D45KS HP Service C18 PDF

023501-002
D40/45/50KS
SERVICE MANUAL
Serial Number 732213 & UP

(rev. 5-05)
SANDVIK MINING and CONSTRUCTION D40/45/50KS
BLASTHOLE
1814 kg / 4,000 lb
Sandvik Mining and Construction

13500 NW County Road 235
Alachua, Florida 32615 - USA
Tel. (386) 462-4100
Fax. (386) 462-3247
The following three hazard signal words are used throughout this manual to emphasize
important instructions. For the purpose of this manual, these signal words are defined as follows:
Indicates an imminently hazardous situation which,

! DANGER if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which,

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

! CAUTION if not avoided, may result in minor or moderate injury.
California Proposition 65
WARNING:
This Product Contains And, When Used, Produces Chemicals Known
To The State Of California To Cause Cancer, And Birth Defects Or
Other Reproductive Harm.
11-06
SAFE OPERATING PRACTICES FOR DRILLERS
Introduction
SANDVIK MINING and CONSTRUCTION drilling equipment is carefully designed, tested and manufactured. When
operated and serviced by trained and qualified personnel, this machine will give safe and reliable service. There are
SANDVIK MINING and CONSTRUCTION offices world-wide to answer questions concerning the safe operation and
maintenance of this equipment.
To minimize the risk of accidents and injuries, all persons involved in the operation and servicing of this machine MUST
read and understand the following safety precautions and the manuals developed for this machine.
While we believe that we have properly identified several potential hazards that could result in property damage or injury
or death to personnel, there are certain hazards which may be present that we have not contemplated. It therefore is
the responsibility of the drill owner, operator and crew to be certain that the drill is properly equipped and safe to operate
to assure accident free operation.
Management's Responsibilities
It is the responsibility of management to:
• See that all operators of this equipment are thoroughly trained (with special emphasis on safety), competent, physi-
cally fit and if required, licensed.
• Assign specific crew members specific safety responsibilities and instruct them how to report any unsafe conditions.
• Enforce the use of protective clothing, eye and hearing equipment.
• See that the operation and maintenance of this drill is in compliance with all Federal, State and local codes, regula-
tions and standards.
• Ensure that the work area is appropriately illuminated when drilling is performed at night.
• Maintain a complete first aid kit at the drill site. At least two members of the drilling crew or personnel in the area
where the drill is operated should be familiar with first aid and Cardiac Pulmonary Resuscitation.
• Contact the utility companies for the exact location of underground transmission lines in the drilling area.
The Operator’s Responsibilities

Safety must always be the operator's most important concern. The operator must refuse to operate the drill if an unsafe
Safe Operating Practices for Drillers iii

11-06
condition exists. It is the responsibility of the drill operator to ensure that the drill is properly equipped, safe to operate
and that the site conditions make it possible for safe operation:
• The operator must see that all emergency stops, "operational aids" and "warning signals" are functional before oper-
ating.
• The operator must be alert, physically fit, and free from the
influences of drugs, alcohol and medications that might
impair eyesight, hearing or reactions
• The operator should not attempt to start, operate or service the drill unless he has been properly trained and read this
manual.
• The operator should not operate this equipment if any

of it's controls display a "lockout" tag.
• If an unsafe condition exists, the operator must place a

tag, identifying this condition, on the starting controls
and alert other potential users of the drill.
iv
11-06
• The operator should not operate the drill without first

checking that all personnel protection devices and
machinery guards are in place.
Operator's Safety Check

The operator must make a safety check before starting to work to ensure that the machine is in proper order for accident
free operation. Somethings to check are:
• Check that there are no "lockouts" or "tagouts" attached to the

controls.
• Check the machine log book to see that periodic maintenance

and inspections have been performed, and that all necessary
repairs have been made.
• After starting the engine, check all indicators, emergency stop,

trip devices and gauges for serviceability.
• Check the fire extinguisher(s) for charge and accessibility.
• Clean the cab interior windows if necessary.
• Test all controls for proper operation.
• Check access ladders and decking for damage and slipping hazards such as mud, oil or ice.
• At the end of the shift, the operator must properly secure the drill to prevent the machine from being operated by
unauthorized individuals.
• The operator must never permit personnel to ride on the machine except in the passenger compartment.
• The operator should treat all power lines as live.
Safe Operating Practices for Drillers v

11-06
Planning the Job
The person in charge must have a clear understanding of the work to be done and consider all the hazards at the site.
He must develop a plan to do the job safely and explain the plan to the crew members involved. Factors such as these
should be considered:
• Will the drilling take place in wet formations?
• Are there utility lines or structures that must be moved or avoided?
• Are there unusual or extreme weather conditions expected?
• Will drilling be done in night hours?
• Will the machine be propelled on inclines?
• Will drilling be done into difficult formations?
• Has a drilling pattern been developed?
• What is the required depth of the drilling pattern?
• Will special drilling tools be required to complete the job?
• Will vertical or angle drilling be required?
vi
11-06
Operating Precautions
• Operating near or contacting a power line with any part of the

machine can result in electrocution.
Do not raise the drilling mast or operate the machine in the
vicinity of electrical power lines without checking the mini-
mum safe operating perimeter set by local, state or federal
regulations.
• Raising or lowering the mast, and drilling with an unsupported or unleveled machine can result in excessive structural
stress to the machine frames or can cause the machine to overturn.
Do not raise or lower the mast or attempt to drill until the machine is fully supported and leveled by the lev-
eling jacks.
• Drilling with an unlocked mast can result in excessive pressure at the mast raising cylinders causing the mast to fall.
Do not attempt to drill until the mast locking pins are fully engaged.
.
• Before leaving the operator's station, all controls must be in the

neutral position with all locking and safety devices engaged.
Do not allow the drill to operate unattended.
• Do not park or position the machine on grades that exceed the tilt
ratings.
Park or position the machine on level ground or across (hori-
zontal) grade
• Park or position the machine to allow the wind to carry engine exhaust fumes away from the operator.
Exhaust fumes from diesel engines are lethal.
Safe Operating Practices for Drillers vii

11-06
• Drill pipe that is free to slide through the opening in the top plate
could be released from the loader while traveling.
Before lowering the mast, index the loader to a position
such that the top plate of the loader prevents all drill pipe
from moving past the top plate
General Maintenance Safety Practices
While operating and servicing this machine be aware of the following:
• The sudden release of a pressurized lid or hose can spray hot

oil.
Do not open hydraulic tanks, air reservoirs or hydraulic
connections while the machine is running or the sys-
tems are under pressure.
• Before entering any enclosure, be sure that the door is secured open. Avoid entrapment, be sure that no one is
inside any enclosure before closing and latching the doors.
Enclosures can cause suffocation.
• Before starting any service or maintenance work, always perform a safety/risk analysis of the task.
Performing maintenance work without the proper tools and personal protection equipment can cause seri-
ous injury or death.
• Climbing the mast is a crushing and falling hazard.

Climbing the mast may cause serious injury or death. Stay off the mast at all times.
• Hydraulic oil under extreme pressure from a small opening

can penetrate the skin and inject oil into the body.
Do not attempt to locate a hydraulic leak by using your
hand.
• Pressure in hydraulic systems can be retained for long peri-

ods of time. If not properly released before maintenance
people attempt to work on the hydraulic system, this pres-
sure can let components move or cause hot oil to spray
and hose ends to shoot out at high speed.
Release system pressure before attempting to make
adjustments or repairs.
viii
11-06
• Carelessness in getting on and off equipment can result in seri-

ous injuries.
Always wait until the machine has completely stopped. Do
not jump on or off. Always use both hands and feet and
use the 3-point contact rule.
• Riding the rotary head up and down the mast is a crushing hazard.
Never ride the rotary head for any reason!!! It was not designed to be an elevator.
When there is a need for an operator or helper to work on the rig in the working area or danger zone and this work
involves activation of one or several machine functions, this work shall only be done under the following conditions:
a. There must be two safety trained people present, one should supervise the safety of the other doing the servicing.
Supervision should be done from the operator’s station to ensure immediate access to an emergency stop at all
times.
b. The area where the service work is to be done should be properly illuminated.
c. A reliable mode of communication should be establish between the servicing person and the supervisor.
d. The rig must be completely shut down and all methods of starting disabled before servicing work begins.
Fire Prevention
• Keep the machine clean of vegetation, coal dust and oily rags.
• Clean-up any oil and fuel spills particularly around hot surfaces
and heat producing components.
• Check the Fire Suppression System (FSS), if fitted, for damaged hoses or cylinders.
• Check all electrical lines and connections including battery terminals for a tight fit, wear, abrasion, and corrosion.
• Do not use the drilling machine in oil, gas or waterwell operations unless the well head is properly equipped with blow-
out preventers and safety equipment required by law or as recommended in the American Petroleum Institute's doc-
ument API 54.
Safe Operating Practices for Drillers ix

11-06
• Check all machine ignition points (engine block, exhaust manifolds, mufflers, turbo-chargers, etc...) to make sure they
are not in contact with any hoses.
• Keep the batteries secured in their compartment and covered.
• Never inject ether or other starting aids into the engine and compressor intake filter(s). Ether or other aids drawn into
the compressor can cause an explosion.
• Do not store flammable fluids on or in the immediate vicinity of the machine.
• Engine oil, hydraulic fluid and compressor oil are flammable. Do not operate a machine with leaking or worn hoses or
lines.
• Do not clean washable filter elements with flammable solvents, diesel fuel, kerosene, or gasoline.
• Do not attempt to perform welding repairs until all flammable materials including oil and fuel spills oily rags, and rock
and coal dust, have been isolated or removed from the machine.
• Disconnect the battery cables before welding on the machine.
• Keep tools away from exposed live electrical parts such as terminals, to avoid arching.
• If charging the batteries, always turn the charger off before making or breaking connections to the battery.
• The compound (ethyl ether) used in the engine starting aid system is extremely flammable. Changing the cylinders
and servicing this system should be done in a well ventilated area. Do not store or install the cylinders in tempera-
tures above 160° F (71° C).
• The anti-freeze compound (methanol) used in the air line anti-ice systems is flammable. Refill the system with com-
pound only in well ventilated areas, away from heat, open flames and sparks. Do not store or expose this system or
the compound to temperatures above 150° F (65° C), or in direct sunlight.
x
11-06
INCLEMENT WEATHER and SAFE DRILLING PRACTICES
GENERAL
The following safety precautions were developed to minimize the risk of injury during inclement weather when using
Driltech drilling equipment.
All persons involved in the planning, operation and serving of Driltech equipment MUST read and understand the follow-
ing safety precautions, the manuals developed for this machine and the Safe Operating Practices outlined in the front of
this manual.
While we believe that we have properly identified several potential hazards that could result in property damage or per-
sonnel injury, there are certain hazards which may be present that we have not contemplated.
Bad weather conditions as they relate to this topic include lightning, thunderstorms and severe rainfall.
MANAGEMENT’S RESPOSIBILITIES
High winds, rainfall and cloud cover are often precursors to actual cloud to ground strikes notifying individuals to take
action. Many reported lightning accidents occur with sun, clear skies and no rain present at the beginning as the storm
approaches because; people ignore these precursors. Generally the lightning threat diminishes with time after the last
sound of thunder, but may persist for more than 30 minutes.
It is the responsibility of management to:
• Be aware of daily weather conditions within a 100 mile (161 Km) radius of the mine property.
• Determine a plan of action relating to expected bad or unexpected weather conditions.
• Notify equipment operators of impending storms. Communication to equipment operators may be given via two way
radio and/or in person.
• Consider that drill operators need ample time:
a. to retrieve drill pipe from blastholes and well bottom.
b. lower masts to a horizontal position or position feed rails into feed supports.
c. give the drill engine an adequate cool down period prior to shutting machine down.
d. leave machine cabin or operator platform and transport to central meeting location.
• Give equipment operators an all clear signal after the storm has cleared the area.
Note To Supervisors!
Recognize that equipment operators should be given adequate time to prepare the machine to move to specific loca-
tions for safe keeping. Crawler mounted drill machines have a maximum travel speed not exceeding 2.2 mph (3.5 kph).
RAINFALL AND FLOODING
When notified of an impending storm, machine operators should:
Safe Operating Practices for Drillers xi

11-06
•Move the drill machine to higher ground conditions.

Never leave a drill machine at the lowest floor position of
a mine or quarry or in a low lying ditch that could trap
water runoff.
•Move the drill machine to stable ground and away from

unstable crests or the face.
Never leave a drill machine on the front face of the drill
pattern while rain and severe weather pose a threat of
loose ground falls or washouts.
•When operating machines in a construction application, equipment operators shall move the drill machine to higher
stable ground.
Never leave a drill machine in any construction zone roadway, river bed or drainage ditch.
•Move the drill machine to stable ground away from high walls and any threat where rock or water erosion may
allow unstable ground to fall or slide.
THUNDERSTORMS AND LIGHTNING
A publication written in MSHA Holmes Safety Association Bulletin April 2001 gives a simple flash bang formula to calcu-
late lightning proximity.
The FLASH BANG method is determined by counting the seconds between the visible lightning and the sound of thun-
der. This delay in seconds when divided by 5 will give an approximate value in miles as to how close the active lightning
is to your worksite.
Example: when you see lightning and it takes (10) ten seconds to hear the thunder divide by (5) five. The approximate
distance of lightning proximity is 2 miles (3.2 km).
If the flash bang measurement is 30 seconds or less seek shelter immediately and remain indoors, away from electrical
devices, water and metal components.
Supervisors shall notify equipment operators in a timely manner. This is to allow the drill operator adequate time to per-
form the required operation principals needed and secure the machine in a safe manner.
• Equipment operators shall retrieve drill pipe from blastholes, secure drilling tools and lower mast to a horizontal
position into the mast rest supports.
Understand that the mast in a vertical position with drill pipe in the ground is capable of attracting high volt-
age lightning.
NOTE !
If the operator and machine are inside or near a blast area follow procedures written in USA Federal Metal and Non-
metal Mine safety Standards 30CFR 56/57/58 manual.
• Equipment operators shall move the machine to secure ground as noted in the rainfall and flooding description.
• Equipment operators shall give adequate engine cool down period prior to shutting machine down. Adequate
engine cool down periods range between 3 to 5 minutes.
Follow engine manufacture specifications as a standard.
xii
11-06
• Equipment operators shall secure the machine, close doors and windows, leave the machine cabin and dismount
the machine in a proper 3 point contact with the boarding ladder.
• Equipment operators shall drive or be transported to a central meeting location away from bad weather and storm
conditions.
There are exceptions to the rules when bad weather develops and time does not permit adequate machine preparation
- shutdown principals.
Exceptions
If you do get caught in an electircal storm and have little or no time to prepare, remember that, no place is absolutely
safe from the lightning threat, however, some places are safer than others.
When operators are inside a enclosed stable structure such as a machine cabin or the truck cab it is recommended that:
• all windows are closed
• all doors closed
• do not touch metal parts
• do not use two way radio communication
NOTE!
Wait inside the enclosed cab as long as it takes for the storm or lightning to subside. Do not attempt to dismount the
machine when lightning is in your immediate work area.
If lightning is present within a 20 mile (32 km) radius of your location be aware of your surroundings when outdoors.
Seek adequate shelter immediately.
If lightning is present within the 20 mile (32 km) radius, and a decision is made to dismount the machine, use a standard
3 point contact down the boarding ladder to dismount the machine.
Move away from the machine quickly and into a enclosed vehicle or adequate shelter. Maintain a distance greater than
100 yards (92 m) to prevent electrical draw in the event lightning did strike the mining equipment.
Static interference on AM radio channels is another indicator as to lightning proximity.
Lightning detectors are available aftermarket as a measuring instrument to determine lightning proximity. Blasting crews
are aware of lightning hazards and may have a lightning detector on site.
If you are caught in the open with lightning nearby and shelter is not available the safest position to be in is to be
crouched down on the balls of your feet. Keep your feet as close to one another as possible.
Do not allow your hands (or other body parts) to touch the ground. Use your hands to cover your ears and brace for a
loud thunderous bang.
Lightning struck victims carry no electrical charge and should be given first aid treatment immediately!
MACHINE MAINTENANCE
If lightning does strike a drill machine parked in any position (mast up or down) expect major component failures. A total
machine inspection is in order.
Safe Operating Practices for Drillers xiii

11-06
Electrical charge should dissipate immediately after impact.
Prior to climbing on board a machine known to have been struck by lightning use the back side of either hand (knuckle
side) to lightly touch the boarding ladder.
Reference material
MSHA Holmes Safety Association Bulletin April 2001
Federal Metal and Nonmetallic Mine Safety and Health Standards 30CRF 56/57/58 Ninth Edition (1999).
National weather service (www.noaa.gov)
xiv
TABLE of CONTENTS
MODELS D40KS, D45KS
and D50KS
SECTION 1 - INTRODUCTION SECTION 7 - HYDRAULIC SYSTEM
INTRODUCTION ............................................................... 1- 1 GEARBOX - 3 pump drive (001003/002233) .......... 001003-000
CHECK VALVE - double pilot .................................. 001316-000
SHAFT SEAL - replacement.................................... 001329-000
SECTION 2 - COOLANT, FUEL & LUBRICANT SPECI- HYDRAULIC PUMP - service .................................. 001330-000
FICATIONS AIR FILTER - hydraulic tank .................................... 001658-000
COOLANT, FUEL & LUBRICANT - specifications ............... 2- 1 HYDRAULIC PUMP - service .................................. 002764-000
GEARBOX - 4 pump drive (004167) ....................... 003837-000
ACCUMULATOR - precharging/recharging inst. ..... 004695-000
SECTION 3 - MOUNT/FRAME HYDRAULIC TANK - air pressure/relief adjust........ 004756-000
PUMP - fan/accessory, oper. & overhaul instruct. ... 008172-000
CRAWLER - undercarriage instructions .................. 018157-000 PUMP - vane ........................................................... 008610-000
FRONT IDLER ........................................................ 018157-063 PUMP - fan drive (019211) ...................................... 019146-000
FINAL DRIVE .......................................................... 018157-106 PUMP - fan drive (020237) ...................................... 019147-000
FINAL DRIVE SPROCKET ..................................... 018157-107 SCHEMATIC - hydraulic (D45KS high pressure) .... 019250-001
UPPER TRACK ROLLER ....................................... 018157-157 SCHEMATIC - hydraulic (D40KS low pressure)...... 019380-001
TRACK ASSEMBLY................................................ 018157-273 SCHEMATIC - hydraulic (D45/D50KS low press.) .. 019385-001
HYDRAULIC TRACK ADJUSTERS ........................ 018157-282 SCHEMATIC - hydraulic (D40KS low pressure)...... 019408-001
RECOIL SPRINGS .................................................. 018157-283 HYDRAULIC CYLINDER......................................... 020050-000
TRACK ROLLER, LOWER...................................... 018157-296 HYDRAULIC CYLINDER PISTON LOCK KIT ......... 020058-055
AIR CONDITIONER/HEATER - Sigma ................... 019148-000 PUMP - fan/accessory (replaces 008172) ............... 021434-000
PUMP - vane (replaces 008610) ............................. 021435-000
SECTION 4 - ENGINE
DRIVESHAFT SERVICE MANUAL ......................... 001022-000 SECTION 8 - MAST/FEED SYSTEM
AIR CLEANER ........................................................ 001036-000 CHAIN - instructions (D40/D45/D50KS) .................. 001085-000
ENGINE - Caterpillar Oper. & Maint. (3408B) ......... 003021-000 CHAIN - adjustment (non-single pass) .................... 001085-001
TACHOMETER - installation/adjustments - CHAIN/SPROCKET - wear limits ............................ 001085-071
Caterpillar engine .................................................... 006269-000 HOLDING VALVE - adjustment ............................... 008737-000
AIR CLEANER ........................................................ 006307-000 CHAIN - adjustment kit information ......................... 015847-000
TACHOMETER - installation/adjustements -
Cummins engine ..................................................... 007672-000
OIL SPINNER.......................................................... 019104-000 SECTION 9 - ROTARY SYSTEM
ENGINE - Caterpillar Oper. & Maint. (3408C) ......... 019079-000
ENGINE - Caterpillar Oper. & Maint. (3406E) ......... 019850-000 PLANETARY DRIVE - instructions .......................... 001004-000
ENGINE - Caterpillar Oper. & Maint. (3408E) ......... 019851-000 ROTARY HEAD - swivel seal housing packing ....... 001111-000
ENGINE - Cummins Oper. & Maint. (QSK19) ......... 020235-000 MOTOR - rotary head drive, overhaul instructions ..001329-01B
AIR CLEANER ........................................................ 021237-000 RELIEF VENT - operation/adjustment..................... 001670-002
ENGINE - Caterpillar Oper. & Maint. (C15 Tier 2)... 024340-000 ROTARY HEAD - overhaul instructions (D55SP
ENGINE - Caterpillar Oper. & Maint. (C16) ............. 027889-000 single rotary head) ................................................... 002153-000
ENGINE - Caterpillar Oper. & Maint. (C15 Tier 3)... 030555-000 HYDRAULIC MOTOR - service ............................... 002746-000
ENGINE - Caterpillar Oper. & Maint. (C18) ............. 030555-010 ROTARY HEAD - sleeve kit (FOR SINGLE HEAD) 009532-000
TOP SUB - installation information .......................... 011201-000
SECTION 5 - COMPRESSOR/COOLER SYSTEM

