the PRIMARY PROPEL position.
Pushing the right (8), left (9), or both joystick levers forward will cause the machine to move
forward, straight, right, or left, depending upon which lever(s) were pushed.
Moving the levers to the rear will cause the machine to move rearward, straight, right, or left,
depending upon which lever(s) were moved.
Full forward or rearward movement of the joystick levers will supply the fastest motion.
The joysticks are equipped with a lock feature. To move the levers out of NEUTRAL position, the
SELECTOR SWITCH PANEL
SELECTOR SWITCH PANEL - OVERVIEW
Manual No. 10528 2 - 16 Sept. 2007

BREAKOUT WRENCH SWITCH
The breakout wrench switch (1) is a three-position spring-return switch. Turning the switch to the
EXTEND position will cause the breakout wrench to extend, grip the pipe and turn, breaking the
pipe joint. Turning the switch to the RETRACT position will retract the breakout wrench arm and
then retract the breakout wrench, away from the pipe.
PIPE POSITIONER SWITCH (Optional)
The pipe positioner switch (2) 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. This switch is functional
whenever the hydraulic pumps are running.
DUST SEAL SWITCH (Optional)
This is a three-position spring-return switch (3) 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 forward 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.
A-FRAME LOCK SWITCH (Optional)
The A-frame lock switch (4) is a three-position spring-return switch. Turning the switch to the
LOCK position will extend the A-frame lock pin cylinder. Turning the switch to the UNLOCK position
will retract the cylinder. For this switch to be functional, the hydraulic pumps must be running, the
mast/winch selector switch must be in a vertical position with mast lock pins in place. When the
machine is drilling at an angle, these pins are in the UNLOCKED position. This switch is only used
in machines equipped with the angle hole drilling package.
MAST BRACE LOCK SWITCH
The mast brace lock switch (5) is a three-position spring-return switch. Turning the switch to the
LOCK position will extend the mast brace lock pin cylinder. Turning the switch to the UNLOCK
Sept. 2007 2 - 17 Manual No. 10528

position will retract the cylinder. For this switch to be operable, the hydraulic pump must be running
and the mast/winch selector switch must be in the MAST position. This will allow the switch to
function in the LOCK position. To function in the UNLOCK position, the rotary head assembly must
be at the lower limit point. This additional restriction, of having the rotary head assembly at the
lower limit, is not required for machines with the angle hole drilling feature.
MAST LOCK SWITCH
The mast lock switch (6) is a three-position spring-return switch. Turning the switch to the LOCK
position will extend the mast lock cylinder. Turning the switch to the UNLOCK position will retract
the cylinder. Before this switch can become operable the hydraulic pumps must be running and
the mast/winch selector switch must be in the MAST position. For the switch to be functional in the
UNLOCK position, the rotary head assembly must be at the lower limit point. On machines with the
angle hole drilling feature, the A-frame locking pins must also be in place before this switch can
become operable.
BOARDING STAIRS SWITCH
The boarding stairs switch (7) is a two-position switch. A like 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.
PEDESTAL HEATER SWITCH (Optional)
The pedestal heater switch (8) is a two-position switch used to turn the heater ON or OFF.
FIRE SUPPRESSION SYSTEM INDICATORS (Optional)
The fire suppression system indicators (9) show the status of the fire suppression system.
RADIO (Optional)
The radio (10) is optional equipment.
Manual No. 10528 2 - 18 Sept. 2007

LEVELING CONTROL PANEL
LEVELING CONTROL PANEL
The leveling portion of the panel consists of four two-directional joysticks, one for each leveling jack
cylinder and an automatic leveling switch.
Sept. 2007 2 - 19 Manual No. 10528