SECTION 10 - WINCH
AIR END SHAFT SEAL KIT - Instructions (H.P.) .... 001958-121
TAPERLOCK BUSHING - installation instructions .. 008674-000 WINCH - model BG4A, maint. & service manual..... 021371-001
COMPRESSOR - air inlet adjustments ................... 010119-000
AIR END SHAFT SEAL KIT - instructions (L.P.) ..... 012457-000 SECTION 11 - WATER INJECTION/DUST COLLECTOR
MOTOR - cooler, service instructions
SYSTEM
(see 019147-000 in Section 7 Hydraulic System)
MOTOR - dust collector ........................................... 001011-000
RELIEF VALVE - Water Injection ............................ 001104-000
SECTION 6 - AIR PIPING PUMP - Water Injection, 9 GPM .............................. 002168-000
AIR PIPING SWIVEL JOINT - FMC Chiksan .......... 001217-000 AIR FILTER/REGULATOR - service information..... 002428-000
AIR PIPING SWIVEL JOINT - OPW/Dover ............. 001217-001 DUST COLLECTOR - Driltech service .................... 007702-000
CYLINDER - service instructions (Hydroline) ......... 001690-001 MOTOR - Water Injection, maint. & serv. manual ... 009999-000
d40serv.toc Table of Contents - Page 1
SECTION 12 - LUBRICATOR SYSTEM SECTION 14 - ELECTRICAL SCHEMATICS
PUMP - oil injection ................................................. 011353-000 SCHEMATIC - heater, cold weather........................ 019314-001
LUBRICATOR - oil injection .................................... 011362-000 SCHEMATIC - heater, schematic, cold weather ..... 019314-004
SCHEMATIC - electrical (D40KS H.P. w/3408B) .... 019489-001
SCHEMATIC - electrical (D45KS L.P.) .................... 020182-001
SECTION 13 - OPTIONAL SYSTEMS SCHEMATIC - electrical (D40KS H.P.) ................... 020683-001
PREHEATER - service manual ............................... 003908-000 SCHEMATIC - electrical (D50KS L.P.) .................... 020791-001
CENTRALIZED LUBRICATION - manual system ... 006111-000 SCHEMATIC - electrical (D40/D45KS L.P.) ............ 020813-001
CENTRALIZED LUBRICATION - automatic system006113-000 SCHEMATIC - electrical (D40KS H.P. w/QSK) ....... 021689-001
FIRE SUPPRESSION - maintenance manual......... 006120-000 SCHEMATIC - electrical (D50KS L.P w/3408C)...... 023121-001
PREHEATER - operation manual ........................... 008868-002 VARIABLE SPEED CONTROL (C40/45/50) .......... 023260-01D
THREAD GREASE LUBRICATOR ......................... 015587-001 SCHEMATIC - electrical (D50KS L.P w/3406E) ...... 023369-001
DRILL MONITOR SYSTEM - instructions ............... 015702-000 SCHEMATIC - electrical (D45KS L.P.w/C15).......... 025424-001
GENERATOR - Oper. & Maint. ............................... 019105-000 SCHEMATIC - electrical (D45KS H.P.Cat. T2-T3) .. 025430-001
GENERATOR ENGINE - service manual, 3.152 .... 019105-001
GENERATOR - service manual (Magnaplus) ......... 019105-003
d40serv.toc Table of Contents - Page 2

SECTION 1
The parts manual should be referred to when it

INTRODUCTION is necessary to order repair parts. For prompt
and efficient parts service, contact your
Sandvik Mining and Construction dealer, giving
GENERAL the model and serial number of the machine,
along with the part number and description of
This manual provides a step-by-step guide to the items required, as their personnel are fully
performing service on your drill. A thorough qualified to assist and advise you on any ser-
study of this manual and the Operator’s Manual vice or operational problems that may be
are recommended before operation or mainte- encountered. Sandvik Mining and Construction
nance of the machine is attempted. Field Representatives are also available to you
for advice and assistance on special problems.
Careful attention should be given to the service
and maintenance instructions for the various
components and systems of the machine. MACHINE SPECIFICATIONS
Experience indicates that the procedures
Application of Rig
described herein are preferred practices and
that failure to comply with them can materially
The D40KS, D45KS and the D50KS machines
shorten the useful life of the equipment and/or
are designed for construction and surface mine
reduce its standard performance.
drilling.
19604s2
Introduction - Page 1-1

NOMENCLATURE/TERMINOLOGY
The terms used on this illustration are used

throughout this manual (D45KS shown).
FRONT
COOLER
AIR CLEANER
BATTERY
BOX
ROTARY HEAD
COMPRESSOR
RECEIVER TANK
FEED CHAIN ENGINE
DRILL PIPE
19604s1
19604s3 PROPEL
PUMP DRIVE
MAST
LUBRICATOR
HYDRAULIC TANK
PUMP DRIVE
DUST COLLECTOR
HYDRAULIC
TANK
MAST
RAISING
CYLINDERS
CAB
JACK
CYLINDER
LOADER
TONG WRENCH
CRAWLERS
DUST HOOD CAB
REAR
Page 1-2
D40KS (100 psi / 750 cfm) SPECIFICATIONS
DRILL RATING
Hole Size 6” to 8” (152 - 203 mm)
Max. 1st pass capacity (Std. tooling) 28’ 6” (8.7m)
Max. 1st pass capacity (Special tooling 30’ 9” (9.4m)
Total Depth Capacity 210’ (64m)
UNDERCARRIAGE
Type Caterpillar® - Model 330
Length 15’ (4.57 m)
Pads (Shoes) Triple Grouser 29.5” (750 mm)
Travel Speed 1.86 mph (3 km/h)
Gradeability (Mast Down) 68% (approximately 34°)
Drive HP each track 175 hp (130 kW)
Ground Bearing Pressure (Std. Equipment) 9.6 psi (66.1 kPa)
Width Over Tracks 12’ 1” (3.68 m)
Rollers 7 Lower - 2 Upper
DRILL POWER
Caterpillar® (std) Model 3406E ATAAC 450 hp (336 kW)
Caterpillar® (opt) Model 3408E DITA 500 hp (373 kW)
Cummins (opt) Model QSK19C 500 hp (373 kW)
Rated Speed 1800 rpm
Fuel Capacity 300 gallons US (1135 l)
COMPRESSOR
Type Single Stage Oil Flooded Screw Type
Manufacturer Sullair 750cfm (21.2m³m) @ 100 psi (6.9 bar) @
1800 rpm
FEED SYSTEM
Type 2 Hydraulic Cylinders and Chains
Rated Bit Loading 40,000 lbs (18,144 kg)
Rated Pullback 26,500 lbs (12,020 kg)
Feed Rate 0-72 fpm (21.9 mpm)
Retract Rate 0-130 fpm (39.6 mpm)
ROTARY HEAD
Type Gear Case Type
Drive Motor Hydraulic Axial Piston
Maximum Rotary Horsepower 102 hp (76 kW)
Standard Rotary Speed/Torque 106 rpm @ 60,000 in-lbs (6,780 Nm)
Optional Rotary Speed/Torque 160 rpm @ 40,000 in-lbs (4,520 Nm)
WEIGHT
Operating Weight w/Drill Pipe 90,000 lbs (40,824 kg)
DIMENSIONS
Length (mast down) 45’ 4” (13.8 m)
Width (operating w/o dust chute) 14’ 4” (4.38 m)
Width (operating w/dust chute) 15’ 2” (4.62 m)
Height (mast up) 46’ 9” (14.2 m)
Height (mast down & workdeck removed) 14’ 4” (4.38 m)
ELECTRICAL
Alternator 24VDC 100amp
Air Conditioner 24VDC
Batteries 2 @ 12 Volt

DRILL RATING
Hole Size 6” to 8” (152 - 203 mm)
UNDERCARRIAGE
Length 15’ (4.57 m)
DRILL POWER
Caterpillar® Model 3408E DITA 500 hp (373 kW)
COMPRESSOR
1800 rpm
FEED SYSTEM
ROTARY HEAD
Type Gear Case Type
WEIGHT
DIMENSIONS
ELECTRICAL
Page 1-4
DRILL RATING
Hole Size 6” to 8” (152 - 203 mm)
UNDERCARRIAGE
Length 15’ (4.57 m)
DRILL POWER
COMPRESSOR
1800 rpm
FEED SYSTEM
ROTARY HEAD
Type Gear Case Type
WEIGHT
DIMENSIONS
ELECTRICAL

DRILL RATING
Hole Size 6” to 9” (152 - 228 mm)
Total Depth Capacity 210’ (64 m)
UNDERCARRIAGE
Length 15’ (4.57 m)
Travel Speed 2 mph (3.2 km/h)
DRILL POWER
Caterpillar® Model 3406E ATAAC 450 hp (336 kW)
Caterpillar® Model C15 T2 450 hp (336 kW)
Cummins Model QSK19C 500 hp (373 kW)
COMPRESSOR
1800 rpm
FEED SYSTEM
Feed Rate 0-125 fpm (38 mpm)
Retract Rate 0-164 fpm (50 mpm)
ROTARY HEAD
Type Gear Case Type
WEIGHT
DIMENSIONS
ELECTRICAL
Page 1-6
DRILL RATING
Hole Size 6” to 9” (152 - 228 mm)
UNDERCARRIAGE
Length 15’ (4.57 m)
DRILL POWER
COMPRESSOR
1800 rpm
FEED SYSTEM
ROTARY HEAD
Type Gear Case Type
TOOL HANDLING EQUIPMENT (Loader)

Type Carousel (Inside Mast)
Number of Positions 4 or 6
Pipe Sizes 4 Position - 3” to 5-1/2” (76 to 140 mm)
6 Position - 6” to 7” (152 mm to 178 mm)
WEIGHT
DIMENSIONS
ELECTRICAL
DRILL RATING
Hole Size 6” to 9” (152 - 228 mm)
UNDERCARRIAGE
Length 15’ (4.57 m)
DRILL POWER
COMPRESSOR
1800 rpm
FEED SYSTEM
ROTARY HEAD
Type Gear Case Type

WEIGHT
DIMENSIONS
ELECTRICAL
Page 1-8
DRILL RATING
Hole Size 6” to 9” (152 - 228 mm)
Max. 1st pass capacity (Std. tooling) 28’ 6” (8.7 m)
Max. 1st pass capacity (Special tooling 30’ 9” (9.4 m)
UNDERCARRIAGE
Length 15’ (4.57 m)
DRILL POWER
Caterpillar® Model 3406E ATAAC 450 hp (336 kW)
COMPRESSOR
1800 rpm
FEED SYSTEM
ROTARY HEAD
Type Gear Case Type
WEIGHT
DIMENSIONS
Length (mast up) 31’ 0” (9.45 m)
ELECTRICAL

DRILL RATING
Hole Size 6” to 9” (152 - 228 mm)
UNDERCARRIAGE
Length 15’ (4.57 m)
DRILL POWER
COMPRESSOR
Manufacturer Sullair 1050 cfm (29.7m³m) @ 100 psi (6.9 bar) @
1800 rpm
FEED SYSTEM
ROTARY HEAD
Type Gear Case Type

WEIGHT
DIMENSIONS
ELECTRICAL
Page 1-10
DRILL RATING
Hole Size 6” to 9” (152 - 228 mm)
UNDERCARRIAGE
Length 15’ (4.57 m)
DRILL POWER
COMPRESSOR
Manufacturer Sullair 1300 cfm (36.8m³m) @ 100 psi (6.9 bar) @
1800 rpm
FEED SYSTEM
ROTARY HEAD
Type Gear Case Type

WEIGHT
DIMENSIONS
ELECTRICAL
D40KS (350psi / 900 cfm) SPECIFICATIONS
DRILL RATING
Hole Size 6” to 8” (152 - 203 mm)
UNDERCARRIAGE
Length 15’ (4.57 m)
DRILL POWER
Caterpillar Model 3406E ATAAC 450 hp (336 kW)
COMPRESSOR
Type 2 Stage Oil Flooded Screw Type
1800 rpm
FEED SYSTEM
ROTARY HEAD
Type Gear Case Type
WEIGHT
DIMENSIONS
ELECTRICAL
Page 1-12
DRILL RATING
Hole Size 6” to 9” (152 - 228 mm)
UNDERCARRIAGE
Length 15’ (4.57 m)
DRILL POWER
Caterpillar Model 3408E DITA 500 hp (373 kW)
COMPRESSOR
1800 rpm
FEED SYSTEM
ROTARY HEAD
Type Gear Case Type
WEIGHT
DIMENSIONS
ELECTRICAL

DRILL RATING
Hole Size 6” to 8” (152 - 203 mm)
UNDERCARRIAGE
Length 15’ (4.57 m)
DRILL POWER
COMPRESSOR
Manufacturer Sullair 1000cfm (28.3m³m) @ 350 psi (24.1 bar)
@ 1800 rpm
FEED SYSTEM
ROTARY HEAD
Type Gear Case Type
WEIGHT
DIMENSIONS
ELECTRICAL
Page 1-14
DRILL RATING
Hole Size 6” to 9” (152 - 228 mm)
UNDERCARRIAGE
Length 15’ (4.57 m)
DRILL POWER
COMPRESSOR
1800 rpm
FEED SYSTEM
ROTARY HEAD
Type Gear Case Type
WEIGHT
DIMENSIONS
ELECTRICAL

DRILL RATING
Hole Size 6” to 9” (152 - 228 mm)
UNDERCARRIAGE
Length 15’ (4.57 m)
DRILL POWER
Caterpillar Model C16 600 hp (447 kW) Sn.732691 & Up
COMPRESSOR
1800 rpm
FEED SYSTEM
ROTARY HEAD
Type Gear Case Type
WEIGHT
DIMENSIONS
ELECTRICAL
Page 1-16
RECOMMENDED TORQUE VALUES FOR STANDARD HARDWARE - UNC
This table applies to Driltech part numbers:

001554-___ CAPSCREW, Hex hd Gr. 5
001559-___ CAPSCREW, Socket hd Gr. 8
001570-___ SCREW, Flat hd socket Gr. 8
001577-___ NUT, Hex - regular Gr. 5
001575-___ NUT, Hex - heavy Gr. 5
001562-___ NUT, Hex - self-locking Gr. 5
Coarse Thread (UNC) Torque Torque

Size Grade 5 Grade 8
(Diameter in Inches) Ft.Lb. (Kg/M) Ft.Lb. (Kg/M)
1/4 6 (.8) 9 (1.2)
5/16 12-14 (1.5) 17-19 (2)
3/8 22-24 (3) 31-34 (4.5)
7/16 36-39 (5) 50-55 (7)
1/2 54-59 (8) 76-84 (11)
9/16 77-85 (11) 110-120 (15-16.5)
5/8 107-118 (15-16) 153-166 (21-23)
3/4 190-210 (26-29) 270-292 (37-40)
7/8 280-310 (38-43) 437-475 (60-66)
1 425-460 (59-63) 650-710 (90-98)
1-1/8 570-620 (79-86) 930-1000 (128-138)
1-1/4 810-870 (112-120) 1310-1410 (181-195)
1-3/8 1060-1140 (146-157) 1730-1850 (239-256)
1-1/2 1410-1510 (195-209) 2290-2460 (316-340)
NOTE: These torque values are to be used for general assembly procedures. Special torque requirements may be
specified on assembly and installation procedures.
NOTE: All fasteners are to be free of dirt and rust at time of assembly. Lubrication is not to be applied to threads
unless so specified.

RECOMMENDED TORQUE VALUES FOR STANDARD HARDWARE - UNF
This table applies to Driltech part numbers:

001560-___ CAPSCREW, Socket hd Gr. 8
001571-___ SCREW, Flat hd socket Gr. 8
001578-___ NUT, Hex - regular Gr. 5
001576-___ NUT, Hex - heavy Gr. 5
001563-___ NUT, Hex - self-locking Gr. 5
Fine Thread (UNF) Torque Torque

Size Grade 5 Grade 8
(Diameter in Inches) Ft.Lb. (Kg/M) Ft.Lb. (Kg/M)
1/4 7 (1) 10-11 (1.5)
5/16 14-16 (2) 20-22 (3)
3/8 25-28 (3.5) 35-39 (5)
7/16 39-43 (6) 55-61 (8)
1/2 63-69 (9) 86-94 (12)
9/16 87-95 (12-13) 123-134 (17-18.5)
5/8 126-138 (17-19) 171-187 (24-26)
3/4 213-233 (30-32) 300-328 (42-45)
7/8 312-338 (43-46) 480-520 (66-72)
1 466-504 (64-70) 715-770 (99-106)
1-1/8 640-695 (89-96) 1040-1120 (144-155)
1-1/4 900-960 (124-133) 1460-1560 (202-216)
1-3/8 1210-1300 (167-180) 1970-2100 (272-290)
1-1/2 1585-1700 (167-180) 2570-2750 (272-290)
NOTE: These torque values are to be used for general assembly procedures. Special torque requirements may be
specified on assembly and installation procedures.
NOTE: All fasteners are to be free of dirt and rust at time of assembly. Lubrication is not to be applied to threads
unless so specified.
Page 1-18
COOLANT, FUEL and WATER QUALITY
LUBRICANT MINERAL MEASUREMENT
SPECIFICATIONS Chloride 40 ppm

as (C1)
Sulfur 100 ppm

as (SO4)
COOLANT SPECIFICATIONS (CUMMINS)
Calcium Magnesium 170 ppm as
(Hardness) (CaCo3 + MgCo3)
Testing the coolant with Cummins test kit CC-
2602 is recommended twice a year to monitor
ppm = parts per million
SCAs (Supplemental Coolant Additive). If the
SCA level is above 3 units, test at subsequent
oil drain intervals until the concentration is back
under 3 units, start installing the correct service Antifreeze (CUMMINS)
filters at each drain interval. If the concentration
is below 1.2 units per gallon, replace the filter Always use a low-silicate ethylene glycol-type
and precharge with liquid. antifreeze that meets ASTM D4985 specifica-
tions (less than 0.10% silicate, expressed as
Always use a mixture of approved fill water, and Na2S103). The correct amount to provide protec-
fully formulated antifreeze. tion to the lowest expected operating environ-
ment.
Refer to the Cummins Operation and Mainte-
nance manual for detailed specifications.
Coolant Conditioner Elements (CUMMINS)
COOLANT SPECIFICATIONS (CATERPIL- Correct use of SCAs (Supplemental Coolant

LAR) Additive) in conjunction with water and anti-
freeze are needed to protect engines from cool-
Always use a mixture of approved fill water, ing system problems. The system must be
antifreeze and Cooling System Conditioner. precharged with the correct concentration of
SCA.
Refer to the engine manufacturer for detailed
specifications, or Caterpillar® form SEBD0518. When coolant is replaced in the field, it must be
replaced with heavy duty coolant precharged
with SCAs. In addition, a service coolant filter
FILL WATER (CUMMINS) must be installed. Together, this will result in a
total precharge of approximately 1.5 SCA units
Never use plain water only in the cooling sys- per gallon of coolant.
tem. Water quality is important for cooling sys-
tem performance. Excessive levels of calcium
and magnesium contribute to scaling problems, FILL WATER (CATERPILLAR)
and excessive levels of chlorides and sulfates
cause cooling system corrosion. Always add conditioner to coolant water. Never
use plain water only in the cooling system.
Acceptable water for use in the preparation of

Coolant, Fuel and Lubricant Specifications - Page 2-1
ethylene glycol type antifreeze and water mix- economy.
ture is shown in the follow chart.
The viscosity of the fuel must be kept above
ACCEPTABLE WATER 1.3cSt to provide adequate fuel system lubrica-
tion.
Water Content 50% Antifreeze/ Without For a more detailed description of fuel proper-
50% Water Antifreeze ties, refer to Cummins Engine Bulletin No.
Chlorides 100 ppm 50 ppm 3379001.
or less or less
Sulphates 100 ppm 50 ppm

FUEL SPECIFICATIONS (CATERPILLAR)
or less or less
Hardness as 200 ppm 100 ppm Caterpillar® manufactured diesel engines have
CaCO3 or less or less the ability to burn a variety of fuels. These fuels
Dissolved 500 ppm 250 ppm are divided into two categories: Preferred or
Solids or less or less Permissible.
pH 6.5 or higher 6.5 or higher
Preferred fuels provide maximum engine ser-
vice life and performance. These fuels are distil-
ppm = parts per million
late fuels and are commonly called; fuel oil,
furnace oil, diesel fuel, gas oil or kerosene.
Antifreeze (CATERPILLAR) Permissible fuels are crude oils or blended
fuels. Use of these fuels can result in higher
Always use ethylene glycol-type antifreeze and maintenance costs and reduced engine service
the correct amount to provide protection to the life.
lowest expected operating environment.
Refer to form SEHS7067 from Caterpillar® for a
detailed summary of preferred fuels and their
Coolant Conditioner Elements (CATERPIL- specifications.
LAR)
Coolant conditioner elements should be used to Cetane Requirement (CATERPILLAR)

maintain a 3 to 6% concentration of conditioner
in the coolant. Use a precharge element when The minimum fuel cetane number recom-
filling the system or changing coolant. Install a mended for this engine is 40.
new maintenance element after every 250
hours of service.
Fuel Cloud Point (CATERPILLAR)
FUEL SPECIFICATIONS (CUMMINS) Fuel waxing can plug the fuel filters in cold
weather. The fuel cloud point must be below the
Cummins Engine Company, Inc. recommends temperature of the surrounding air to prevent fil-
the use of ASTM No. 2 diesel fuel. The sue of ter waxing and power loss. Fuel heating attach-
No. 2 diesel fuel will result in optimum engine ments can minimize fuel filter waxing and are
performance. At operating temperatures below available from your Driltech or Caterpillar®
0°C (32°F), acceptable performance can be dealer.
obtained by using blends of No.2 and No.1 die-
sel fuel. The use of lighter fuels can reduce fuel
Page 2-2
Fuel Sulphur Content (CATERPILLAR) LUBRICANT SPECIFICATIONS
The percentage of fuel sulphur content will

affect the engine oil and filter change intervals General
(refer to the following chart).
The classifications listed below follow S.A.E.
J183 classifications. The MIL specifications are
CRANKCASE OIL CHANGE INTERVALS USA Military Specifications. The following defi-
(CUMMINS) nitions will be of assistance in purchasing lubri-
The recommended method used to determine cants. The specific classifications for this
the proper oil and filter change interval is the machine are found on the Lubricant Chart.
Chart Method (base on known fuel and oil con-
sumption rates). Using the Chart Method will
require information listed below to determine Engine Oils (CH-4) (CUMMINS)
the correct oil and filter change interval:
• Fuel Consumption Rate Only use oils that meet API performance classi-
• Oil Consumption Rate fication CH-4.
• Total System Capacity
At the factory, this machine was filled with BP
The Cummins engine Operation and Mainte- 15W - 40.
nance manual provides information on deter-
mining these rates. NOTE!
The engine oil and filter should be changed
after the first 50 hours of service on new and
CRANKCASE OIL CHANGE INTERVALS reconditioned engines.
(CATERPILLAR)
Engine Oils (CH-4) (CATERPILLAR)
Fuel Sulphur Oil Change Interval Only use oils that meet Engine Service Classifi-
0.0% to 0.4% 250 Hours cation CH (MIL-L-2104D).
0.4% to 1.0% 125 Hours
At the factory, this machine was filled with BP
1.0% to 1.5% 62 Hours 15W - 40. Consult the Caterpillar form
SEBU5939 for a listing of CH oil brands.
NOTE!
If the fuel has over 0.5% sulphur content, the NOTE!
CG engine oil must have a Total Base Number The engine oil and filter should be changed
(TBN) of 20 times the percentage of fuel sulphur after the first 50 hours of service on new and
(TBN as measured by the ASTM D-2896 reconditioned engines.
method). If the sulphur content is greater than
1.5% by weight, use an oil with a TBN of 30 and
reduce the oil change interval by one half. Con- Lubricating Grease (MPGM)
sult your Caterpillar® dealer for correct engine
oil recommendations. Use only multi-purpose grease (MPGM) which
contains 3 to 5% molybdenum disulphide. NLGI
No, 2 Grade is suitable for most temperatures.
Use NLGI No. 1 or No. 0 Grade for extremely
low temperatures.

Compressor Oils (COMP) REFILL CAPACITIES
As with any oil Do not mix different types of oils.

Contamination of synthetic oils with traces of
COMPONENT GALLON LITRE
AFT may lead to foaming or plugging of orifices.
RECEIVER TANK 70 265
When operating between 80 and 100°F (27 and FUEL TANK 200 757
38°C) and with relative humidity above 80%, a
HYDRAULIC TANK 135 511
synthetic hydrocarbon type fluid is recom-
mended. PUMP DRIVE GEARBOX 3 qt 3
ROTARY DRIVE GEARBOX 5.5 21

Machines shipping today are filled with Shell
Corena compressor oil. LUBRICATOR TANK 10 38
CENTRALIZED LUBRICA- 30 lb 13.5 kg

NOTE! TIONS SYSTEM
Compressor oil change intervals will change ENGINE CRANKCASE 9 34
depending on the type of oil used. The oil manu- (CATERPILLAR 3406E, C15)
facturers recommendations supersede the rec- ENGINE CRANKCASE 12 45
ommended interval suggested in this manual. (CATERPILLAR 3408E, C16)
ENGINE CRANKCASE 13 49
(CUMMINS QSK19)
Hydraulic Oils (HYDO)
COOLANT 25 95
(CUMMINS QSK19)
Use industrial-type hydraulic oils that are approximately
certified by the oil supplier to have anti-wear,-
COOLANT 25 95
foam, -rust, and -oxidation additive properties (CATERPILLAR 3406E, C15)
for heavy duty usage. approximately
COOLANT 25 95
At the time of shipment this machine was filled (CATERPILLAR 3408E, C16)
with Citgo 32 AW hydraulic oil. approximately
WINCH 2 pt 1
Multipurpose - Type Gear Lubricant (MPL) CRAWLER FINAL DRIVE (ea) 2 8
WATER INJECTION 230 870

Use Gear Lubricant Classification GL-5 (MIL-L- TANK(WO/DUST COLLECTOR
2105B) EP140. Use SHC 75 x 90 in cold ambi- WATER INJECTION TANK(W/ 120 454
ent conditions and SHC 5 x 90 in arctic condi- DUST COLLECTOR
tions.
WATER INJECTION PUMP 1 qt 1
Refrigeration Oil (REF)
Use an ISO 100 refrigeration oil.
Page 2-4
505
RECOMMENDED LUBRICANT VISCOSITIES

OUTSIDE °F -22 -4 +14 +32 +50 +68 +86 +104 +122
TEMPERATURE °C -30 -20 -10 0 +10 +20 +30 +40 +50
ENGINE CRANKCASE SAE 5W-30

CH-4 (CUMMINS) SAE 10W-30
SAE 15W-40
SAE 5W -20(SPC)
SAE 5W-20
ENGINE CRANKCASE SAE 10W

CH-4 (CATERPILLAR) SAE 10W-30
SAE 15W-40
SAE 30
SAE 40
COMPRESSOR -40°F ISO 32

COMP
Note oil change intervals ISO 46
ISO 68
CD SAE 10W
UNDERCARRIAGE, CD SAE 30
FINAL DRIVE GEARBOX CD SAE 40W
MPL CD SAE 50W
32AW
HYDRAULIC SYSTEM 46AW
HYDO 68AW
100AW
WATER INJ. PUMP - CH SAE 30

SAE 10W-30
ROTARY HEAD, WINCH and

GL-5 EP 90
PUMP DRIVE GEARBOX
MPL SHC 75W-90
SHC 5W-90
ISO 46-100
HAMMER OIL ISO 100-220
RDO
220-460
AUTOLUBE PUMP CH SAE 10W

996
EQUIVALENT HYDRAULIC OILS
LUBRICANT ISO ISO ISO ISO

MANUFACTURER
BRAND NAME 22 32-46-68 100 150
ACCITE HIDRAULICO MH PETROLEOS MEXICANOS X X
AMOCO AW OIL AMOCO OIL CO. X
AMOCO RYDON OIL MV AMOCO OIL CO. X X
ANTECH EXXON/ESSO X
ASHLAND VG ASHLAND OIL CO. 32
BARTRAN HV BP OIL CO. 46 & 68
BRESLUBE VG BRESLUBE LTD.-CANADA X X
CANADIAN OIL MOXY T OIL CANADA X X X
CANVIS AW BP OIL CO. X X
CHAMPION SUPER GRADE LOWE OIL X
CHEVRON AW CHEVRON X
CITGO AW CITGO X X X
D-A WEAR GUARD II VG D-A LUBRICANT CO.-USA X
DECOL ANTI-WEAR SHELL CANADA X X X
DTE 24-25-26 MOBIL OIL CORP. X
DURO AW ARCO X X
EAL SYNDRAULIC MOBIL OIL CO. X
ELF OLNA DS ELF/ANTAR X
ENERGOL HLP-HD SERIES BP OIL CO. X X
EPPCO UNIVIVERSAL GP EPPERT OIL CO. X
GULF HARMONY AW GULF R&D X
GULF SYNFLUID SL H__AW GULF USA X
HIDRALUB EP MARAVAN S.A. X X
HARMONY AW GULF CANADA LTD. X X
HYDRAFLOW PETRO CANADA X X X
HYDRALUBE AW LUSCON IND. X X
HYDRELF DS ELF 46 & 68
HYSPIN AWS-AD CASTROL INC. X
HYTAC DISTAC LUBRICANTS X X
KENOIL R&O AW KENDALL REFINING CO. X X
LUSCON HD LUSCON IND. X X
MARATHON MULTI. VG MARATHON PETROLEUM X X
MOBIL HYD. OIL NZ MOBIL OIL CO. X
MOBIL HYD. OIL ZF MOBIL OIL CO. X
MYSTIK AW/AL CATO OIL & GREASE CO. X X
(Page 1 of 2)
Page 2-6
996
LUBRICANT ISO ISO ISO ISO
MANUFACTURER
BRAND NAME 22 32-46-68 100 150
NERVOL FLUID SH2 NERVOL X X X
NUTO-H EXXON/ESSO X X X
NUTO-HP EXXON/ESSO 32 & 46
NUTO-H PLUS EXXON/ESSO X
NYCO HYD. OIL NYCO LUBRICANT CORP. X X
ORLY AGENA ORLY INTERNATIONAL X
ORLY GALA ORLY INTERNATIONAL X
ORLY HYDRO ORLY INTERNATIONAL X
PACER POWER V PACER LUBRICANT INC. X X X
PARADENE ANTI-WEAR AW DRYDEN OIL CO. - USA X X X
PEAK HYDRA AW SERIES PEAK OIL CO. 46 & 68 X
PEN PREMIUM EP PENTAGON CORP. 32 & 68 X
PENNZBELL AW PENNZOIL PROD. CO. X X
PENNZOIL AW PENNZOIL PROD. CO. X X X
PENNZOIL AWX PENNZOIL PROD. CO. X X
RANDO OIL HD TEXACO INC. - USA X X
ROL ANTELITTERAM HVI ROL RAFFINERIA X
ROYAL AW EPPERT OIL CO. X
ROYAL PREMIUM VG EPPERT OIL CO. X
RYKON OIL AMOCO OIL CO. X
SELCO SF 330 SELCO X X X
SHARLU HYDROFLUIDS AW SHARJAH NATIONAL LUBE OIL X

CO. LTD.
SHOSEKI W-R SHOWA OIL LTD.-JAPAN X 32, 46 & 56
STAR PREMIUM VG EPPERT OIL CO. X
SUNVIS 8__ WR SUNCOR or SUNTECK X X X
SUPER BLUE HYD. OIL AUTOLINE OIL CO. X X X
SUPER HYD. OIL VG CONOCO X X
TELLUS SHELL CANADA LTD. X X X
TELLUS SHELL CO. - USA X X
TERRAPIN IND. OIL AUTOLINE OIL CO. X X X
TOTAL AZOLI A ZS J.W.LANE 46 & 68 X
TRC HYD. OILS VG TEXACO REFINERY X
UNION UNAX AW VG UNION OIL - USA 32 & 46 X X
UNIVIS N EXXON/ESSO X X
UNIVIS N PLUS EXXON/ESSO X X
UNIVIS SHP EXXON/ESSO 32 & 46
YUKONG SUPERVIS YUKONG LTD. X
(Page 2 of 2)

MINIMUM PERFORMANCE STANDARDS FOR HYDRAULIC OILS
The following are typical properties of hydraulic oils for use in severe duty applications of axial pis-
ton and vane pumps. Any oil which meets these or similar properties or which is listed in the
approved list of Equivalent Hydraulic Oils may be used.
32 46 68 100
ISO VISCOSITY GRADE
(32AW) (46AW) (68AW) (100AW)
ASTM Viscosity Grade No.

(Saybolt) 150 215 315 465
Gravity: API 31.1 30.3 29.5 28.9
Viscosity, Kinematic: cSt

104°F (40.0°C) 30.04 42.70 62.9 96
212°F (100.0°C) 5.26 6.57 8.43 11.03
Viscosity, SSU
100°F (37.8°C) 155 220 325 500
210°F (98.9°C) 43.9 48.2 54.6 64
Viscosity Index,
ASTM D 2270 106 105 104 99
Interfacial Tension,
D 971
77°F:dyn/cm 31 31 31 32
Flash, P-M: °F (°C) 400 (205) 405 (208) 450 (233) 465 (241)
Flash, OC: °F (°C) 425 (219) 430 (222) 470 (244) 490 (255)
Fire, OC: °F (°C) 455 (235) 470 (244) 500 (260) 545 (285)
Pour: °F (°C) -25 (-32) -25 (-32) -20 (-29) +5 (+15)
Color, ASTM D 1500 L0.5 L0.5 L1.0 L1.5
Carbon Residue,
Ramsbottom:% 0.30 0.30 0.36 0.37
Rust Preventive Test,

ASTM D 665
Procedure A, 24 hr Passes Passes Passes Passes
Procedure B, 24 hr. Passes Passes Passes Passes
Neutralization No.
ASTM D 974
Total Acid No. 0.68 0.68 0.68 0.68
Oxidation Test, ASTM D 943

Time Oxidized
Hr. to 2.0 Acid No. 2000+ 2000+ 2000+ 1500+
Emulsion, FTMS 791 3201,

180°F
Dist. Water: Minutes 40-40-0 (3) 40-40-0 (3) 40-40-0 (4) 40-40-0 (6)
Aniline Point, ASTM

D 611: °F (°C) 217 (103) 220 (105) 228 (109) 234 (113)
Page 2-8
AIR COMPRESSOR LUBRICANT RECOMMENDATIONS
Driltech Mission encourages the user to participate in an oil analysis program with the oil supplier.
This could result in an oil change interval differing from what is stated in these tables.
NOTE!
Mixing synthetic oils with an ATF may lead to operational problems, foaming, or plugging of orifices.
Do not mix different types of fluids.
AMBIENT CHANGE LUBRICANT

ISO
TEMPERATURE INTERVAL DESCRIPTION
-40°F to +95°F (-40°C to +35°C) 1000 Hours 32 Mobil SHC-624, 924 & 1024
-40°F to +100°F (-40°C to +38°C) 1000 Hours* 32 Mobil Rarus 424
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Chevron HiPerSYN
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Chevron Tegra Synthetic
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Shell Corena PAO
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Royco 432
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Conoco Syncon R&O
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Texaco Cetus PAO
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Valvoline Syn Guard CP
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Petro-Canada Super SCF32
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Chevron HiPerSYN
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Citgo CompressorGuard
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Conoco Syncon R&O
+30°F to +100°F (-1°C to +38°C) 1000 Hours* 46 Mobil Rarus 425
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Petro-Canada Super SCF46
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Royco 446
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Texaco Cetus PAO
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Valvoline Syn Guard CP
+80°F to +120°F (+27°C to +49°C) 1000 Hours 68 Conoco Syncon R&O
+80°F to +120°F (+27°C to +49°C) 1000 Hours 68 Mobil SHC-626, 926 & 1026
Low and High Pressure Compressors
When operating between +80 and 100°F (+27 and 38°C) with a relative humidity above 80%, syn-
thetic hydrocarbon type fluid Mobil SHC or equivalent as recommended above should be used.
All lubricant recommendations are based on 1200 rpm maximum WARM-UP speed.
* 500 Hour interval with High Pressure compressors.

Page 2-10
6-10-98
UNDERCARRIAGE tom of seal ring ramp (7) and against retaining

lip (8).
(018157-000)
GENERAL
The crawlers used on this machine are a modi-

fied version of the crawlers used on Caterpil-
lar’s® 330 series excavators.
DUO-CONE SEAL INSTALLATION
The following instructions are for installing Cat- NOTE !

erpillar® Duo-Cone Seals used in several appli- Be sure that toric ring (2) is straight on seal ring
cations on the machine crawlers. (1) and is not twisted. Nicks, cuts and scratches
can cause leaks.
It is most important that correct assembly and
installation procedures are followed when Duo- 3. Put installation tool (9) onto seal ring (1) with
Cone Seals are used. Many of the Duo-Cone toric ring (2). Lower the rings into a container
Seal failures are the direct result of one or more with Trichloroethane until all surfaces of toric
mistakes made during assembly or installation ring (2) are wet.
of the seal components.
! WARNING
Avoid prolonged skin contact with Trichloro-
ethane. Avoid breathing the vapors in
enclosed areas without adequate ventilation
and no not smoke. Do not use near open
flame or welding operations or other heated 4. With all surfaces of toric ring (2) wet, use
surfaces exceeding 482° C (900° F). installation tool (9) to position seal ring (1) and
toric ring (2) squarely against housing (5) as
1. Remove any oil film, dust or other foreign shown. Use sudden and even pressure to pop
matter from toric rubber rings (2) and from (push) toric ring (2) under retaining lip (3) of
ramps (4) and (7) and lips (3) and (8) of both housing (5).
seal rings (1) and housings (5). Use Trichloro-
ethane and clean cloth or paper towels for wip-
ing.
NOTE !
Never permit oil to get on the toric rings or
ramps before both seal rings are put together in
their final assemblies position.
2. Put toric ring (2) on seal ring (1), at the bot-

018157-000 Sheet 1 of 2
6-10-98
5. Check assembled height (A) in at least four age.

places, 90° apart. The difference in height
around the ring must not be more than 1 mm
(.04”).
6. If small adjustments are necessary, do not

push directly on seal ring (1); use installation 9. Put a thin film of clean oil on the seal faces.
tool (9). Use an applicator, a disposable tissue or a
clean finger to distribute the oil evenly. Be care-
ful not to get any oil on the rubber toric rings.
7. Toric ring (2) can twist if it is not wet all

around during installation or if there are burrs or
fins on retaining lip (3) of housing (5).
NOTE !
Misalignment, twists and bulges of a toric ring
will cause seal failures. 10. Make sure both housings (5) are in correct
alignment and are concentric. Move the parts
IMPORTANT: Toric rings (2) must never slip on slowly and carefully toward each other.
the ramps of either seal rings (1) or seal ring
housings (5). To prevent slippage, wait a mini- NOTE !
mum of two minutes to let the Trichloroethane Do not slam seals together. High impact can
evaporate before further assembly. Once cor- scratch or break the seal components.
rectly in place, the toric ring must roll on the
ramps only. 11. Once in place, fasten all parts tightly.
8. Wipe seal faces (6) of seal rings (1) clean.

Use a lint free cloth or paper towel. No particles
of any kind are permissible on the sealing sur-
faces. Even a small piece from a paper towel
can hold the seal faces apart and cause leak-
018157-000 Sheet 2 of 2
6-10-98
FRONT IDLER NOTE!