MANUAL LEVELING JOYSTICKS
The four two-directional joysticks (1, 2, 3, & 4) are used to manually raise or lower the leveling
jacks. Moving a joystick forward will extend the corresponding jack cylinder and raise that corner
of the machine. Pulling the joystick toward the operator will retract the corresponding leveling jack
cylinder and lower that corner of the machine. These joysticks are not functional if the automatic
leveling switch is being used.
NOTE: The joysticks should be moved in pairs. Single joysticks may be used for the final
adjustment of leveling jacks. All four leveling jack joysticks should not be moved at the
same time.
AUTOMATIC LEVELING SWITCH
The automatic leveling switch (5) is a three-position spring return switch. Turning the switch to the
EXTEND position will extend the leveling jack cylinders and raise the machine. Turning the switch
to the RETRACT position will retract the cylinders and lower the machine. When this switch is
being used, the manual leveling joysticks 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.
WATER INJECTION ON/OFF SWITCH (Optional)
The water injection on/off switch (6) is a two-position switch used to start-up or shut-off the water
injection system. When the switch is turned to the OFF position, it will stop the pump.
When the machine is equipped with a deck washdown system, this switch has an additional position
designated WASHDOWN. When the switch is in the WASHDOWN position, water to the main air
pipe is shutoff and all water is directed to the washdown system on the deck.
WATER INJECTION FLOW CONTROL (Optional)
The water injection flow control (7) is a potentiometer used to regulate the water flow. Full
counterclockwise rotation of the control will shut-off water flow. Full clockwise rotation of the control
will supply maximum flow of water.
Manual No. 10528 2 - 20 Sept. 2007

HORN PUSH-BUTTON
The horn push-button (8) is used to sound the warning horn of the machine.
DEPTH INDICATOR RESET PUSH-BUTTON
The depth indicator reset push-button (9) is used to zero out the depth meter, as shown on the
Operator’s display terminal Operator’s Display screen, when one hole is completed and another is
to be started. This function can also be performed on the operator’s display terminal keypad.
PROGRAMMED DRILL CONTROL SWITCH
The programmed drill control switch (10) is used to activate or deactivate the programmed drill
control system on the machine. This function can also be performed on the operator’s display
terminal keypad.
EMERGENCY STOP PUSH-BUTTON (OPTIONAL)
The emergency stop push-button (11) on the leveling control panel 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 electrical and
immediate mechanical braking. This button should therefore only be used if the operator intends
the harshest braking for all motions.
CAUTION: PRESSING THIS BUTTON WHEN ANY DRIVE IS IN MOTION MAY

RESULT IN COMPONENT DAMAGE.
Sept. 2007 2 - 21 Manual No. 10528

OPERATOR’S DISPLAY TERMINAL
The Operator’s Display Terminal consists of an active matrix display, keypads and industrial
computer (PC).
OPERATOR’S DISPLAY PANEL
The operator’s Display Terminal displays status information for all PLC controlled machine functions.
Some machine setup parameters may be entered using the keypad.
Refer to a separate manual for further operational procedures for the Operator’s Display Terminal.
Manual No. 10528 2 - 22 Sept. 2007

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 right 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.
Sept. 2007 2 - 23 Manual No. 10528

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.
TYPICAL LOW VOLTAGE START CABINET
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.
TYPICAL LOW VOLTAGE CABINET
Manual No. 10528 2 - 24 Sept. 2007

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
Sept. 2007 2 - 25 Manual No. 10528

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.
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
Manual No. 10528 2 - 26 Sept. 2007

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
LUBE CONTROL PANEL
The Lube control panel is located next to the lube pump station in the machinery house and contains
the controls as shown.
LUBE CONTROL PANEL
Sept. 2007 2 - 27 Manual No. 10528

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 s i n g l e
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.
Manual No. 10528 2 - 28 Sept. 2007

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.
Sept. 2007 2 - 29 Manual No. 10528

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.
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 and change or refill drums as necessary.
Manual No. 10528 2 - 30 Sept. 2007

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.
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
Sept. 2007 2 - 31 Manual No. 10528

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.
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.
Manual No. 10528 2 - 32 Sept. 2007

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. Turn the house pressurization fan switch to the desired operating
position. Verify that the operator’s display terminal power supply, PLC input and PLC output
breakers are in the ON 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.
Sept. 2007 2 - 33 Manual No. 10528

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
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.
Manual No. 10528 2 - 34 Sept. 2007

OPERATION
Operation of this machine is the same as the operation of any other blasthole 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.
Sept. 2007 2 - 35 Manual No. 10528

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 (see APPENDIX 5).
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: The drill should only be propelled 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.
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 Bucyrus International, Inc.
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.
Manual No. 10528 2 - 36 Sept. 2007

PROPEL CONTROLS - OVERVIEW
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 PRIMARY PROPEL, SECONDARY PROPEL,
or to 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 and normal. 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.
Sept. 2007 2 - 37 Manual No. 10528