To aid in the disassembly, rotate the idler and
(018157-063) spring 180° and slide it back into the frame.
Loosen the four bolts (3) but do not remove
them at this time. Slide the assembly out of the
crawler frame.
REMOVAL
5. Remove the four bolts (3) that hold the front
NOTE !
idler to the front support for the recoil spring.
The recoil spring and hydraulic track adjuster
Separate the front idler from the recoil spring
are removed at the same time.
and hydraulic track adjuster. The weight of the
front idler is 208 kg (460 lb). The weight of the
1. Refer to the topic “Track Assembly” and sep-
recoil spring and hydraulic track adjuster as a
arate the crawler track.
unit is 175 kg (385 lb).
2. Using the hydraulic track adjuster, extend
the front idler and recoil spring in the undercar-
riage frame assembly as far out as possible.
OVERHAUL
Disassembly
1. Thoroughly clean the outside of the front

1615395a.tif idler prior to disassembly.
2. Remove the fill/drain plug from the front

idler. Drain the oil from the idler into a suitable
container. The capacity of the idler is 555 ml
(19 oz.).
3. Using a pry bar, move the front idler and 3. Position the front idler on its side as shown
recoil spring assembly (1) partially out of the the below. The weight of the front idler is 208 kg
frame, and attach lifting straps as shown. (460 lb).
4. Remove two spring pins (1) from bearings

1615395b.tif (2). Fasten a hoist to two bearings (2), and
remove them from the shaft of the front idler.
The weight of each bearing is approximately 34
kg (75 lb).
4. Slide front idler and recoil spring out of the

undercarriage frame assembly as a unit. The
weight of the unit is 383 kg (845 lb).
018157-063 SHEET 1 OF 3
6-10-98
5. Remove Duo-Cone seals (3) from bearings 4. Temporarily install a bearing (2) on shaft (5).
(2). Install the shaft in the front idler. Install the
other bearing (2) on the shaft. Check the end
play of the shaft. The shaft end play must be
0.26 to 1.26 mm (.010 to .050 in). Remove two
bearings (2) and shaft (5) from the front idler.
NOTE !
The rubber seals and all surfaces that make
contact with the seals must be clean and dry.
After installation of the seals, put clean SAE 30
oil on the contact surfaces of the metal seals.
5. Install a Duo-Cone seal (6) in each side of

6. Remove shaft (5) from the front idler. the idler with tool (A).
7. Remove two O-ring seals (4) from shaft (5). NOTE !

Refer to the Introduction topic of the crawler
8. Remove Duo-Cone seal (6) from each side section of this manual for more information on
of the front idler. installing Duo-Cone seals.
9. Remove bushings (7) from each side of the

idler.
6. Install a Duo-Cone seal (3) in each bearing

(2) with tool (A).
Assembly
1. Thoroughly clean all parts of the front idler

prior to assembly.
2. Check the condition of bushings (7). If the

bushings are worn or damaged, use new parts
for replacement.
3. Lower the temperature of bushings (7), and 7. Check the condition of O-ring seals (4) used
install one in each side of the front idler with a on shaft (5). If the seals are worn or damaged,
press. use new parts for replacement. Install two O-
ring seals (4) on shaft (5). Put clean SAE 30 oil
018157-063 SHEET 2 OF 3
6-10-98
on the seals. INSTALLATION
8. Check the condition of spring pins (1) used 1. Be sure the mating surfaces on the front
to hold bearings (2) to shaft (5). If the spring support for the recoil spring and the two bear-
pins are worn or damaged, use new parts for ings for the front idler are clean and free of dirt
replacement. and debris prior to reassembly.
9. Install shaft (5) in either bearing (2). Be sure 2. Fasten a hoist to the recoil spring and
the spring pin hole in the shaft is in alignment hydraulic track adjuster. Put the unit in position
with the spring pin hole in the bearing. Also, be on the front idler. Temporarily install four bolts
sure the marking “R” and the milled surface of (3) that hold the unit together.
the shaft is facing toward the rear of the bearing
as positioned in the machine. Install a new 3. Fasten a hoist to the front idler and recoil
spring pin (1) to hold the unit together. Position spring and put the unit partially into the crawler
the slit in the spring pin as shown in the illustra- frame leaving the bolts (3) exposed. Tighten
tion that follows. the bolts.
4. Slide the front idler, recoil spring and

hydraulic track adjuster partially into the under-
carriage frame assembly leaving bolts (3)
exposed. Remove the hoist from the unit.
Tighten bolts (3) to 325 Nm (30 ft-lbs).
1615395b.tif
10. Install the shaft and bearing in the front idler.
11. Install the other bearing (2) on shaft (5). Be

sure the spring pin hole in the shaft is in align-
ment with the spring pin hole in the bearing.
Install a new spring pin (1) to hold the bearing to 5. Open the relief valve on the track adjuster
the shaft. only one turn.
12. Check the front idler for air leaks. Apply 245 6. Pull the assembly out of the crawler frame
to 265 kPa (35.5 to 38.5 psi) of air to the idler for and intall it in its correct position. Using a pry
a minimum of 30 seconds. If the pressure bar, slide the front idler and recoil spring the
gauge reading does not change in a 30 second remainder of the way into the crawler frame
time period, it can be assumed there are no assembly.
leaks in the front idler.
7. Refer to the topic “Track Assembly” and
13. Put the front idler in a vertical position. Fill reconnect the track assembly.
the front idler with 555 ml (19 oz.) of clean SAE
30 oil. Put a thin coat of thread lock on the
threads of the fill/drain plug, and reinstall it.
018157-063 SHEET 3 OF 3
6-10-98
018157-063 SHEET 4 OF 3
5-6-99
CRAWLER FINAL DRIVE into a suitable container.
(018157-106)
DESCRIPTION
c40-20
The final drive has an integral piston motor and
a hydraulically released (350 psi / 24 bar) multi-
ple disk brake. It is installed as a complete unit
into the crawler frame. The drive and hydraulic
motor have independent oil reservoirs. Although
the motor is integrated, servicing or replacing
the motor can be done without removal of the
drive.
DRAIN FILL/LEVEL
PLUG PLUG
The final drive consists of three planetary
stages. Each stage incorporates a set of
matched planetary gears which provide an 2. Remove bolts (23) holding motor (118) and
equal load distribution. All torque transmitting remove the motor from the drive. Plug all hoses
components are made of forged, quenched and and cap all ports.
tempered high-alloy steels. External gears are
carbonized. Precision roller bearings are used 3. Remove plug (108) from the drive cover to
exclusively. Two large, tapered roller bearings access and remove screw (109).
support the sprocket. A metal face seal protects
the unit against contamination. NOTE!
This screw does not need to be removed if only
The spring applied, hydraulically released, mul- the brake disks are being replace.
tiple disk brake is used as a safety brake. The
brake is released when pressurized by hydrau- 4. Compress brake back-up plate (26) and
lic oil. The inner disks (30) are splined to the remove snap ring (28). Release pressure on the
input coupler (3). The outer disks (29) are back-up plate until loose. Remove the back-up
splined to the spindle (1). When the brake is not plate.
pressurized, both the inner and outer disks are
compressed by a spring applied piston (25).
When the brake is pressurized, the springs (31
and 32) are compressed between the piston
and back-up plate (26), this frees the multiple
disks, which in turn, releases and opens the 1878163a.tif
brake.
PLATE
OVERHAUL
28
Disassembly
26
1. Position drive so that one of the drain hole is
at the bottom of the end cover and drain the oil
018157-106 SHEET 1 OF 5
5-6-99
5. Springs (31 & 32) should be removed from whether further disassembly is required.
brake piston (25) and kept together.
20. Rotate ring gear (49) of the drive assembly
6. Inject pressurized air into the brake release by hand. Listen carefully for sounds of rough-
port to help remove brake piston (25). ness in the bearings and feel for any tight or
loose spots while rotating. The drive should be
7. Remove brake disk stack (29 & 30) together stiff and have a uniform resistance to rotating. If
with coupling (3), and if screw (109) was the bearings do not feel loose or rough, do not
removed, remove shaft (87). Inspect the disk go any farther with the disassembly.
stack for wear or burned surfaces. Replace with
a brake disk kit and seal kit if any damage is 21. If face seal (15) is leaking, bearings (20 &
indicated. 21) have rough spots, or ring gear (49) rotates
too easily, the tapered roller bearings must be
8. Remove shaft (87). replaced.
9. Position the drive with the motor side facing 22. If face seal (15) was leaking, bearings (20 &
down. 21) and the face seal should be replaced.
10. Remove the twelve capscrews (106) and lift NOTE!

cover (104) off. Remove thrust washer (105). We strongly recommend replacement of the
face seal any time the tapered roller bearings
11. Remove the twelve bolts (67) and remove are adjusted or replaced. Under no circum-
ring gear end cover (51). stances should a new seal part be mated with
an old one.
12. Remove first stage sun gear (88).
23. Cut spindle nut (19) at dowel pins (44) and
13. Remove first stage planetary assembly (89). remove.
14. Remove snap ring (59) and remove sun 24. Press spindle assembly (1) out of flange
gear (52) from first stage planetary assembly (47).
(89)
25. Pull bearings (20 and 21) off of spindle (1)
15. Remove second stage planetary assembly and flange (47).
(53).
26. Remove snap ring (6) and slide out pilot ring
16. Remove snap ring (18) and remove sun (5) together with bearing (99).
gear (17) from second stage planetary assem-
bly (53). 27. Inspect the planetary stage assemblies as
complete units. Thoroughly clean the planetary
17. Remove the 24 socket head screws (48) and carriers as complete units, and the inside of the
lift ring gear (49) off. drive. Be sure to flush all old oil and contamina-
tion from the drive and tapered roller bearings.
18. Remove snap ring (8), and lift third stage Thoroughly clean and check both the gearing
planetary assembly (4) off of spindle (1). and the bearings for damage and apply new oil.
Remove thrust washer (100). If the gears or bearings need replacing they
must be replaced as complete sets.
19. If face seal (15) on the drive assembly is not
leaking, the pre-load on the tapered roller bear- 28. First stage planetary bearings (91) must be
ings (20, 21) has to be checked to determine replaced in sets of three pieces.
018157-106 SHEET 2 OF 5
21 47 5 4 99 100 11 12 17 18 54 55 67
20 19
15
8
1
51
90
118
91
106
59
88
109
018157-106
108
28
107
23 110
111
SHEET 3 OF 5
26 101
31 104
32
3
25
105
37
38
87
35
36
89
44 29 6 49 53 52 66
48 46
30
5-6-99
5-6-99
29. First stage planetary gears (90) must be NOTE!

changed as a complete set of three. We recom- It is recommended that the cups be cooled with
mend changing sun gear (88) along with this set dry ice or liquid nitrogen to help during installa-
of gears. tion.
30. Second stage planetary bearings (55) must 2. Press the cone of tapered bearing (20) onto
be replaced in sets of three pieces. spindle (1).
31. Second stage planetary gears (54) must be 3. Install one half of face seal (15) in output
changed as a complete set of three pieces. We flange (47) and the other half in spindle (1). Do
recommend changing sun gear (52) along with not use oil on the O-rings of the seal during
this set of gears. installation.
32. To remove sun gear (52) from the first stage NOTE!
planetary carrier, remove the snap ring (59). Be careful not to damage the metal face of the
seal or cut the O-rings during installation. Wipe
33. Third stage planetary bearings (12) must be the face of the seal with a lint free cloth to
replaced in sets of ten pieces. remove any contaminants.
34. Third stage planetary gears (11) must be 4. Lower the output flange (47) onto the spindle
changed as a complete set of five pieces. We (1). Take care not to damage the seal.
recommend changing sun gear (17) along with
this set of gears. 5. Install the cone of the tapered bearing (21)
on spindle (1).
6. Apply Loctite #638 to the threads of nut (19).

Assembly
7. While continuously rotating ring gear output
Before any assembly of the final drive can take flange (47) in one direction only, tighten spindle
place, the new spindle nut (19) must be lapped nut (19) to 5,531 ft-lb (7,500 Nm). This is
onto the threads of spindle (1). Lap the nut onto required to correctly pre-load the tapered roller
the threads as follows: bearing.
A. Apply a valve lapping compound to the 8. Install dowel pins (44) into nut (19) flush.
threads of the spindle.
9. Install bearing (99) in pilot ring (5). Install the
B. The new spindle nut (19) should be worked pilot ring in spindle (1) and secure it with snap
onto and off of the threads until the nut can be ring (6).
easily screwed on and off by hand. This proce-
dure ensures that the best torque setting can be 10. Install thrust washer (100) on pilot ring (5)
reached when setting pre-load. before placing third stage planetary assembly
(4) onto spindle (1).
C. Thoroughly wash spindle (1) and nut (19) to
remove all traces of the compound. 11. Lock the third stage planetary assembly to
the spindle by installing the snap ring (8) onto
1. Install the cup portions of bearings (20 & 21) the end of the spindle.
in output flange (47). Use a soft brass punch to
drive the cups fully against the shoulders. 12. Place O-ring (46) on ring gear (49) before
mounting the gear on flange (47). Secure with
018157-106 SHEET 4 OF 5
5-6-99
screws (48). Using a feeler gauge measure the clearance

between thrust washer (105) and sun gear (88).
13. Install sun gear (17) in planetary (4). Ideally the clearance should be.039 to.078 inch
(1 to 2 mm). If necessary replace the thrust
14. Install second stage planetary assembly (53) washer.
onto sun gear (17).
27. Secure cover (104) in place with twelve
15. Lock the second stage planetary assembly socket head screws (106). Torque the screws to
to sun gear (17) by installing the snap ring (18). 15.5 ft-lbs (21 Nm).
16. Install sun gear (52) in planetary assembly 28. Install screw (109) and tighten. Install plug
(53). (108).
17. Install first stage planetary assembly (89), 29. Place sleeve (103) in bushing (101) and
snap ring (59), and sun gear (88) into the drive. install in cover (104).
18. Install new O-ring (66) on ring gear end 30. Install capscrew (109) and tighten.
cover (51).
31. Install capscrews (110 & 111) and plug
19. Install cover (51) on ring gear (49) and (108).
secure with the twelve hex head bolts (67).
Torque the bolts to 64 ft-lbs (86 Nm). 32. Insert springs (31 & 32) into the back of pis-
ton (25).
20. Install input shaft (87) from the motor end
of the drive making sure to engage the splines 33. Place back-up plate (26) into position on top
with the sun gear (88). of springs (31 & 32).
21. Install coupling (3) over shaft (87) and into 34. Put snap ring (28) in the motor pilot and
bearing (99). compress the brake springs sufficiently to install
the snap ring (28) into the groove of the spindle.
22. Install new back-up rings (35) into spindle
(1). Install new back-up rings (38) onto piston 35. Before installing the motor CHECK THAT
(25). Install the back-up rings first and then THERE IS 1-2 mm OF CLEARANCE
install the piston seals between the back-up BETWEEN THE MOTOR SHAFT AND COU-
rings. Apply a thin coat of gear lube to piston PLER (3).
seals (36 & 37) before installation.
36. Install motor (118) and install the drive on
23. Assemble the brake disk stack (item 29 x 8 the crawler frame. Reconnect the hydraulic
pieces & item 30 x 7 pieces). hoses.
24. Install the assembled piston (25) into the 37. Rotate drive so that one fill plug is at 12
drive making sure to fully seat it against pilot o’clock position and the other is at 3 o’clock. Fill
ring (5). drive to bottom of 3 o’clock plug with gear oil.
Reinstall plugs.
25. Install O-ring (107) in cover (104). Apply
Loctite #270 to surface of thrust washer (105) 38. After four hours of operation, recheck the oil
before installing it in the cover. level.
26. Install cover (104) on ring gear cover (51).
018157-106 SHEET 5 OF 5
5-6-99
018157-106 SHEET 6 OF 5
10-15-02
FINAL DRIVE SPROCKET INSTALLATION
(018157-107 & -109) 1. Thoroughly clean the mating surfaces of the

sprocket and final drive prior to installation of
the sprocket.
REMOVAL
2. Fasten eyebolt (B) and a hoist to sprocket
(2), and put it in position on the final drive.
1. Separate the crawler track as described in
the topic’ Track Assembly - Separate’ in this
3. Put a thin coat of thread lock on the threads
section.
of the sixteen bolts (1) that hold the sprocket to
the final drive. Install the bolts that hold the
2. Using the jack cylinders, raise the machine
sprocket to the final drive. Tighten the bolts to a
so that the crawlers are not touching the
torque of 900 ± 100 Nm (660 ± 75 lb ft).
ground.
4. Lower the machine onto the crawler track
3. Remove the sixteen bolts (1) that hold the
and reconnect the track as described in the
sprocket to the final drive.
topic’ Track Assembly - Connect’ in this section.
4. Fasten an eyebolt (B) and a hoist to

sprocket (2) as shown. Remove the sprocket.
The weight of the sprocket is 88 kg (195 lb).
018157-107 & 018157-109 SHEET 1 OF 1

6-10-98
3-13-98
UPPER TRACK ROLLER riage frame assembly.
(018157-157)
REMOVAL
Remove the upper track rollers from the crawl-

ers as follows:
1. Position the machine on a flat level floor. 4. Place wood blocks and jack (A) under the
track assembly as shown and lift the track
! WARNING assembly off of the track carrier roller.
The grease in the track adjusting cylinder is

under high pressure. Grease coming out of
the relief valve of the track adjuster, which is
under high pressure, can penetrate the body
causing personal injury or death. When
loosening the tension on the track, loosen
the relief valve only one turn. Do not visu-
ally inspect the relief valve to see if grease is
being released from the track adjuster.
Instead, watch the track to see if it loosens.
If the track does not loosen after opening the 5. Support the roller and remove bolt (2) and
relief valve, move the machine forward and track carrier roller (3). The weight of the track
backward to release the tension. carrier roller is 25 kg (55 lb).
2. Release the tension on the track. Loosen

relief valve (1) only on turn. If the track does not
OVERHAUL
loosen after opening the relief valve, move the
machine forward and backward until the tension
Disassembly
is released.
1. Thoroughly clean the outside of the track
carrier roller prior to disassembly.
2. Remove plug (2), and drain the oil from the

carrier roller into a suitable container. The
capacity of the track carrier roller is 210 ml
(7oz.).
3. Loosen bolt (2) that holds track carrier roller

(3) to the mounting bracket on the undercar-
018157-157 SHEET 1 OF 5
3-13-98
3. Remove the three socket head bolts (1) and carrier roller.
cover (3) from the track carrier roller.
4. Remove O-ring seal (4) from cover (3).
5. Lift the washer off of retainer (7) then

remove socket head bolts (5) and (6) and 8. Remove Duo-Cone seal (10) from shaft
retainer (7) from the end of the shaft assembly. assembly (8).
6. Carefully remove shaft assembly (8) from 9. Measure distance (X) on the shaft assembly.
the track carrier roller. Record this dimension for assembly purposes.
Using a press, push shaft (8) out of collar (11).
Remove the O-ring seal from inside the collar.
10. Remove bearings (12) and (13) from the

track carrier roller.
7. Remove Duo-Cone seal (9) from the track
018157-157 SHEET 2 OF 5
3-13-98
4. Check the condition of the O-ring seal used

in collar (11). If the seal is worn or damaged,
use a new part for replacement. Install the O-
ring seal in the collar. Put clean oil on the seal.
5. Using a press, install collar (11) on shaft (8)

until dimension (X) is 127.4 ± 0.2 mm (5.02 ±
.008 in).
6. Determine shaft end play as follows:
NOTE !
Do not install the Duo-Cone seals in the track
Assembly carrier roller or collar (11) at this time.
1. Thoroughly clean all parts of the track carrier A.Install shaft assembly (8) in the track carrier
roller prior to assembly. roller without Duo-Cone seals.
NOTE ! B. Install retainer (7) and socket head bolts (5)
Do not reuse bearings (12) and (13). Use new and (6) on the end of shaft assembly (8).
parts for replacement.
C. Use a dial indicator to measure the end play
NOTE ! of shaft assembly (8). The end play of the shaft
Bearing (13) is a straight bearing. assembly must be 0.25 to 1.25 mm (.0098 to
.0492 in). Bearing (12) controls the amount of
2. Lower the temperature of bearing (13), and shaft end play.
install it in the inside bore of the carrier roller
with a press. Install the bearing until it is even D. Disassemble the track carrier roller, but do
with the shaft counterbore in the carrier roller. not remove collar (11) from shaft (8).
NOTE ! NOTE !
Bearing (12) has a flange on it. The rubber seal and all surfaces that make con-
tact with the seals must be clean and dry. After
3. Lower the temperature of bearing (12), and installation of the seals, put clean SAE 30 oil on
install it in the outside bore of the carrier roller the contact surfaces of the metal seals.
with a press. The outside bore can be identified
by the three threaded holes (H) in the track car- 7. Install Duo-Cone seal (10) in collar (11).
rier roller. Install the bearing until the flange on
the bearing makes contact with the counterbore NOTE !
in the track carrier roller. Refer to the Introduction topic of the Undercar-
018157-157 SHEET 3 OF 5
3-13-98
riage section of this manual for more information. Fill the track carrier roller with 210 ml
tion on installing Duo-Cone seals. (7oz.) of clean SAE 30 oil. Put a thin coat of
Caterpillar pipe sealant on the threads of plug
8. Install Duo-Cone seal (9) in the track carrier (2). Install plug (2).
roller (side without three threaded holes). .
.
9. Carefully install shaft assembly (8) in the

track carrier roller. Install retainer (7) and
socket head bolts (5) and (6). Install the washer
on retainer (7). INSTALLATION
.
1. Be sure the shaft of the track carrier roller
and the bore in the mounting bracket on the
undercarriage frame assembly is clean and free
of dirt.
2. Put the track carrier roller in position in the

mounting bracket. Adjust the carrier roller until
distance (B), the distance between the outside
face of the mounting bracket and the carrier
roller is 7.0 ± 0.5 mm (.28 ± .02 in).
10. Check the condition of O-ring seal (4) used

on cover (3). If the seal is worn or damaged,
use a new part for replacement. Put clean oil
on O-ring seal (4), and install it on cover (3).
11. Install cover (3) on the track carrier roller and

three socket head bolts (1) that hold it. 3. After adjusting the position of the carrier
roller in the mounting bracket, tighten bolt (2).
12. Put the track carrier roller in a vertical posi-
018157-157 SHEET 4 OF 5
3-13-98
4. Be sure the carrier roller rotates smoothly by

hand. Slowly lower the track assembly on to
the carrier roller.
5. Tighten the tension of the track. See the

Preventive Maintenance section in the Opera-
tors Manual.
018157-157 SHEET 5 OF 5
3-13-98
018157-157 SHEET 6 OF 5
6-10-98
TRACK ASSEMBLY the master pin.
(018157-273) 5. Using a ram, press the master pin out of the

master link and install a pilot pin in its place.
6. Start the machine and position the pilot pin

on top of the final drive sprocket.
SEPARATING THE TRACK
7. Remove the load off of the pilot pin and
1. Position the machine on level ground. remove the pilot pin.
8. Fasten a hoist to the rear of the track assem-

!! bly. Raise the track assembly off of the
WARNING sprocket and lower the track assembly to the
The grease in the track adjusting cylinder is floor.
under high pressure. Grease coming out of
the relief valve of the track adjuster, which is 9. Tram the machine off the track assembly
under high pressure, can penetrate the body
loosening the tension on the track assem-
bly, loosen the relief valve only one turn. Do CONNECTING TRACK
not visually inspect the relief valve to see if
grease is being released from the track 1. Install tooling (A) in the track link and on the
adjuster. Instead, watch the track assembly final drive sprocket as shown below.
to see if it loosens. If the track assembly
does not loosen, move the machine forward
and backward to release the tension.
2. Release the tension on the track assembly.