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
6. To make a gradual forward right turn, leave the right joystick in neutral and operate the left
joystick forward.
GRADUAL RIGHT HAND TURN
Manual No. 10528 2 - 38 Sept. 2007

GRADUAL LEFT HAND TURN
7. To make a gradual forward left turn, leave the left joystick in neutral and operate the right
joystick forward.
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.
Sept. 2007 2 - 39 Manual No. 10528

COUNTER-ROTATION LEFT HAND TURN
9. To make a sharp right (counter-rotation) turn, push the left joystick forward and pull the right
joystick to the rear. To make a sharp left turn, push the right joystick forward and pull the left
joystick to the rear.
ENSURE GRADUAL TURNS ARE MADE - 15O 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.
Manual No. 10528 2 - 40 Sept. 2007

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 turn sharply 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.
Sept. 2007 2 - 41 Manual No. 10528

TOWING PROCEDURE
CAUTION: Be sure crawlers are securely blocked before disengaging gearbox

clutch for towing.
1. Secure the machine by blocking crawlers.
2. Secure the tow bar to the towing vehicle.
TOWING PROCEDURE
3. Fasten a lanyard to the towing safety valve lever. The valve is mounted to the left front jack
casing. Run the lanyard down the casing, along the tow bar and secure it to the towing
vehicle. If during towing the tow bar should come loose from either the drill or the towing
vehicle, the lanyard will trip the safety valve and set the drill propel brakes.
4. Disconnect the drive tumbler gearbox from the propel motor as follows:
a. Ensure that the propel pump controls are in neutral position

b. Loosen shifter lever lock screw
c. Pull out shifter lever to disengage clutch
d. Tighten shifter lever lock screw
Manual No. 10528 2 - 42 Sept. 2007

5. Use the hand pump mounted to the right front jack casing. Pump the jack until 1,500 PSI
(10,350 kPa) shows on the gauge near the pump.
NOTE: Anytime pressure drops below 800 PSI (5,520 kPa), brakes could drag resulting in
premature brake failure.
NOTE: Do not tow at speeds greater than 1.1 mph (1.8 kph) Excessive planetary gearbox
heating can occur.
6. When towing is completed, reverse the above procedure. The hand pump pressure can be
released by turning the release valve on the pump.
Sept. 2007 2 - 43 Manual No. 10528

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:
CABLE REEL
1. Start the main air compressor motor or turn ON the external cable reel switch. This will
automatically start the cable reel hydraulic system motor. Allow the oil to circulate for about 5
minutes.
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.
Manual No. 10528 2 - 44 Sept. 2007

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.
Sept. 2007 2 - 45 Manual No. 10528

4. To level the machine manually, use the four joysticks and the automatic leveling screen on the
operator’s display terminal. The operator is seated at the control console as they operate the
joystick controls and at the same time observes the operator’s display terminal 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 levelling 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.
LEVELING CONTROLS
Manual No. 10528 2 - 46 Sept. 2007

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 Bucyrus Service Department if
unsure of slope limitation for propelling.
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.
Sept. 2007 2 - 47 Manual No. 10528

2. The main air compressor motor must be energized. Move the winch/mast selector switch to
the MAST position. Slowly raise the mast by lifting and then slowly pushing the mast/winch
joystick, located on the main control panel, 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.
MAST RAISING/LOWERING CONTROLS
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 to the LOCK position to lock the mast
in the vertical position. Return the lever to the neutral position when the latch is in position.
Blinking (Mast Pins Out) on operator’s display terminal operator’s display screen will disappear
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.
Manual No. 10528 2 - 48 Sept. 2007

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 Out and Mast Brace Pin Out) will show up on the bottom
of operator’s display screen of the operator’s display terminal.
5. Verify that the winch/mast selector switch is still in the mast 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.
MAST LOWERING
NOTE: Refer to cautions at beginning of mast raising.
To lower the mast:
1. 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. Verify that the machine is level.
2. Check the condition of the mast hinge pins, lugs and cylinder pins.
3. 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.
MAST CONTROLS TO ADJUST FOR ANGLE DRILLING
Sept. 2007 2 - 49 Manual No. 10528