Loosen relief valve (1) for the track adjuster only
one turn. If the track assembly does not loosen
after opening the relief valve, move the machine
forward and backward until the tension is
released.
2. Start the machine. Move the sprocket for-

ward until the track assembly is pulled up on the
sprocket and the end of the track assembly is
forward of a vertical line through the center of
the sprocket. Remove tooling (A).
3. Install tool (B) between the first bushing in

the track link and the sprocket as shown below.
3. Move the track assembly until the master pin

is in located between the two upper rollers.
4. Remove the two track shoes directly above

018157-273 SHEET 1 OF 2
6-10-98
each other. The machine may have to be

moved back and forth to align the pin bores.
9. Put multipurpose grease in the master pin

bores in the track assembly and on the pilot pin.
Install the washers and spacers in the master
link and install the pilot pin used during track
removal. Move the track until the master link is
located between the two top rollers.
4. Move the sprocket forward. Use tool (B) to
guide the track assembly over the carrier rollers 10. Press in the master pin.
and the front idler.
11. Reinstall the track shoes.
5. Install pin and chain assembly (C) and pin
(1) between the links in the ends of the track 12. Tighten the tension of the track. See the
assembly as shown. Preventive Maintenance section in the Opera-
tors Manual.
6. Move the track assembly forward or back-

ward until the separation in the track assembly
is below a horizontal line through the center of
the sprocket.
7. Put multipurpose grease on two track bush-

ings (2), and install them in the track links as
shown. The grease will hold the bushings in
place.
8. Install tool (D) under the rear of the track

assembly as shown. Move the track assembly
backwards until the separation in the track
assembly closes and the pin bores in both ends
of the track assembly are in alignment with
018157-273 SHEET 2 OF 2
6-11-98
HYDRAULIC TRACK ASSEMBLY
ADJUSTERS 1. Be sure all parts of the hydraulic track

adjuster are clean and free of dirt and debris
(018157-282) prior to assembly.
DISASSEMBLY NOTE !
Install back-up rings (2) and (3) and O-ring
1. Refer to the topic ‘Front Idler’ for information seals (1) on piston (4) in the positions shown.
on removing the idler and track adjusting Back-up rings (2) and (3) can be identified by
assembly. their color. Back-up ring (2) is brown. Back-up
ring (3) is black. Do not interchange the posi-
2. Thoroughly clean the outside of the hydrau- tions of the back-up rings and O-rings. When
lic track adjuster. piston (4) is installed in cylinder (8), be sure to
keep it square to prevent possible damage to
3. Attach a grease gun to fill valve (6). Pump the back-up rings and O-ring seals.
grease through the fill valve and into cylinder (8)
to remove piston (4). Remove the piston. 2. Install O-ring seals (1) and back-up rings (2)
and (3) on piston (4) in the positions shown.
4. Remove the O-ring seals (1) and back-up
rings (2 & 3) from piston (4). 3. Put a small amount of multipurpose grease
on the sliding surface of piston (4). Be sure the
5. Remove the two bolts and stopper plate grease covers back-up rings (2) and (3) and O-
assembly (7) from cylinder (8). Remove relief ring seals (1). Also, put grease in the lower end
valve (5) and fill valve (6) from the cylinder. of cylinder (8). This will prevent air from getting
into the cylinder during installation of the piston.
6. Remove seal (9) from the cylinder. Install piston (4) in the cylinder. It may be nec-
essary to use a soft faced hammer to install the
piston in the cylinder.
4. Center the piston in the cylinder. Put a small
1 2 3 1 2 3 9
16153s91
6 7 8
5 4
018157-282 Sheet 1 of 2
6-11-98
amount of multipurpose grease on the inside

diameter of seal (9). Install seal (9) in the cylin-
der. Install the seal until it is even with the
outside surface of the cylinder or not more
than 0.5 mm (.02 in) below the outside sur-
face of the cylinder.
5. Reinstall relief valve (5) and fill valve (6) in

the cylinder. Tighten the relief valve and fill
valve to a torque of 34 N.m (25 lb ft).
6. Reinstall the stopper plate assembly (7) and

the two bolts which hold it.
018157-282 Sheet 2 of 2
6-11-98
RECOIL SPRINGS 3. Thoroughly clean the outside of the recoil

spring assembly.
(018157-283)
4. Install a ram adapter (D) on the service
stand ram cylinder (B) as shown.
DISASSEMBLY
General
1615114a
The disassembly of this component will require
several specialized tools. Contact the Caterpil-
lar Service Technology Group for more infoma-
tion.
The following procedure was written with the
assumption that a recoil spring service stand is NOTE !
availible. Two adjustable supports (1), reaction plate (2)
and movable plate (3) are part of service stand
(A).
! WARNING
The recoil spring assembly is assembled
with a force of several tons. Do not put the
recoil spring assembly under compression
or release the tension with nut (6). Damaged 1615114b
threads on recoil spring retaining rod (12) or
in nut (6) that holds the unit together, can
cause the assembly to come apart with
force, resulting in personal injury or death.
1615114g
5. Adjust the spacing between reaction plate

(2) and movable plate (3) so it is approximately
the same length as the recoil spring assembly.
Also, be sure two adjustable supports (1) are
positioned between the reaction plate and the
movable plate as shown.
NOTE !
Do not remove the hoist from the recoil spring
1. Refer to the topic ‘Front Idler’ for information assembly until the unit is leveled, centered and
on removing the idler and spring assembly. locked in tool (A).
2. Prior to disassembling and assembling the 6. The weight of the recoil spring assembly is
recoil spring assembly, be sure the recoil spring 175 kg (385 lb). Fasten a hoist to the recoil
service stand is on a level surface. spring assembly. Put the recoil spring assem-
bly in position on two adjustable supports (1) in
018157-283 Sheet 1 of 3
3-13-98
service stand (A). Adjust the two adjustable the service stand, resulting in personal
supports to align the centerline of the recoil injury or death.
spring assembly with the centerline of service
stand (A).
1615114e
1615114c
7. Put level (4) on the recoil spring assembly.

Reposition the recoil spring assembly until it is 8. Close covers (7) on service stand (A). Using
level, and the recoil spring retaining rod and nut hydraulic ram (B), compress the recoil spring
(6) are centered in the hole in reaction plate (2). assembly a small amount. Through the open-
The recoil spring assembly is leveled by moving ing in the end of the service stand, remove the
adjustable supports (1) up or down. After the two socket head bolts and the lock strip from
recoil spring assembly is leveled and centered, the end of the recoil retaining rod. Using a
install two pins (5) on the back side of reaction socket, remove nut (6) and the washer from the
plate (2) as shown. Operate tool (B) a small end of the recoil spring retaining rod. Release
amount to hold the recoil spring assembly in the force on the recoil spring assembly.
position between reaction plate (2) and mov-
able plate (3). Again, check to be sure the 9. Open the covers on the service stand. Fas-
recoil spring assembly is leveled and centered. ten a hoist to the disassembled recoil spring
assembly, and remove it.
1615114d
1615114f
! WARNING
The recoil spring assembly is assembled 10. Separate the components of the recoil
under a force of several tons. Do not put the spring assembly. Remove recoil spring retain-
recoil spring assembly under compression ing rod (12), support (10), and spring (9) from
until covers (7) on service stand (A) have support assembly (8).
been closed. It is possible for the recoil
spring assembly to twist and come out of
018157-283 Sheet 2 of 3
6-11-98
ASSEMBLY spring assembly.
5. Close covers (7) on the service stand. Com-

press the recoil spring with hydraulic ram (B).
! WARNING Open the covers and measure the assembled
The spring in the recoil spring assembly is length of the recoil spring assembly. Measure
assembled under a force of several tons. Do the distance from the end of recoil spring
not put the recoil spring under compression retaining rod (12) to the far end of support
or release the spring tension with nut (6) on (10). The assembled length of the recoil spring
the end of recoil spring retaining rod (12). assembly must be 697 mm (27.44 in). If the
Damaged threads on recoil spring retaining assembled length is not correct, close covers
rod (12) or in nut (6) can cause the assembly (7) on service stand (A), and adjust the spring
to come apart with force, resulting in per- length. If the assembled length is correct, install
sonal injury or death. washer (11) and nut (6).
1. Check the condition of the threads on recoil 6. Fasten a hoist to the recoil spring assembly,
spring retaining rod (12) and nut (6). If the and remove it from service stand (A). Put
threads are worn or damaged, use new parts for thread lock on the threads of the two socket
replacement. head bolts that hold lock strip (13) in place.
Install the lock strip and the two socket head
2. Check the inside of support assembly (8). bolts that hold it. Bend the lock strip over the
Be sure the support assembly is clean and free flats on nut (6).
of dirt and debris.
3. Assemble the recoil spring assembly

loosely. Install spring (9) in support assembly
(8). Install recoil spring retaining rod (12) and
support (10).
1615114g
4. Fasten a hoist to the recoil spring assembly,

and put it in position in service stand (A). Cen-
ter and level the recoil spring assembly. Oper-
ate ram (B), and guide the end of the recoil
spring retaining rod through the hole in reaction
plate (2). Again, check to be sure the recoil
spring assembly is leveled and centered in ser-
vice stand (A). Remove the hoist from the recoil
018157-283 Sheet 3 of 3
3-13-98
018157-283 Sheet 4 of 3
6-10-98
TRACK ROLLER, LOWER is enough clearance provided for removal of any

one of the track rollers.
(018157-296)
REMOVAL
1. Position the machine on a flat level floor.
! WARNING
The grease in the track adjusting cylinder is
under high pressure. Grease coming out of 4. Loosen the four bolts that hold track guide
the relief valve of the track adjuster, which is (1) to the undercarriage frame assembly. Do
under high pressure, can penetrate the body not remove the bolts at this time.
loosening the tension on the track, loosen 5. Position a lifting fork under track guide (1)
the relief valve only one turn. Do not visu- as shown. Remove the bolts that hold the
ally inspect the relief valve to see if grease is guide; then remove the guide.
being released from the track adjuster.
Instead, watch the track to see if it loosens.
If the track does not loosen after opening
the relief valve, move the machine forward
and backward to release the tension.
2. Release the tension on the track. Loosen

the relief valve (1) for the track adjuster only one
turn. If the track does not loosen after opening
the relief valve, move the machine forward and
backward until the tension is released.
6. Loosen the four bolts that hold track roller
(2) to the undercarriage frame assembly. Do
not remove the bolts at this time.
7. Position the lifting fork under track roller

(2) as shown. Remove the bolts that hold the
track roller; then remove the track roller. The
weight of the track roller is 54 kg (120 lb).
3. Lift the side of the machine, and install

tooling (A) under the frame as shown.
NOTE !
Adjust the height of the support stands so when
installed under the frame of the machine, there
018157-296 SHEET 1 OF 5
6-10-98
OVERHAUL
Disassembly
1. Thoroughly clean the outside of the track

roller prior to disassembly.
2. Drive plug (1) into the stopper in the end

of the track roller, and drain the oil from the
track roller into a suitable container. The capac-
6. Remove and discard the O-ring seal from
ity of the track roller is 380 ml (12 oz.).
shaft (5); then remove shaft (5) from roller (6).
3. Put the track roller in a press as shown.

The weight of the track roller is approximately
54 kg (120 lb). Press down on end collar (3),
and remove snap ring (2). Release the pres- 7. Remove and discard Duo-Cone seal (9)
sure on the end collar. Remove end collar (3). from end collar (8).
4. Remove plug (1) from inside the track

roller. 8. Remove spring pin (7) from end collar (8)
and shaft (5). Using a press, remove shaft (5)
5. Remove Duo-Cone seal (4) from end col- from end collar (8). Remove the remaining O-
lar (3). ring seal from shaft (5).
9. Remove and discard Duo-Cone seal (10)

from each end of the track roller.
0181573-296 SHEET 2 OF 5
6-10-98
NOTE !
Do not install the Duo-Cone seals (9 and10) in
the track roller or end collars at this time.
A. Install an O-ring seal in shaft (5) at the

end that has the spring pin hole. Lubricate the
O-ring seal with clean oil.
B. Lubricate the bore in end collar (8) with
clean oil. Using a press, install shaft (5) in end
collar (8). Using a press, install shaft (5) in end
collar (8). Be sure the spring pin hole in the
shaft is in alignment with the spring pin hole in
the end collar. Install spring pin (7) in the end
10. Remove bearing (11) from each end of collar and shaft.
the track roller with a press.
C. Install shaft (5) in track roller (6) without

the Duo-Cone seals. Install end collar (3) with-
Assembly out Duo-Cone seals; then install snap ring (2).
D. Use a dial indicator to measure the end
1. Thoroughly clean all parts of the track play of shaft (5). The end play of the shaft must
roller prior to assembly. be 0.25 to 1.25 mm (.0098 to 0.0492 in). Bear-
ings (11) control the amount of shaft end play.
NOTE ! E. Disassemble the track roller, but do not
Do not reuse bearings (11). Use new parts for remove shaft (5) from end collar (8).
replacement.
NOTE !
2. Check the condition of the two O-ring The rubber seals and all surfaces that make
seals used on shaft (5). If the seals are worn or contact with the seals must be clean and dry.
damaged, use new parts for replacement. After installation of the seals, put clean SAE 30
oil on the contact surfaces of the metal seals.
3. Lower the temperature of bearings (11),
and install one in each end of the track roller 5. Install a Duo-Cone seal (10) in each end
with a press. Install the bearings until they of the track roller.
make contact with the counterbore in the track
roller. NOTE !
Refer to the Introduction topic of the crawler
4. Determine shaft end play as follows: section of this manual for more information on
installing Duo-Cone seals.
018157-296 SHEET 3 OF 5
6-10-98
6. Install Duo-Cone seal (9) in end collar (8). the roller for a minimum of 30 seconds. If the
pressure gauge reading does not change in a
7. Install Duo-Cone seal (4) in end collar (3). 30 second time period, it can be assumed there
are no leaks in the roller.
13. Put the track roller in a vertical position.

Fill the track roller with 380 ml (12 oz.) of the
type oil specified in the Lubrication section of
this manual. Install a new plug in the stopper in
the end of the track roller.
INSTALLATION
8. Install shaft (5) with end collar (8) in track
roller (6).
7. Be sure the mounting surfaces on the track
roller, the guide and the undercarriage frame
assembly are clean and free of dirt and debris
prior to installation of the track roller and guide.
8. Put track roller (2) in position on the under-

carriage frame assembly with the lifting fork (B).
Be sure the fill plug on the roller is facing out.
Install the four bolts that hold the roller in posi-
tion.
9. Install the O-ring seal in the groove on the

end of shaft (5). Lubricate the O-ring seal with
clean oil.
10. Lubricate the bore in end collar (3) with

clean oil.
11. Put the track roller in a press. Install end

collar (3) on the end of shaft (5). Push down on
end collar (3) with the press, and install snap 9. Put track guide (1) in position on the under-
ring (2). carriage frame assembly with tool (B). Install
the four bolts that hold the guide.
12. Check the track roller for air leaks. Apply

10. Prior to lowering the machine to the ground
245 to 265 kPa (36 to 39 psi) of air pressure to
and tightening the track, be sure all of the track
0181573-296 SHEET 4 OF 5
6-10-98
rollers rotate smoothly by hand.
11. Lift the machine off of the supporting stands

and remove the stands from under the machine.
Lower the machine to the floor.
12. Tighten the tension of the track. See the

topic Preventive Maintenance section in the
Operators Manual.
018157-296 SHEET 5 OF 5
6-10-98
0181573-296 SHEET 6 OF 5
FINAL DRIVE 1. Release the hydraulic system pressure.
Refer to Disassembly and Assembly,
018157-393 “Hydraulic System Pressure – Release” in
this manual.
GENERAL
Procedures for the Final Drives are Based on

330B Track Type Excavators.
REMOVAL
Separate the track assembly.
NOTE!
Care must be taken to ensure that fluids are 2. Remove four bolts (1) and the washers that
contained during performance of inspection, secure cover assembly (2). Remove cover
maintenance, testing, adjusting and repair of assembly (2) from the inside rear of the
the product. Be prepared to collect the fluid with undercarriage frame assembly.
suitable containers before opening any com-
partment or disassembling any component con-
taining fluids.
Refer to Special Publication, NENG2500, “Cat-

erpillar Tools and Shop Products Guide” for
tools and supplies suitable to collect and con-
tain fluids on Caterpillar products.
Dispose of all fluids according to local regula-

tions and mandates.
! WARNING NOTE!
At operating temperature, the hydraulic oil is When two tube assemblies (3) are doscon-
hot and under pressure. Hot oils can cause nected from the travel brake valve, oil will flow
burns. from the tube assemblies. Oil will also flow from
two hose assemblies (4) and (5) when the hose
To prevent possible personal injury, release assemblies are disconnected from the travel
the pressure in the implement hydraulic cir- motor. Place a suitable container under the
cuit (boom stick, bucket, and swing), travel tube assemblies and under the hose assem-
circuits, and the hydraulic oil tank at the blies in order to collect the oil.
filler cap before any hydraulic lines or com-
ponents are disconnected or removed. 3. Disconnect two tube assemblies (3) from the
travel brake valve. Disconnect hose assem-
Remove the filler cap only when the engine blies (4) and (5) from the travel motor. Put
is stopped and the filler cap is cool enough plugs in the ends of the tube assemblies and
to touch. in the ends of the hose assemblies in order
to prevent oil loss and keep contaminants
out of the hydraulic system.
Sheet 1 of 15
08-09-06
4. Remove elbow (6) from the travel motor. 8. Install two suitable sized forcing bolts (10) in
the forcing bolt holes in the frame. Tighten
the two forcing bolt holes in the frame.
Tighten the two forcing bolts evenly in order
to loosen the final drive from the undercar-
riage frame assembly
9. Carefully remove final drive (7) from the

undercarriage frame assembly. The com-
bined weight of the final drive and travel
motor is approximately 651 kg (1435 lb).
10. Remove two forcing bolts (10) from the

undercarriage frame assembly.
5. Fasten tooling (A) and a hoist to final drive
(7), as shown. Put a slight lifting tension on 11. Remove the travel motor from the final drive.
the final drive. Refer to Disassembly and Assembly, “Travel
Motor – Remove” in this manual.
DISASSEMBLY
Remove the final drive. Refer to Disassembly

and Assembly, “Final Drive – Remove” in this
manual.
1. Thoroughly clean the outside of the final

drive prior to disassembly.
6. Remove two plugs (9) from the forcing bolt
2. Put an alignment mark across the sections
holes in the undercarriage frame assembly.
of the final drive for assembly purposes.
The parts must be reinstalled in the part’s
7. Remove 20 bolts (8) and the washers that
original locations
secure the final drive to the undercarriage
frame assembly.
Sheet 2 of 15
3. Fasten the final drive to Tool (A), as shown. 8. Remove sun gear (6). Remove carrier
The combined weight of the final drive and assembly (7) by lifting the carrier assembly
final drive sprocket is 531 kg (1170 lb). straight up. The weight of the carrier assem-
bly is approximately 14 kg (30 lb).
4. Remove 20 bolts (1) and the washers that
secure the cover to the final drive.
5. Use a soft faced hammer and break the seal

between cover (2) and the ring gear. Fasten
Tool (B) and a hoist to cover (2), as shown.
Remove the cover. The weight of the cover
is 30 kg (66 lb).
NOTE!
Two spacers (8) are used with carrier assembly
(7). One of the spacers fits on the top side of
carrier assembly (7). The other spacer (8) is
located in the carrier of carrier assembly (15).
9. Remove spacer (8) from the carrier assem-

bly (7).
NOTE!
6. Remove thrust plate (5) from the cover.
Planetary gears (11) might have oil grooves “L”.
Note the position of the oil grooves in relation to
7. Remove 12 socket head bolts (3) and ring
the carrier for assembly purposes.
gear (4) from the cover.
10. Remove retaining ring (9) with Tool ( C ).
Remove two thrust washers (10) and plane-
tary gear (11) from the carrier. Remove
bearing (12) from the planetary gear.
11. Repeat Step 10 in order to remove the other

two planetary gears from the carrier.
Sheet 3 of 15
08-09-06
NOTE!
Spacer (16) may remain with carrier assembly
(15), or the spacer may remain with carrier
assembly (24). Refer to Step 19.
14. Remove spacer (16) from carrier assembly

(15).
12. Use a screwdriver, and remove retaining ring

(13) from the carrier. Remove sun gear (14)
from the carrier.
13. Use two people in order to remove carrier

assembly (15). Remove the carrier assem-
bly by pulling the carrier assembly straight NOTE!
up. The weight of the carrier assembly is If spring pin (17) is recessed below the outside
approximately 25 kg (55 lb). surface of the carrier, measure the depth of the
spring pin and record this measurement for
assembly purposes.
15. Drive spring pin (17) into planetary shaft (18)

with a hammer and a punch.
NOTE!
Planetary gears (20) might have oil grooves
“M”. Note the position of the oil grooves in rela-
tion to the carrier for assembly purposes.
16. Remove planetary shaft (18), two thrust

washers (19) and planetary gear (20) from
the carrier. Remove bearing (21) from the
planetary gear. Remove spring pin (17) from
Sheet 4 of 15
planetary shaft (18) with a hammer and a
punch.
17. Repeat Steps 15 and 16 in order to remove

the other two planetary gears from the car-
rier.
18. Use a screwdriver, and remove retaining ring

(22). Remove sun gear (23) from the carrier.
NOTE!
If spring pin (25) is recessed below the outside
surface of the carrier, measure the depth of the
spring pin and record this measurment for
assembly purposes.
21. Drive spring pin (25) into planetary shaft (26)

with a hammer and a punch.
NOTE!
Planetary gears (28) might have oil grooves “N”.
19. If spacer (16) was not removed in Step 14, Note the position of the oil grooves in relation to
remove the spacer from carrier assembly the carrier for assembly purposes.
(24) at this time.
22. Remove planetary shaft (26), two thrust
20. Slide a piece of steel bar stock between the washers (27) and planetary gear (28) from
planetary gears in carrier assembly (24), as the carrier. Remove two bearings (29) from
shown. Make sure that the bar stock is cen- the planetary gear. Drive spring pin (25) out
tered in the carrier assembly. Fasten a lifting of planetary shaft (26) with a hammer and a
sling and a hoist to the steel bar stock, as punch.
shown. Slowly lift carrier assembly (24) from
the final drive. The weight of the carrier 23. Repeat Steps 21 and 22 in order to remove
assembly is approximately 36 kg (80 lb) the other planetary gears from the carrier.
Sheet 5 of 15
08-09-06
NOTE! 26. Remove socket head bolts (33) from gear

It will be necessary to pry ring gear (30) away (34).
from the main housing (31) in order to install the
lifting slings. 27. Use Tooling (D) to remove gear (34) from
the housing.
24. Fasten lifting slings and a hoist to ring gear
(30), as shown. Remove the ring gear from
main housing (31). The weight of the ring
gear is 66 kg (145 lb).
28. Remove shims (35) from the housing.
25. Remove O-ring (32) from main housing (31).
29. Fasten Tool (E) and a hoist to main housing

(31), as shown. Separate the main housing
and the final drive sprocket from the motor
housing. The combined weight of the main
Sheet 6 of 15
housing and final drive sprocket is 191 kg bly and Assembly, “Final Drive Sprocket –
(420 lb). Remove and Install” in this manual for the
procedure to remove the final drive sprocket
from the main housing.
ASSEMBLY
! CAUTION
Make sure that all of the parts of the final
drive are thoroughly clean and free of dirt
and debris prior to assembly.
30. Remove Duo-Cone seal (36) from the motor
housing.
1. Check the condition of all the O-ring seals
that are used in the final drive. If any of the
O-ring seals are damaged, use new parts for
replacement.
NOTE!
If the final drive sprocket was removed from the
main housing, refer to Disassembly and Assem-
bly, “Final Drive Sprocket – Remove and Install”
in this manual for the correct installation proce-
dure.
2. Assemble the final drive on Tool (A).
31. Remove Duo-Cone seal (37) from the main

housing. 3. Apply 5P – 3931 Anti-Seize Compound to
the surfaces inside the main housing that
32. Use tooling (F) to remove bearings (38) and contact bearings (38) and (39). Install bear-
(39) from the main housing. ings (38) and (39) in the bearing’s original
locations in the main housing with a press.
33. If necessary, remove the final drive sprocket Install the bearings until the bearings contact
from the main housing. Refer to Disassem- the counterbore in the main housing.
Sheet 7 of 15
08-09-06
C. Rotate the main housing in order to seat the

bearings.
D. Reduce the load on bearing (39) to 1000 ±

100 kg (2200 ± 220 lb).
E. Maintain the load on bearing (39). Measure

the distanc between the top face of the motor
housing and the bearing inner race. Use a
depth micrometer to take this measurement in
several locations around the bearing. Compute
the average of the measured dimensions and
record the number. Call this dimension “Y”.
4. Use the following procedure to determine
the correct bearing preload and the correct
thickness of shims (35) that are used under
gear (34).
F. Use a depth micrometer and measure the

distance between the hub face and the gear
face of gear (34). Take measurements at sev-
eral locations around the gear. Compute the
A. Fasten Tool (E) and a hoist to main housing average of the measured dimensions and
(31), as shown. Install the main housing on the record the number. Call this dimension “X”.
motor housing.
G. Determine the correct thickness of the shim
B. Use a suitable press and a spacer to apply a pack which is made up of shims (35). The shim
load of 4000 kg (8820 lb) on bearing (39). pack is used between the motor housing and
gear (34). Use the following equation to deter-
mine the shim pack thickness.
Sheet 8 of 15
Shim pack thickness…. (Y) – (X) ± 0.05 mm NOTE!
(.002 inch) During the installation of the main housing on
the motor housing, make sure that the Duo-
NOTE! Cone seals are not scratched or damaged.
If two shims are required, install the thinner After installation of the main housing on the
shim next to gear (34) when the gear is motor housing, there will be a small gap
installed. between the components. The gap is caused
by the Duo-Cone seals. The gap will be elimi-
5. Remove the main housing from the motor nated during installation of gear (34).
housing.
NOTE!
The rubber seals and all of the surfaces that
contact the seals must be clean and dry. After
installation of the seals, apply clean SAE 30 oil
on the contact surfaces of the metal seals. For
more information concerning the assembly and
installation of Conventional Duo-Cone Seals,
refer to Disassembly and Assembly, “Duo-Cone
Conventional Seals – Install” in this manual
8. Fasten Tooling (E) and a hoist to main hous-

ing (31). Place the main housing and the
final drive sprocket in position on the motor
housing. Be careful not to damage the Duo-
Cone seals in either of the components dur-
ing installation.
6. Install Duo-Cone seal (37) in the main hous-

ing with Tool (D).
9. Place shim pack (35), which was determined

in Steps 4.a through 4.g, and gear (34) in the
correct position on the motor housing. If two
shims were required, put the thinner shim in
contact with gear (34). Make sure that all of
the holes in the components are in align-
ment with eachother.
7. Install Duo-Cone seal (36) in the motor hos-
ing with Tool (D).
Sheet 9 of 15
08-09-06
10. Apply a thin coat of 9S – 3263 Thread Lock

Compound on the threads of socket head
bolts in order to hold gear (34) in place.
Tighten the bolts evenly and tighten the bolts
in diagonally opposite pairs. Tighten the
bolts to a torque of 900 ± 100 N-m (660 ± 75
lb ft).
11. Use the following procedure to assemble

carrier assembly (24).
A. Apply clean SAE 30 oil on bearings (29).

Install two bearings (29) in planetary gear (28).
B. Install thrust washer (27) on each side of

planetary gear (28).
C. Install planetary gear (28) and thrust washers

(27) in carrier (24).
NOTE!
If planetary gear (28) has oil grooves “N”, make
sure that the planetary gear’s oil grooves are
facing in the correct direction. The oil grooves
must be facing toward gear (34) after installa-
tion in the carrier assembly (24) and in the main
housing.
D. Install planetary shaft (26) in carrier (24) and

through planetary gear (28). Make sure that the
spring pin hole in the planetary shaft is in align-
ment with the spring pin hole in the carrier.
E. Install spring pin (25) in the carrier and into

the planetary shaft. Install the spring pin to the
spring pin’s original depth below the outside
Sheet 10 of 15
surface of the carrier which was recorded during
disassembly. Orient the split in the sping pin so
that split faces either side in the carrier, as
shown.
F. Make a stake mark on each side of the spring

pin hole in the carrier. This will prevent the
spring pin from falling out of the spring pin hole.
Each stake mark should be approximately 1.5
mm (.06 inch) from the outside diameter of the
spring pin hole.
12. Repeat steps 11 through 11.f in order to 14. Install O-ring seal (32) in main housing (31).
install the other planetary gears in carrier
(24).
15. Thoroughly clean the mating surface of the

main housing (31) that contacts ring gear
13. Install carrier assembly (24) in ring gear (30). Apply a bead of 1U-8846 Sealant on
(30). The weight of carrier assembly (24) is the mating surface of ring gear (30). Fasten
approximately 36 kg (80 lb). Slide a piece of lifting slings and a hoist to ring gear (30).
steel bar stock between the planetary gears Place the ring gear in position on the main
in carrier assembly (24), as shown. Make housing. Make sure that the alignment mark
sure that the bar stock is centered in the car- on the main housing and the alignment mark
rier assembly. Fasten a lifting sling and a on the ring gear line up with each other. It
hoist to the steel bar stock, as shown. may be necessary to use a soft faced ham-
Lower the carrier assembly into position in mer to seat the ring gear on the main hous-
the ring gear. It may be necessary to move ing.
the carrier assembly back and forth during
installation in order to ensure that all gears
align and all gears mesh properly. Make
sure that the carrier assembly is seated
properly.
Sheet 11 of 15
08-09-06
C. Apply clean SAE 30 oil on bearing (21).

Install bearing (21) in planetary gear (20).
D. Install thrust washer (19) on each side of the

E. Install planetary gear (20) and thrust washers

(19) in carrier (15).
F. Install planetary shaft (18) in carrier (15) and

through planetary gear (20). Make sure that the
spring pin hole in the carrier is in alignment with
the spring pin hole in the planetary shaft.
G. Install spring pin (17) until the spring pin is to

the spring pin’s original depth below the outside
surface of the carrier which was recorded during
disassembly. Orient the split in the spring pin so
that the split faces either side of the carrier, as
shown.
H. Make a stake mark on each side of the

spring pin hole in the carrier. This will prevent
the spring pin from falling out of the spring pin
hole in the carrier. Each stake mark should be
approximately 1.5 mm (.06 inch) to 2.5 mm
(0.10 inch) from the outside diameter of the
spring pin hole.
17. Repeat Steps 16.a through 16.h in order to

install the other two planetary gears in car-
rier (15).

A. Install sun gear (23) in carrier (15).
NOTE!
If planetary gear (20) has oil grooves “M”, make
facing in the correct direction, which was noted
during the disassembly of carrier assembly (15).
B. Use a screwdriver in order to install retaining

ring (22) which secures sun gear (23) in the car-
rier.
Sheet 12 of 15
18. Place spacer (16) in position on carrier
assembly (24). Use two people to install
carrier assembly (15) in carrier assembly
A. Install sun gear (14) in carrier (7), as shown,
(24). The weight of the carrier assembly is
Refer to Illustration 456.
approximately 25 kg (55 lb). Rotate the car-
rier back and forth during the installation in
B. Use a screwdriver in order to install retaining
order to ensure that all gears engage prop-
ring (13) which secures sun gear (14) in the car-
erly. Make sure that the carrier assembly is
rier.
seated properly.
C. Apply clean SAE 30 oil on bearing (12).
Install bearing (12) in planetary gear (11).
D. Install thrust washer (10) on each side of

E. Install planetary gear (11) and thrust washers

(10) on the shaft of carrier (7).
NOTE!
If planetary gear (11) has oil grooves “L”, make
facing nit he same direction, which was noted
during the disassembly of carrier assembly (7).
F. Use Tool ( C ) in order to install retaining ring

(9) that secures the planetary gear in position.
NOTE!
Make sure that retaining ring (9) is installed with
the cross section of the ring in the position that
is shown.
20. Repeat Steps 19.a through 19.f in order to

install the other two planetary gears on car-
rier assembly (7).
Sheet 13 of 15
08-09-06
21. Install a spacer (8) on each side of sun gear

(14) in carrier assembly (7). 24. Use a 25.4 mm (1.00 inch) thick straight
edge and a depth micrometer in order to
measure dimension “Q”. Dimension “Q” is
from the machined surface of cover (2) to
the bottom of the insertion hole of thrust
plate (5). Record dimension “Q”.
NOTE!
Thrust plate (5) is available in several thickness-
ness.
25. Determine the correct thickness of thrust

plate (5). Use the following equation to
22. Install the spacers (8) and carrier assembly determine the thrust plate thickness. Thrust
(7) in carrier assembly (15). Make sure that plate thickness…. (Q) – (P) – 1.0 mm (0.04
the carrier assembly is seated properly. inch) to 2.0 mm (0.08 inch).
Install sun gear (6) in carrier assembly (7).
26. Use a plastic hammer in order to install the
correct thickness of thrust plate (5) in cover
(2).
23. Use a 25.4 mm (1.00 inch) thick straight

edge and a depth micrometer in order to
measure dimension “P”. Dimension “P” is 27. Place ring gear (4) in position in cover (2).
between the upper surface of sun gear (30). Make sure that all of the mounting bolt holes
Record dimension “P”. in both components are in alignment with
each other. Apply 9S-3263 Thread Lock
Compound on the threads of 12 socket head
Sheet 14 of 15
bolts (3) that hold ring (4) in place. Install
the socket head bolts. Tighten the socket
head bolts evenly.
29. Apply a thin coat of 9S-3263 Thread Lock

Compound on the threads of 20 bolts (1)
that hold cover (2) in position. Install the
28. Make sure that the machined surface of ring washers and bolts. Tighten the bolts evenly
gear (30) is thoroughly clean and dry and to a torque of 900 ± 100 N-m (660 ± 75 lb ft).
that the machined surface is free of dirt and
debris. Apply a bead of 1U-8846 Sealant 30. Install the final drive. Refer to Disassembly
around the machined surface of the ring and Assembly, “Final Drive – Install” in this
gear. Fasten Tooling (B) and a hoist to cover manual.
(2). Place the cover in the cover’s original
position on the ring gear. It will be neces-
sary to rotate the cover back and forth in
order to engage the planetary gears of car-
rier assembly (7) with the ring gear in cover
(2).
Sheet 15 of 15
08-09-06
Sheet 16 of 15
6-23-97
AIR CONDITIONER 500 Hours or Quarterly

• All daily and monthly services.
(019148-000) • Check motor brushes and blow out motor.
• Replace pressurizer filter.
• Replace return air filter media.
PREVENTIVE MAINTENANCE
2000 Hours or Annually
Although the system has been designed for
NOTE !
industrial use, it still requires routine service. It
This is probably best scheduled immediately
will improve performance, reliability and life.
prior to the cooling season.
• All daily, monthly, and quarterly checks.
• Replace compressor drive belts.
Two Weeks After Initial Start-Up Check the
• Replace receiver.
Following:
• Compressor mount, drive, and bracket for
NOTE !
alignment, tightness, belt tension.
On 134a systems this is very important as the
• System for leaks.
synthetic oils absorb far more moisture than
• Mounting bolts for tightness.
the mineral oils used on R12 systems.
• Fastening bolts for tightness.
Although refrigerant hoses should be barrier
• Any sign of malfunction.
type, they still allow moisture to be absorbed
• Motor brushes for signs of abnormal wear.
into the system.
• Fans for tightness on shaft.
• Electrical connections for tightness.
These filters can best be changed by “pumping
• Hoses for signs of chafing or rubbing.
the system down”. With the engine idling,
close the valve in the liquid line between the
condenser and receiver. Close the lid, and
Maintenance Schedule
operate on cool until the system cuts out on
“Low Pressure” .7 bar (10 psi), and stays cut
These are based on an “average” site condition
out. Open the condenser cover and close the
and should be adjusted according to your envi-
valve in the liquid line leading to the TX valve.
ronment.
The refrigerant between the two valves should
8 Hours or Daily
• Clean return air and pressurizer filters. be all vapor. The filters can then be removed,
• Check over system for signs of any abnor- replaced and the short section between the
mality. valves evacuated, and then pressure charged
with 134a.
250 Hours or Monthly
• All daily services. There should be no need to add more refriger-
• Leak check. ant, and filter replacement can be done is a
• Flush out drains. fraction of the time and cost if the whole charge
• Check seals. was lost.
• Flush out condenser area and coil.
• Check all connections. • Check motor commutator and brushes and
• Check compressor mount, drive and repair, or replace, as required. Consenser
bracket for alignment, tightness, belt ten- motors require particular attention as they
sion. are exposed, and if one fails it will cause
• Check hoses. operational problems with other areas. In
most cases, it is cost effective to put 2 new
motors in at the start of each year. Motors
019148-000 SHEET 1 OF 3
6-23-97
can typically have 1 brush change, and the Power is connected to the multi-pin connector
second set of brushes will only last half the and goes to the MODE switch, then the FAN
time of the first. SPEED (wire 101) or the cooling cycle (wire
• Replace internal heater hoses. 108). Circuit breakers protect all motors, and
• Thoroughly flush out evaporator and con- these are located behind the return air filter.
denser coils and chambers.
• Check and replace cover seals if necessary. If the button is out, there is an over current prob-
• Check fan blades and replace if damaged. lem and it should be checked & repaired.
The clutch cycles on pressure switches through

TROUBLESHOOTING a relay.
Many of the problems can be diagnosed by Fault finding is a process of elimination.

tracking the power line throughout the system.
PROBLEM REMEDY
WILL NOT START Check supply to Mode Switch in return air plenum, wire 100.
Check ground.
Check circuit breakers.
FAN SPEED Check power to 102 on Low, 103 on Med., 104 on High.
Check center tapping makes contact with resistor. This may be adjusted to suit.
Check if it is cycling on high pressure or low pressure controls. Gauges will indicate which one.
If suction cuts down to .7 bar (10 psi); it is low side, if discharge gets to 24 bar(350 psi) it is high
side.
INTERMITTENT COOLING. Refrigerant charge, is there a full sightglass?

IF IT IS LOW PRESSURE Is there a blockage in the system? (e.g. - drier, TX valve) A blockage can sometime be identified
CUT OUT CHECK THE FOL- by a drop in temperature after the blockage.
LOWING: Are liquid line valves wide open?
Is return air filter blocked?
Is evaporator fan running? In right direction?
Is evaporator pressure regulator set correctly?
INTERMITTENT COOLING. Is condenser coil blocked? If so, clean it.

IF IT IS HIGH PRESSURE Are both fans running? In right direction?
CHECK THE FOLLOWING: Is system overcharged? Full sightglass even after recovering some refrigerant.
Are liquid lines valves open?
Is there a blockage in the liquid lines.
Is there air in the system? Has system been opened and not evacuated properly?
INSUFFICIENT COOLING Charge, is there a full sightglass?