4. Turn the mast brace lock switch to the UNLOCK position to release the mast lock pins, then
raise the mast to the vertical position (figure 4-13). Turn the A-frame lock switch to the LOCK
position to lock the A-frame front leg. The readout (A-frame Pins Out) on the operator’s display
terminal will disappear when the A-frame pins are in the LOCKED position. Now proceed to
step 5 to lower the mast.
5. 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. A blinking readout (Mast Pins Out and Mast
Brace Pins Out) will appear on the operator’s display terminal when the pins are released.
6. Slowly lower the mast by lifting and then pulling the joystick to the rear (figure 4-13). 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.
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.
7. 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.
Manual No. 10528 2 - 50 Sept. 2007

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.
HOIST/PULLDOWN CONTROLS
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. “Pulldown” readout will show on the operator’s
display terminal operator’s display screen.
4. Turn the hoist brake switch to the RELEASE position. “Head Brake Released” will appear on
operator’s display terminal 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.
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.
Sept. 2007 2 - 51 Manual No. 10528

7. When the hoist/pulldown operations are complete, set the hoist/pulldown speed rheostat to
the “0” position and then turn the hoist brake switch to the SET position.
CAUTION: Whenever the hoist/pulldown speed rheostat is in the “0” 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:
WINCH OPERATION CONTROLS
1. Place the winch/mast control selector switch in the WINCH position.
2. Place the operating mode selector switch in the DRILL position.

The main air compressor must be energized.
3. To hoist the auxiliary winch line, lift and move the mast/winch
joystick, located on the main control panel, forward. To stop the
line, return the joystick to the NEUTRAL position.
4. To lower the winch line, lift and move the joystick rearward. To
stop the line, return the joystick to the NEUTRAL position.
Manual No. 10528 2 - 52 Sept. 2007

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.
PIPE RACK OPERATING CONTROLS
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 main control panel, out of neutral to
perform the desired operation.
Sept. 2007 2 - 53 Manual No. 10528

PIPE RACK OPERATION
Manual No. 10528 2 - 54 Sept. 2007

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.
Sept. 2007 2 - 55 Manual No. 10528

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.
CAUTION: Limitations exist as to the length, diameter, wall thickness and

number of drill pipes that may be stored in the tool racks when
raising or lowering the mast. Refer to the pipe size limitation chart in
the appendix of this manual before loading pipe onto the machine
with themast down and before raising or lowering 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.
Refer to the appendix of this manual for an alternate method of
loading and unloading pipe from the machine in order to comply with
the mast raising and lowering limitations.
Manual No. 10528 2 - 56 Sept. 2007

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.
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.
Sept. 2007 2 - 57 Manual No. 10528

10. Repeat the procedure for additional lengths of pipe.
11. Unloading the pipe is the reverse of the procedure used for loading the pipe.
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
Manual No. 10528 2 - 58 Sept. 2007

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
DRILL PIPE INSTALLATION CONTROLS
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.
Sept. 2007 2 - 59 Manual No. 10528

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. Press the drill/propel control ON push-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 rearward (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.
Manual No. 10528 2 - 60 Sept. 2007

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 forward 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
drill/propel control OFF push-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.
Sept. 2007 2 - 61 Manual No. 10528

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 drill/propel control OFF push-button. The tool string is now
complete for single pass drilling or for the first pass of multiple pass drilling.
BREAKOUT WRENCH OPERATION
CAUTION: When working with the breakout wrench it is important that the hoist
brake be set, the drill/propel control OFF push-button be pressed 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.
Manual No. 10528 2 - 62 Sept. 2007

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 EXTEND position. Make sure the lower tool is
held securely by the tool wrench and that the slots in the tool are aligned with the tool wrench
jaws.
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.
Sept. 2007 2 - 63 Manual No. 10528

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 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 drill/propel control OFF push-button 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.
Manual No. 10528 2 - 64 Sept. 2007

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.
After indexing the pipe to allow the one-half turn rotation, repeat step 6 above to break the joint.
Repeat this procedure as many times as is necessary 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.
Sept. 2007 2 - 65 Manual No. 10528

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 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, 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 tool
wrenches. This allows the drill pipe to rotate almost one-half turn before being stopped by the
tool wrenches. The spring loaded inserts in the tool wrench allow the pipe to rotate while
being clamped by the wrench.
After indexing the pipe to allow the one-half turn rotation, repeat step 3 above to break the joint.
Repeat this procedure as many times as is necessary 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.
Manual No. 10528 2 - 66 Sept. 2007

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.
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. Unclamp 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.
Sept. 2007 2 - 67 Manual No. 10528

ANGLE DRILLING
ANGLE DRILLING EQUIPMENT
Manual No. 10528 2 - 68 Sept. 2007

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.
Sept. 2007 2 - 69 Manual No. 10528

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: THE CASING 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 30 DEGREES
THE CRANE SHOULD BE EXTENDED TO THE 6.5 FOOT POSITION.
JIB CRANE
Manual No. 10528 2 - 70 Sept. 2007

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 insure proper cleaning of the filter elements.
Sept. 2007 2 - 71 Manual No. 10528

WATER INJECTION SYSTEM
Manual No. 10528 2 - 72 Sept. 2007

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 30 degrees). This section of the Operator’s Manual details the
procedures involved in the drilling of vertical holes.
CONTROLS UTILIZED WHILE DRILLING
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.
Sept. 2007 2 - 73 Manual No. 10528

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.
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 drill/propel control ON push-
button. 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 compressor
vent/drill switch in the DRILL position to supply bailing air to the bit.
Manual No. 10528 2 - 74 Sept. 2007

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.
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 (30 PSI for machines with water
injection and 40 PSI for machines with dry-type dust control) 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.
Sept. 2007 2 - 75 Manual No. 10528

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. 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 (30 PSI [206.85 kpa] for machines with water
injection and 40 PSI [275.8 kpa] for machines with dry-type dust control) indicate that the hole is
starting to plug with cuttings. Stop the pulldown by returning the hoist/pulldown rheostat to the “0”
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
Manual No. 10528 2 - 76 Sept. 2007

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 on the operator’s display terminal 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.
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 “0” 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.
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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.
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
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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.
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
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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.
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
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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.
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 pipewith 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.
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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.
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.
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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 30 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.
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.
PROGRAMMED DRILL CONTROLS UTILIZED
1. Make sure the hoist/pulldown rheostat and the rotary rheostat are in the “0” 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.
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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 compressor vent/drill switch in the DRILL 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.
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.
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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. Turn 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.
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.
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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
involved 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.
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.
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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
casing 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.
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.
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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.
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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.
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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.
Manual No. 10528 2 - 90 Sept. 2007

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.
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 by Bucyrus) 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.
Sept. 2007 2 - 91 Manual No. 10528

DRILL STABILITY CHARTS
Manual No. 10528 2 - 92 Sept. 2007

Sept. 2007 2 - 93 Manual No. 10528

Manual No. 10528 2 - 94 Sept. 2007

Section 3
Lubrication
Always refer to the safety information in Section 1 of this manual before
starting any maintenance procedure on this machine.
Table of Contents
LUBRICATION PRINCIPLES ......................................................................................................... 3

Auto Lube Control Panel ............................................................................................................. 4
Auto Lube Reservoir ................................................................................................................... 5
Auto Lube Piping ~Mainframe (View #1) ...................................................................................... 6
Auto Lube Piping ~Mainframe (View #2) ...................................................................................... 7
Auto Lube Piping ~Crawlers ........................................................................................................ 8
Auto Lube Piping ~Mast (View #1) .............................................................................................. 9
Auto Lube Piping ~Mast (View #2) ............................................................................................. 10
LINCOLN TYPE SL-1 LUBRICANT INJECTORS .................................................................. 11
LUBRICANT INJECTOR OPERATION ............................................................................ 12
INJECTOR ADVANTAGES .............................................................................................. 13
TROUBLESHOOTING .......................................................................................................... 14
BIT LUBRICATOR ................................................................................................................. 15
FLOWMASTER PUMP SERVICING ..................................................................................... 16
PRESSURE CONTROL VALVE ADJUSTMENT .............................................................. 16
FLOW CONTROL VALVE ADJUSTMENT ............................................................................. 17
FlowMaster Rotary Driven Hydraulic Pump Schematic ................................................................ 17
CRANK CASE OIL ................................................................................................................ 17
PUMP DISASSEMBLY PROCEDURE .................................................................................. 18
FlowMaster Rotory Driven Hydraulic Pump Assembly ................................................................. 19
PUMP ASSEMBLY PROCEDURE ........................................................................................ 20
FlowMaster Rotary Driven Hydraulic Pump Components ............................................................. 21
TROUBLESHOOTING .......................................................................................................... 22
Lube Pump Hydraulic Schematic ............................................................................................... 23
LUBRICATION POINTS ............................................................................................................... 24
GEARCASE AND RESERVOIR CAPACITIES ...................................................................... 24
LOWER WORKS LUBRICATION ......................................................................................... 25
MAIN FRAME LUBRICATION ................................................................................................. 26
MAST LUBRICATION ~PART 1 ............................................................................................. 27
LUBRICANT CLEANLINESS ................................................................................................. 30
Sept. 2007 3-1 Manual No. 10528