Are condenser area and coil clean?
Is TX valve operation satisfactory?
Is thermostat calling for cooling?
Does compressor have good pressure differential between high and low side at normal speeds?
Discharge should be 12-17 bars (175-250 psi) and suction .7-1.7 bars (10-25 psi). .
019148-000 SHEET 2 OF 3
NOTE: 1R = 1 OHM
2R = 1 OHM
1CB - 6 CB = 8 AMP
MODE SWITCH FAN SPEED SWITCH

2
3 4
HEAT
5 1 3
VENT
OFF
LOW
2
OFF
COOL
1R
HIGH
REHEAT
MEDIUM
1 6
1CB
2R BN
1M EVAPORATOR BLOWER
2CB MOTOR R.H.
2M
EVAPORATOR BLOWER MOTOR L.H.
3CB
019148-000 SHEET 3 OF 3
FRESH AIR BLOWER MOTOR 3M
4CB
CONDENSER FAN MOTOR #1
4M
5CB
CONDENSER FAN MOTOR #2
5M
1PS 2PS CLUTCH RELAY 1CR

6CB
TO COMPRESSOR CLUTCH
1CR
6-23-97
6-23-97
019148-000 SHEET 4 OF 3
6-6-97
DRIVESHAFT
(001022-000)
GENERAL
The following procedures are for driveshafts
manufactured by Spicer as the 1550 series.
The following topics are discussed; safety,
inspection, lubrication, and problem analysis.
SAFETY PRECAUTIONS
3. Check the slip spline for excessive radial
movement. Radial looseness between the slip
! WARNING yoke and the tube shaft should not exceed .17
mm (.007 inch).
Rotating driveshafts can be dangerous. You
can snag clothes, skin, hair, hands, etc.
This can cause serious injury or death.
Do not work on driveshaft (with or without a

guard) when machinery is operating.
If driveshaft is still exposed after installa-

tion, install a guard.
GENERAL INSPECTION 4. Check the shaft for damaged, bent tubing

or missing balance weights. Make certain there
is no build up of foreign material on the shaft. If
1. Check the mounting hardware torque of
found, foreign material should be removed care-
companion flanges on both ends of the shaft.
fully to avoid damage to the driveshaft.
2. Check for excessive wear across the ends
of the bearing assemblies and trunnions. This ! CAUTION
looseness should not exceed .15 mm (.006 Do not try to take runout readings from a
inch) maximum. rotating driveshaft under power!
5. If runout readings should be taken with

the driveshaft mounted such that it will rotate by
hand.
001022-000 SHEET 1 OF 4
6-6-97
ent from regular lube fittings and require a nee-

dle nose attachment for the grease gun.
.50 mm (.020 inch)
3. Don’t overlook slip yoke lubrication.
4. Use correct lube technique. New Lube

Must Flow From All Four Bearing Seals.
.25 mm (.010 inch)
5. Use correct lubricant. It should be a rec-
.12 mm (.005 inch)
ommended type, such as N.L.G.I. Grade 1 or 2
T.I.R. (Total Indicator Readings)
with E.P. additives and high temperature resis-
tance.
The runout readings taken at the various loca-
tions should not exceed an additional .25 mm 6. New U-joints must be lubricated when
(0.010 inch) T.I.R. (Total Indicator Reading) assembled into the driveshaft yokes.
over the manufacturer’s specified runout.
7. Observe recommended lubrication cycle.
FIELD PROBLEM ANALYSIS Generally, a lubrication problem is one of two

types--brinelling or end galling. The grooves
made by the needle roller bearings on the trun-
U-joint problems, as a rule, are of a progressive nion of the cross are known as brinelling.
nature. They generally accelerate rapidly and Brinelling can also be caused by too much
result in ruined components. torque for the capacity or the U-joint used. End
galling is a displacement of metal at the end of
Some recognizable signs of U-joint deterioration the trunnion and can also be related to angular-
are: ity problems. Both of these problems can be
caused by lack of lubrication.
1. Vibration
2. U-joint looseness Problems which are not a result of lubrication
3. U-joint discoloration due to excessive heat are associated with the installation, angles and
build-up speed of the driveshaft. Fractured parts caused
4. Inability to purge all four trunnion seals by torque, fatigue and bending are associated
5. An audible noise or squeal from the drive- with overload, excessively high u-joint angles
line and driveshaft lengths exceeding critical speed
limitations.
Lubrication-Related Problems
Vibration Related Problems
The most common reasons for U-joint wear are
lack of lubrication, inadequate lube quality, Vibration is a driveshaft problem that can be
inadequate initial lubrication or failure to lubri- either transverse or torsional.
cate properly and often enough. To avoid lubri-
cation-related problems: Transverse vibration is the result of unbalance
acting on the supporting shafts as the driveshaft
1. Lube all fittings including those that are rotates. When a part having an out-of-balance,
often overlooked, out-of-sight, dirt-covered or or heavy side, is rotated an unbalanced force is
difficult to reach. created that increases with the square of the
speed. The faster the shaft turns, the greater
2. Know how some lube fittings appear differ- the unbalanced force acting on the shaft.
001022-000 SHEET 2 OF 4
6-6-97
occur from the power impulses of the engine or

from improper U-joint angles. This type of
vibration is difficult to identify but certain charac-
teristics do exist. It causes a noticeable sound
disturbance and can occasionally transmit
mechanical shaking.
Torsional vibrations can exist at one or more

periods any place in the operating range and
tend to be more severe at lower speeds.
Changes in torque load usually effect the vibra-
TRANSVERSE VIBRATION tion. The nonuniform velocity obtained when a
u-joint operates at an angle produces torsional
The force produced by this out-of-balance con- vibration. In a driveline having two or more
dition tends to bend the supporting members. joints in series, it is desirable to have the individ-
As the members have a natural frequency of ual joint angles arranged such that the net result
vibration similar to a swinging pendulum, a vio- minimizes nonuniform velocity characteristics
lent vibration may exist at certain periods when over the system. The amount of torsional exci-
the speed of rotation and the natural frequency tation which can be accepted without causing
of supports coincide. excessive disturbance depends upon operating
speed and characteristics of supporting struc-
Each end of the shaft must be balanced individ- tures and other units in the driveline and driv-
ually as each support is responsive to an out-of- etrain system. Other vibrational problems in a
balance condition in the portion of the shaft it driveshaft could be caused by worn or damaged
supports. Out-of-balance affects operating con- u-joints. These joints must be constantly main-
ditions only when rotating. tained according to Spicer lubrication specifica-
tions.
Transverse vibration caused by a driveshaft
out-of-balance will usually emit sound waves
that you can hear and mechanical shaking that Repair
you can feel. The force from out-of-balance
increases with speed, not torque load. The repair of universal shafts should be carried
out by our universal driveshaft service experts.
Torsional vibration, although similar in effect to Here the overhaul is done by using genuine
transverse vibration, is an entirely different parts. The repair of universal shafts in the
motion. The transverse vibration is a bending user’s own workshop should be undertaken for
movement, whereas torsional vibration is a emergency only and can be done for equipment
twisting motion. only where the working speed does not exceed
300 rpm. Above 300 rpm the universal shafts
must be balanced. Contact your local Spicer
Distributor for Quality Repair Service.
LUBRICATION PROCEDURE
Relubrication cycles vary depending on the

application and operating conditions. In gen-
eral, to obtain maximum life of driveshaft com-
TORSIONAL VIBRATION ponents, lubricate points A and B every 500
The energy to produce torsional vibration can hours of normal service or every 200 hours of
001022-000 SHEET 3 OF 4
6-6-97
continuous service.
1. Apply grease gun pressure to the lube fit-
ting until lubricant appears at the pressure relief
hole in the plug at the slip yoke end of the
spline.
2. Now cover the pressure relief hole with

your finger and continue to apply pressure until
grease appears at the slip yoke seal.
1. Use the proper lubricant to purge all four

seals of each U-joint. This flushes abrasive
contaminants from each bearing assembly and
assures all four are filled. Pop the seals. Spicer
seals are made to be popped.
2. On center twin zerk design or single zerk

kits, if any seals fail to purge, move the drive-
shaft from side to side and then apply gun pres-
sure. This allows greater clearance on the
thrust end of the bearing assembly that is not
purging. On two-zerk kits, try greasing from the
opposite lube fitting. Check for a fully seated
snap ring or burrs on the snap ring or snap ring
! CAUTION
groove.
In cold temperatures be sure to operate your
3. Because of the superior sealing capability machine immediately after lubricating. This
of the seal design there will occasionally be one activates the slip spline and removes the
or more bearing assembly seals that will not excessive lubricant. Failure to do so could
purge. cause the excess lubricant to stiffen in the
cold weather and force the plug out. The
Release seal tension by loosening the bolts end of the spline would then be open to col-
holding the bearing assembly that doesn’t lect contaminants and cause the spline to
purge. It may be necessary to loosen the bear- wear and/or seize. Personal injury or death
ing assembly approximately 1.5 mm (.06 inch) may result from loss of driveshaft function.
minimum. If loosening it does not cause purg- If in doubt as to how many times bolts have
ing, remove the bearing assembly to determine been removed, replace with new bolts.
cause of blockage.
Lubrication for Slip Splines
The lubricant used for U-joints is satisfactory for

slip splines. Glidecote and steel splines both
use a good E.P. grease meeting N.L.G.I. Grade
2 specifications.
Relube splines at the intervals recommended

for u-joints.
001022-000 SHEET 4 OF 4
5-8-96
AIR CLEANERS - ENGINE sure that all connections are sealed properly.
and COMPRESSOR
(001036-000)
EMPTYING DUST CUPS AND CLEANING

PRE-CLEANER TUBES
Dust cups should be dumped when 2/3 full or
CLEANING PRE-CLEANER TUBES
after every 8 hours of machine service.
1. Unlatch the dust cup as shown to remove

CHANGING ELEMENTS
dust.
2. Loosen the dust cup housing retainer band

and remove the housing. General
Proper air cleaner servicing will result in maxi-
! CAUTION mum protection against dust. Proper servicing
can also save time and money by increasing fil-
Never clean the air cleaner tubes with com- ter life and dust cleaning efficiency. Two of the
pressed air or water with the elements most common servicing problems are: Over
installed in the assembly. Never steam clean Servicing and Improper Servicing. Replace or
the tubes. clean elements only when the restriction indica-
tor on the filter or the warning light on the instru-
3. Light dust plugging of the tubes can be ment panel indicate to do so. Don’t be fooled by
removed with a stiff fiber brush. If heavy plug- filter appearance, the filter should look dirty.
ging is evident, remove the lower body section Careless servicing procedures can cause con-
of the air cleaner and clean with compressed air tamination. Use the following procedures as a
or hot water not exceeding 160°F (71°C). guide to air cleaner maintenance.
SAFETY SERVICE Primary Element

ELEMENT INDICATOR/NUT
1. Loosen the wing nut and gently slide the pri-
mary element out of the air cleaner assembly.
2. Inspect the service indicator for the safety

element. Remove and replace the element if
the indicator is in the red zone.
3. Inspect the inside of the filter housing and if

TUBES cleaning is required remove the safety element.
Be careful not to allow dust to enter the intake
duct.
PRIMARY
ELEMENT
4. If the filter is dented or bunched it must be

DUST
CUP replaced. Never rap or hit the element to
remove dirt. The primary element can be
4. After cleaning, reassemble the filter making cleaned with compressed air, pressurized water
001036-000 SHEET 1 OF 3
5-8-96
or washed with detergent. If cleaning the pri-

mary element with proceed as follows:
COMPRESSED AIR
! WARNING
Always use a face shield and protective
clothing when using compressed air.
Failure to do so can cause eye damage or
PRESSURIZED WATER
blindness.
! CAUTION WASHING WITH DETERGENT

A. Remove excess dust with compressed air
Using compressed air above 30 psi (205 or water as described earlier.
kPa) can damage the filter element. B. Wash the element in warm water with a
non-sudsing household detergent or Donaldson
A. Blow air ALONG (not across) the pleats D-1400 Washing Compound.
inside and outside of the element as shown. C. Rise the element with clean water from both
sides if necessary.
D. Let dry in warm circulating air of less than
160°F (71°C).
E. After drying, inspect the element with a light
bulb as shown. Replace the element if neces-
sary.
INSPECTION
COMPRESSED AIR
B. After cleaning, inspect the element with a

light bulb as shown. Replace the element if
necessary.
PRESSURIZED WATER
! CAUTION 5. Before installing the cleaned or new ele-

Using compressed water above 40 psi (with- ment press the element gasket to ensure that it
out nozzle) (280 kPa) can damage the filter has not gotten brittle.
element.
6. Slide the primary element over the safety
A. Direct water ALONG (not across) the pleats element and tighten the wingnut.
inside and outside the element.
B. Air dry the element Do Not dry with a light 7. Inspect all air cleaner and air duct connec-
bulb. tions for leakage before starting the engine.
C. After drying, inspect the element with a light
sary.
001036-000 SHEET 2 OF 3
5-8-96
Safety Element
4. Clean the inside of the filter housing espe-
The safety element should be replaced every cially around the areas of the element sealing
third time the primary element is cleaned or surfaces.
replaced or as indicated by the service indicator
in the safety filter hold down nut as shown. 5 Install a new safety element.
1. Remove the primary element as described 6. Install the primary element.

earlier.
2. Remove the split pin and nut that hold the

safety element in place.
3. Remove and discard the safety element.

The safety element should not be cleaned.
001036-000 SHEET 3 OF 3
5-8-96
001036-000 SHEET 4 OF 3
03-09-93
CATERPILLAR ENGINE TACHOMETER INSTALLATION/

ADJUSTMENT (006269-000)
SCREW THE PICK-UP IN UNTIL IT ENGAGES

THE FLYWHEEL, THEN BACK OFF ONE
QUARTER TURN AND TIGHTEN THE
LOCKNUT
NOTE! THIS INFORMATION

APPLIES TO MACHINES
EQUIPPED WITH CATERPILLAR
ENGINES ONLY.
GAUGE PANEL
GROUND
SIGNAL
POWER LEAD (IGNITION)
FOR 3306 - SET AT POSITION “A” FROM NEAREST ELECTRICAL
FOR 3406 - SET AT POSITION “6” GAUGE (USUALLY WATER TEMP.)
FOR 3408 - SET AT POSITION “6”
FOR 3412 - SET AT POSITION “6”
FOR 35O8 - SET AT POSITION “A”
FOR 3512 - SET AT POSITION “A”
006269-000 SHEET 1 OF 1
03-09-93
006269-000 SHEET 1 OF 1
5-8-96
AIR CLEANERS - ENGINE guide to air cleaner maintenance.
and COMPRESSOR Primary Element

1. Loosen the wing nut and gently slide the pri-
(006307-000) mary element out of the air cleaner assembly.
2. Inspect the service indicator for the safety

element. Remove and replace the element if
VACUATOR VALVE INSPECTION the indicator is in the red zone.
Vacuator valves should be inspected very 8 3. Inspect the inside of the filter housing and if
hours of machine service. Check to see that the cleaning is required remove the safety element.
valve is not inverted, damaged or plugged. Be careful not to allow dust to enter the intake
Replace as needed. duct.
4. If the filter is dented or bunched it must be

replaced. Never rap or hit the element to
SAFETY remove dirt. The primary element can be
ELEMENT
cleaned with compressed air, pressurized water
or washed with detergent. If cleaning the pri-
PRIMARY
ELEMENT mary element with proceed as follows:
COMPRESSED AIR
! WARNING
Always use a face shield and protective
SERVICE
INDICATOR/NUT clothing when using compressed air.
VACUATOR Failure to do so can cause eye damage or
VALVE
blindness.
! CAUTION
Using compressed air above 30 psi (205
CHANGING ELEMENTS kPa) can damage the filter element.
A. Blow air ALONG (not across) the pleats

General inside and outside of the element as shown.
mum protection against dust. Proper servicing
ter life and dust cleaning efficiency. Two of the
most common servicing problems are: Over
Servicing and Improper Servicing. Replace or
clean elements only when the restriction indica-
tor on the filter or the warning light on the instru-
ment panel indicate to do so. Don’t be fooled by COMPRESSED AIR
filter appearance, the filter should look dirty.

Careless servicing procedures can cause con- B. After cleaning, inspect the element with a
tamination. Use the following procedures as a
006307-000 SHEET 1 OF 2
5-8-96
light bulb as shown. Replace the element if

necessary. INSPECTION
PRESSURIZED WATER
! CAUTION
Using compressed water above 40 psi (with-
out nozzle) (280 kPa) can damage the filter
element.
A. Direct water ALONG (not across) the pleats

inside and outside the element. 5. Before installing the cleaned or new ele-
B. Air dry the element Do Not dry with a light ment press the element gasket to ensure that it
bulb. has not gotten brittle.
C. After drying, inspect the element with a light
bulb as shown. Replace the element if neces- 6. Slide the primary element over the safety
sary. element and tighten the wingnut.
7. Inspect all air cleaner and air duct connec-

tions for leakage before starting the engine.
Safety Element
The safety element should be replaced every

PRESSURIZED WATER third time the primary element is cleaned or
replaced or as indicated by the service indicator
in the safety filter hold down nut as shown.
WASHING WITH DETERGENT
A. Remove excess dust with compressed air
1. Remove the primary element as described
or water as described earlier.
earlier.
B. Wash the element in warm water with a
non-sudsing household detergent or Donaldson
D-1400 Washing Compound.
C. Rise the element with clean water from both
sides if necessary.
D. Let dry in warm circulating air of less than
160°F (71°C).
E. After drying, inspect the element with a light
cially around the areas of the element sealing
sary.
surfaces.
5 Install a new safety element.
6. Install the primary element.
006307-000 SHEET 2 OF 2
07-25-96
CUMMINS ENGINE TACHOMETER

INSTALLATION/ADJUSTMENTS
007672-000
SCREW THE MAGNETIC PICKUP

IN UNTIL IT ENGAGES
THE FLYWHEEL.
BACK-OFF ONE QUARTER TURN
AND TIGHTEN THE LOCK NUT.
OPERATOR’S STATION
GAUGE PANEL
GROUND
CUMMINS KTA-19 POSITION “8” SIGNAL

CUMMINS KT-19C POSITION “8”
CUMMINS QSK-19C POSITION “6”
007672-000 SHEET 1 OF 1
07-25-96
9-8-00
ENGINE OIL CLEANING 6. Finish removing nut (h) and remove bowl (k)
together with baffle/screen (m).
CENTRIFUGE
7. Examine the dirt deposit in the bowl (k) for
(019104-000) signs of engine wear or abnormal operation. A
sudden change in the amount or character of
the deposit indicates a problem.
GENERAL
8. Wash the baffle/screen (m) and the turbine
This section addresses the maintenance and base (i). Properly dispose of bowl (k) and seal
troubleshooting of this component. (n).
9. Inspect the top and bottom bushings in the

SERVICE turbine base (i) for wear. Replace the turbine
assembly if worn.
Servicing intervals will vary with conditions and
oils used. Determine what interval best suits 10. Inspect the housing assembly (e) for wear at
your machine and add this component to your the spindle. Replace the housing assembly if
preventive maintenance schedule. Always tag worn.
the start button to prevent engine start-up.
11. Clean the groove in cover (a) and install a
Service the oil centrifuge as follows: new seal (c).
1. With the oil warm, shut off the engine and 12. Place baffle/screen assembly (m) over the
allow the turbine assembly (d) to come to a stem of base (i).
complete stop.
13. Install a new seal (n) over the outer edge of
! WARNING base (i).
Hot oil or components can cause burns if 14. Slide a new bowl (k) over the stem of base
they contact skin. (i) and secure with nut (h). Finger tighten the
nut.
2. Loosen the handle on clamp (b). Disengage
the tee bolt and using a coin pry off cover (a). 15. Install the assembled turbine (d) over the
Discard the seal (c). spindle of housing (e). The turbine should rotate
freely.
3. Partially lift the turbine assembly (d) from the
housing (e) to allow oil to drain from nozzles (o). 16. Replace the cover assembly (a) and secure
Remove the turbine assembly after draining. with clamp (b). Tighten the clamp by hand. only.
4. Loosen the knurled nut (h) several turns until 17. Remove and clean the idle cut out valve
the face of the nut projects beyond the bronze assembly (s). Replace the valve seal (t) if nec-
bushing face. essary.
5. While holding the bowl (k) of the turbine 18. Start the engine and check for leaks.
assembly (d) in one hand, strike the face of the
nut (h) with the palm of the other hand to sepa-
rate the bowl (k) from base (i). Do not use a
hard surface to strike the nut or damage may
result.
019104-000 Sheet 1 of 3
9-8-00
TROUBLESHOOTING
PROBLEM: Centrifuge remove too little dirt.