LUBRICANT SELECTION ........................................................................................................... 31

ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT ................................................ 32
MPO - MULTIPURPOSE OIL................................................................................................. 33
RWRL - RUNNING WIRE ROPE LUBRICANT ..................................................................... 34
HYDO – HYDRAULIC OIL ..................................................................................................... 36
PAO SYNTHETIC HYDRAULIC FLUID ............................................................................ 37
Recommended Viscosity vs. OAT Chart .................................................................................... 37
PARAFFINIC BASE PETROLEUM HYDRAULIC FLUID .................................................. 37
Recommended Viscosity vs. OAT Chart .................................................................................... 38
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)
Manual No. 10528 3-2 Sept.2007

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.
Sept. 2007 3-3 Manual No. 10528

Auto Lube Control Panel

Auto Lube Reservoir
Sept. 2007 3-5 Manual No. 10528

Auto Lube Piping ~Mainframe (View #1)

Auto Lube Piping ~Mainframe (View #2)
Sept. 2007 3-7 Manual No. 10528

Auto Lube Piping ~Crawlers

Auto Lube Piping ~Mast (View #1)
Sept. 2007 3-9 Manual No. 10528

Auto Lube Piping ~Mast (View #2)
Manual No. 10528 3 - 10 Sept.2007

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 Bucyrus recommends 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.
Sept. 2007 3 - 11 Manual No. 10528

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.
Manual No. 10528 3 - 12 Sept.2007

NOTE: The injectors may be mounted individually, or grouped in a manifold at one location.
INJECTOR ADVANTAGES
Sept. 2007 3 - 13 Manual No. 10528

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.
Manual No. 10528 3 - 14 Sept.2007

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.
Sept. 2007 3 - 15 Manual No. 10528

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.
Manual No. 10528 3 - 16 Sept.2007

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.
Sept. 2007 3 - 17 Manual No. 10528

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49HR Blast Hole Drill

Manual No. 10528 Sept. 2007

49HR Blast Hole Drill

Section 4 - SCHEDULED MAINTENANCE

Section 5 - MAJOR MAINTENANCE

Section 6 - BRAKES AND COUPLINGS

Section 7 - COMPRESSED AIR SYSTEM

Section 8 - HEATING, VENTILATION AND AIR CONDITIONING

Section 9 - ENGINEERING DATA

Sept. 2007 Manual No. 10528

Manual No. 10528 Sept.. 2007

DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE

DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE

Sept. 2007 Manual No. 10528

Manual No. 10528 Sept.. 2007

49HR Blast Hole Drill

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

DECK PLAN - Color ...................................................................................................... ( foldout )

Sept. 2007 1-1 Manual No. 10528

49HR Blast Hole Drill

Manual No. 10528 1-2 Sept. 2007

49HR Blast Hole Drill

Bucyrus International, Inc.

Sept. 2007 1-3 Manual No. 10528

49HR Blast Hole Drill

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.

Manual No. 10528 1-4 Sept. 2007

49HR Blast Hole Drill

Sept. 2007 1-5 Manual No. 10528

49HR Blast Hole Drill

Manual No. 10528 1-6 Sept. 2007

49HR Blast Hole Drill

Sept. 2007 1-7 Manual No. 10528

49HR Blast Hole Drill

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.

Manual No. 10528 1-8 Sept. 2007

49HR Blast Hole Drill

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

Sept. 2007 1-9 Manual No. 10528

49HR Blast Hole Drill

DOG EVERYTHING Clasp hands together in front of body.

Manual No. 10528 1 - 10 Sept. 2007

49HR Blast Hole Drill

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

Sept. 2007 1 - 11 Manual No. 10528

49HR Blast Hole Drill

WARNING SIGNS AND DECALS

Manual No. 10528 1 - 12 Sept. 2007

49HR Blast Hole Drill