SOLUTION: Check for proper operation.
PROCEDURE: Warm up the engine and bring
to RUN speed (high idle). Shut the engine down
and immediately listen for the centrifuge turbine
spinning. If the turbine is not spinning properly
disassemble and install a new turbine assembly.
PROBLEM: Air in the centrifuge flows con-

stantly or not at all or, air bleeds overnight.
SOLUTION: Leaking air valve or cartridge seal.
PROCEDURE: Disconnect the air supply and
remove and replace the air valve cartridge (q)
and seal (r).
019104-000 Sheet 2 of 3
9-8-00
ENGINE OIL CLEANING CENTRIFUGE
019104-000 Sheet 3 of 3
9-8-00
019104-000 Sheet 4 of 3
5-6-98
AIR CLEANERS - ENGINE Careless servicing procedures can cause con-

tamination. Use the following procedures as a
and COMPRESSOR guide to air cleaner maintenance.
(021237-000)
Changing Elements
GENERAL
mum protection against dust. Proper servicing Primary Element
ter life and dust cleaning efficiency. Two of the 1. Unlatch the filter cover and remove the
most common servicing problems are: Over cover and gasket.
Servicing and Improper Servicing. Replace or
clean elements only when the restriction indica- 2. Loosen the wing nut and gently slide the pri-
tor on the filter or the warning light on the instru- mary element out of the housing.
ment panel indicate to do so. Don’t be fooled by
filter appearance, the filter should look dirty.
COVER
LATCHES
SAFETY
ELEMENT
21237s1 SPLIT PIN
PRIMARY
ELEMENT
SERVICE
INDICATOR/NUT
BODY & TUBE

ASSEMBLY GASKET
COVER
GASKET
CUP CLAMP
DUST CUP
021237-000 SHEET 1 OF 2
5-6-98
3. Inspect the service indicator/nut for the not steam clean!

safety element. Remove and replace the ele-
ment if the indicator is in the red zone.
Inspect Dust Cup
4. Inspect the inside of the filter housing and if
cleaning is required remove the safety element. The dust cup at the base of each air cleaner
Be careful not to allow dust to enter the intake should be removed and emptied. Turn the
duct. thumb screw and loosen the cup clamp.When
installing the cup, be sure the cup is fully sealed
5. If the element is dented or bunched it must by the gasket.
be replaced. Never rap or hit the element to
remove dirt.
Safety Element
The safety element should be replaced every

third time the primary element is replaced or as
indicated by the service indicator in the safety
filter hold down nut as shown.
1. Remove the primary element as described

earlier.



cially around the areas of the element sealing
surfaces.
5. Install a new safety element.
6. Install the primary element.
Body & Tube Assembly
Remove the dust cup and check the tubes. If

the tubes have become plugged, remove the
dust with a bottlebrush. If heavy plugging is evi-
dent, clean the tubes with compressed air (the
primary and secondary filters must be installed),
or with water no hotter than 160°F (72°C). Do
021237-000 SHEET 2 OF 2
HIGH PRESSURE COMPRESSOR SAFETY
• Operating pressures of 350 psi (24.1 bar) may be present in the air control system during a loaded
condition.
Do not use high pressure air to clean the machine. Do not use compressed air for personnel
cleaning.
• Safety relief valves on air receiver tanks

The safety relief valve must be checked periodically for proper operation, manually move the
vent handle to purge the relief valve on a monthly basis. Do not tamper with or change the
relief valve setting.
• Air hose connections are secured with safety chain restraints to prevent hose ends from being acci-
dentally disconnected or expelled.
Operating the high pressure air without hose restraints can lead to death of personnel or
equipment damage.
• Discharge opening of air hoses and tools.

Keep personnel out of line with and away from discharge opening of hoses or tool or other
points of air discharge, death or personnel injury may result from sudden burst of high pres-
sure air.
• Air blowdown or cleaning attachments

Do not use air at pressures higher than 30 psi (2 bar) for cleaning purposes and then only
with effective chip guarding and personnel protective equipment PPE per OSHA standard 29
CFR 1910.242b
• Horseplay
Do not engage in horseplay with air hoses as death or serious injury may result.
• PPE Personnel protective equipment

Wear appropriate personnel protective equipment for the work environment to include hear-
ing protection, eye wear when working with compressed air.
• Batteries
Disconnect the battery cable ground terminal or open the battery disconnect switch prior to
maintenance or compressor service.
• Fire extinguisher
Keep a fully charged class BC or ABC fire extinguisher or extinguishers present when servic-
ing or operating a high pressure compressor system.
TABLE OF CONTENT
HIGH PRESSURE COMPRESSOR SAFETY . . . 1 AIR COMPRESSOR LUBRICANTS . . . . . . . . . . . . . . .21
HIGH PRESSURE COMPRESSOR SYSTEM INTRO- COMPRESSOR OIL CHANGE PROCEDURE . . 23

DUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Draining Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
ENGINE AND COMPRESSOR SPECIFICATIONS 3

AIR RECEIVER RESERVOIR SEPARATOR MAINTE-
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 NANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
COMPRESSOR SYSTEMS SPECIFICATIONS . 5 Static Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 AIR RECEIVER RESERVOIRS . . . . . . . . . . . . . . . . . . .26
FEATURES AND CUSTOMER PREFERRED OPTIONS

ADDED ON TO THE AIR SYSTEM . . . . . . . . . . . . . . . . 6 HIGH PRESSURE COMPRESSOR COOLING SYS-
TEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
POWER GROUP COMPONENTS . . . . . . . . . . . . 7 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FAN SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

New Compressor Installations . . . . . . . . . . . . . . . . . . . . 7
HP COMPRESSOR HOSING CIRCUIT . . . . . . . . . . . . . 8
HIGH PRESSURE COMPRESSOR CONTROL REGU-
ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 LATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 29
Low Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
High Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
COMPRESSOR OIL LUBRICATION . . . . . . . . . . 11 Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Calibrating Regulators . . . . . . . . . . . . . . . . . . . . . . . . . .33
Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Operator Station Monitoring . . . . . . . . . . . . . . . . . . . . . .34
Air Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Minimum Pressure Valve . . . . . . . . . . . . . . . . . . . . . . . . 12
Separator Element Filter . . . . . . . . . . . . . . . . . . . . . . . . 12 VOLUME CONTROL . . . . . . . . . . . . . . . . . . . . . . 39
Scavenge Oil Return . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compressor Main Oil Filters . . . . . . . . . . . . . . . . . . . . . . 13 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Thermal Manifold With Bypass . . . . . . . . . . . . . . . . . . . . 14
Oil Coolers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Oil Stop Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Mechanical Adjustment Type Volume Control Mounted On A
Two Stage Air End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Butterfly Inlet Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Discharge Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . 17
Compressor Safety Relief Valves . . . . . . . . . . . . . . . . . . 18
Compressor Test Pressures . . . . . . . . . . . . . . . . . . . . . . 18
AUXILIARY AIR COMPONENTS . . . . . . . . . . . . 41
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Dust Collection And Dust Suppression . . . . . . . . . . . . . 41
Dust Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Automatic Thread Greasing System . . . . . . . . . . . . . . . 44
Hydraulic Tank Pressurization . . . . . . . . . . . . . . . . . . . . 45
Bit Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Automatic Grease System . . . . . . . . . . . . . . . . . . . . . . . 47
Chain Lubrication System . . . . . . . . . . . . . . . . . . . . . . . 47
Air Line Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Drain Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
TROUBLESHOOTING HIGH PRESSURE COMPRES-

SOR SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . 55
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
HIGH PRESSURE Auxiliary air components
Troubleshooting HP compressor systems
COMPRESSOR SYSTEM Service literature
INTRODUCTION
DESCRIPTION
GENERAL The compressor (air end) is centrally located in

the front of the crawler and truck machine
Sandvik Mining and Construction blasthole and frame.
waterwell drilling machines utilize high volumes
and high pressure air delivery to the rock drilling Compressor oil and air components are local to
tools. the compressor.
This HP compressor system manual is to be Auxiliary air options for drilling and non-drilling
used with machines that use rotary and DTH features are positioned at strategic areas on the
down the hole drill tools. machine deck.
Sandvik Mining and Construction can supply a

full line of rotary bits, hard rock DTH hammers
and custom made drill bits.
Sandvik Mining and Construction rotary and FRONT

blasthole drill machines that are equipped with
high pressure compressors are: COMPRESSOR
• D25KS
• T25KW
machineoverview.tif
• D245S
• D45KS
• D55SP
• D75KS
This manual is to be used in factory approved

drill clinic training programs and compressor
specialty training programs.
• Book one
HP compressor system introduction
REAR
Engine and compressor specification
Compressor spec sheet
Power group components (HP) CRAWLER MODEL BLASTHOLE DRILL
Oil lubrication (HP)
Compressor oil change procedure
Separator maintenance
HP compressor cooling system
HP compressor control regulation system
Volume controls
High Pressure Compressor System Introduction Page 1

COMPRESSOR
TRUCK MODEL WATERWELL DRILL
Published by Sandvik Mining and Construction - USA
All rights reserved. No part of this manual may be repro-

duced in any form without the prior written consent from
Sandvik Mining and Construction.
Part No. 023501-066
Page 2
ENGINE AND COMPRESSOR
SPECIFICATIONS
GENERAL
Sandvik Mining and Construction have part-

nered with Caterpillar and Cummins engine
manufactures to offer Caterpillar ‘MEUI’ and
‘HEUI’ Acert series and Cummins ‘QSK and
QSX Celect series’ electronic engines.
DESCRIPTION
Compressor ratings are based on volumes of
Engine horsepower is used to drive the com- air discharged or SCFM standard cubic feet per
bined volume and pressure of a two stage high minute. There are many compressors available
pressure air end. for various drilling conditions.
Engine horsepower requirements are greater Sandvik Mining and Construction have part-
when driving a 1350 cfm (38.2m³ m) air com- nered with Sullair Corporation to offer a engine
pressor verses the 900 cfm (25.5m³ m) air com- mounted two stage high pressure rotary screw
pressor. compressor package for rotary and down the
hole drill applications.
Common engine horsepower (HP) is based on
high idle engine speed and revolution per The main concept for the air compressor is to
minute (RPM). The speed rating given is engine drill a hole in the earth with tool(s) known as
loaded high idle speed. down the hole hammer (DTH). Consult Sandvik
Mining and Construction for compressed air
The following horsepowers are offered on volume requirements for a specific hammer
D45KS machines. size.
• 525 HP (389kw) C15(Tier 2) @ 1800 RPM
Common compressor volumes CFM and maxi-
• 530 HP (395 kw) QSX(Tier 2) @ 1800 RPM mum pressure ratings PSI:
• 540 HP (403 kw) C15(Tier 3) @ 1800 RPM • 900 CFM / 350 PSI (25.5m³ m / 24 bar)
• 600 HP (447 kw) C16(Tier 2) @ 1800 RPM • 1000 CFM / 350 PSI (28.3m³ m / 24 bar)
• 600 HP (447 kw) QSX(Tier 2) @ 1800 RPM • 1150 CFM / 350 PSI (32.8m³ m / 24 bar)
• 630 HP (470kw) C18(Tier 3) @ 1800 RPM • 1250 CFM/350 PSI (35.3m³ m / 24 bar)
• 1350 CFM / 350 PSI (38.2m³ m / 24 bar)

The actual ‘TEL’ Top Engine Limit calibration
will be slightly higher than 1800 rpm.
Engine and compressor packages are compati-
ble for specific drilling applications.
Engine and Compressor Specifications Page 3

• When determining actual compressor output
or standard cubic feet per minute (SCFM).
• In selecting the correct DTH drilling tools.
Example:
900 CFM @ 5000 feet (1500 meters).

compressor output = 900 x.82 = 738 SCFM
1150 CFM @ 11,000 feet (3400 meters).

compressor output = 1150 x.65 = 748 SCFM
Down the hole drilling tools may need to be pur-

chased or modified to compensate for air loss
due to altitude conditions.
Climactic conditions and operating conditions
such as altitude are factors in selecting the
proper power group components to fit the over- SANDVIK DTH
all drilling needs. M55 SERIES HAMMER
M65 SERIES HAMMER
When selecting a compressor size and drilling JUNE 2005
tools (DTH) follow the altitude correction chart
TOP SUB API THREAD
as shown.
CHECK VALVE
ALTITUDE ALTITUDE CORRECTION VARIABLE CHOKE

FEET METERS FACTOR
4000 1200 .86 FLUSHING VALVE
5000 1500 .82
6000 1800 .79
7000 2100 .76 PISTON

8000 2400 .73
9000 2700 .70 PISTON RETAINING RING
10000 3000 .68 BIT GUIDE

11000 3400 .65
BIT RETAINER RINGS
12000 3700 .63
13000 4000 .60 DRIVER SUB

(CHUCK ASSEMBLY)
14000 4300 .58
DRILL BIT
Use the altitude correction table;
• For drilling applications above 4000 feet

(1200 meters). Consult your hammer supplier for details
regarding flushing valve or choke modifications.
Page 4
COMPRESSOR SYSTEMS SPECIFICATIONS (HP)
GENERAL
The components listed are engineered purchased parts designed specific for Sandvik Mining and
Construction D45KS high pressure drill machines. The primary drilling concept is DTH down the
hole drill applications with the secondary drill concept being rotary drilling.
COMPONENT SPECIFICATION
STANDARD COMPRESSOR OIL THERMOSTATS COLD SIDE EXTEND TO CLOSE @ 184° F (84.4° C) *
* ALTERNATE STATS AVAILABLE HOT SIDE EXTEND TO CLOSE @ 175° F (79.4° C) *
900 SERIES THERMOSTATS COLD SIDE EXTEND TO OPEN @ 185° F (84.6° C)
OIL COOLER BYPASS VALVES 1 0R 2 @ 50 PSI (3.5 BAR)
AIR RECIEVER SAFETY RELIEF VALVE 1 @ 375 PSI (26 BAR) OR

FOR HIGH PRESSURE MODELS ONLY 1 @ 400 PSI (27.5 BAR)
COMPRESSOR SAFETY RELIEF VALVES 1 OR 2 @ 140 PSI (9.7 BAR)
MINIMUM PRESSURE VALVE 1 @ 140 PSI (9.7 BAR)
UNLOAD PRESSURE @ LOW PRESSURE 150-160 PSI (10.3-11 BAR)

UNLOAD PRESSURE @ HIGH PRESSURE 350 PSI (24 BAR)
SEPERATOR DIFFERENTIAL INDICATOR (CSP) 1 @ 10 PSI (.70 BAR)
MAIN OIL FILTER BYPASS VALVE (CFP2) 25 PSI (1.7 BAR) SWITCH - 30 PSI BYPASS OR
35 PSI (2.4 BAR) SWITCH - 40 PSI BYPASS
AIR CLEANER FILTER INDICATOR (CFP1) 1 @ 25 INCHES WATER MECHANICAL OR

1 @ 22 INCHES WATER ELECTRICAL
AIR/OIL TEMPERATURE SWITCH (CAT) 265° F (129° C) COMPRESSOR AIR TEMP

AIR/OIL TEMPERATURE SWITCH (CIT) 250° F (121° C) COMPRESSOR INTERSTAGE TEMP
COMPRESSOR PRESSURE SWITCH (COP) 90 PSI (6.2 BAR) COMPRESSORE OIL PRESSURE
FACTORY FILL COMPRESSOR OIL SHELL CORENA POA 32
Specifications listed are consistent on all Sandvik Mining and Construction high pressure model
machines.
When connecting electrical switches into the compressor system refer to the abbreviated descrip-
tions (COP) (CAT) (CIT) on the machine specific electrical system schematic.
Compressor Sytems Specifications (HP) Page 5

FEATURES AND CUSTOMER PREFERRED OPTIONS ADDED ON TO THE AIR SYSTEM
FEATURE/OPTION SPECIFICATION
HYDRAULIC TANK PRESSURIZATION 5 PSI (.3 BAR) RELIEF @ 12 PSI (.8 BAR)
DRY DUST COLLECTION AIR REGULATION 50 PSI (3.5 BAR) RELIEF @ 90 PSI (6.2 BAR)
HAMMER LUBRICATOR TANK REGULATION 60 PSI (4 BAR)
AIR BLOWDOWN REGULATION 30 PSI (2 BAR)
AUTOMATIC THREAD LUBE REGULATION 100 PSI (6.8 BAR)
AUTOMATIC GREASE SYSTEM REGULATION 60-100 PSI (4-6.8 BAR)
CHAIN LUBRICATION SYSTEM REGULATION 60 - 80 PSI (4 - 5.5 BAR)
Routine maintenance for the featured and optional components are listed in the machine specific
lubrication and maintenance manual
Page 6
POWER GROUP
COMPONENTS 1350/350
SHOWN
GENERAL
This section will describe the engine, drive cou-

pling and two stage compressor mounting.
DESCRIPTION
The engine and compressor driven compo-

nents are purchased parts installed according
to vender specifications.
The compressor shaft and drive coupling
Two stage high pressure compressors are
should rotate free after final installation.
direct drive to the customer selected engine.
! CAUTION
Using a hammer on or applying high forces
to the input shaft when installing the cou-
pling can damage the compressor shaft seal
and bearings.
Shaft seal replacement literature is available as

a service procedure.
BOLT TORQUE New Compressor Installations

75 - 85 FT LB
(102 - 115 Nm) It is a recommended practice to add 5 gallons
LOCTITE 242 (20 liters) of clean customer supplied compres-
sor oil into the open compressor inlet prior to
starting a new or remanufactured air end unit.
It is recommended to replace the drive ring and The compressor inlet porting will have a intake
coupling set when changing compressors. manifold, inlet control valve (butterfly plate)
using gaskets as seals between the compo-
Apply loctite 242 and administer proper bolt nents.
torque to the cap screws supporting the drive
ring to the engine fly wheel. NOTE!
Two of a series of bolts mounting the inlet man-
Refer to service material 008674-000 taperlock ifold are inside the manifold. It is essential to
bushing installation procedure for new (air end) use loctite 242 during the bolt mounting proce-
compressor installations. dure. Final intake manifold bolt torque shall be
280 -310 FT LB (280 - 420 Nm).
Power Group Components Page 7

• Follow system cleaning procedures
• Replace worn components as needed
• Record appropriate documentation for

return to vendor, startup papers provided
with replacement air end
• Specify oil type
• Follow common mechanical procedures

during compressor installation, some of
3/4 GRADE 8 BOLTS which are stated herein
LOCTITE & TORQUE
280 -310 FT LB
(280 - 420 Nm)
When mounting the inlet control valve, align-

ment and free acting butterfly plate movement
are requirements for correct acting air pressure
build-up (load and unload modes) of operation.
Incorrect inlet control cylinder linkage alignment

and butterfly plate mounting lead to improper
air pressure control and regulation troubles.
Maintain all intake pipe and hump hose connec-

tions. Replace worn and weathered rubber COMPRESSOR TO ENGINE INSTALLATION
seals as needed.
Some component locations and hose configu-
When removing and installing a compressor rations vary from views shown.
with warranty consideration it is necessary to:
HP COMPRESSOR HOSING CIRCUIT
• Locate Equipment Serial Numbers
The following diagram is a parts manual repre-
sentation of a high pressure hose circuit. Con-
firm machine specific parts manuals for part
numbers of hoses and components.
COMPRESSOR
DATA PLATE
• Maintain cleanliness during component

removal and return process
Page 8
MINIMUM PRESSURE
VALVE
SEPERATOR
FILTER INSIDE
AIR/OIL
RECEIVER TANK
INLET
SCAVENGE OIL
RETURN FILTER
OIL STOP
VALVE
MAIN OIL
FILTERS
THERMAL COMPRESSOR
VALVES OIL COOLER
BYPASS
VALVES
WORKING AIR PRESSURE

0 PSI NOT DRILLING
RECEIVER AIR PRESSURE

160 PSI UNLOADED
HYDRAULIC TANK
PRESSURIZATION
021003-002
The operator station console panel supports gauges that enable visual reference to drilling air/oil
temperature and air/oil pressure functions.
Power Group Components Page 9

ENGINE SPEED High Idle Speed
Maintaining the correct engine high and low idle High idle engine speed is required in order to
speeds are essential for the compressor, drive deliver the expected compressor air delivery or
coupling, machine frame cross members and (SCFM standard cubic feet per minute).
related equipment longevity.
Engine high idle speed settings will vary from
A minimum engine low idle speed of 1200 machine model according to compressor vol-
RPM is essential to minimize drive coupling ume.
wear and machine vibrations.
High idle speeds are typically 1800 rpm. In
ENGINE SPEED METER (ESM) some applications the high idle speed is 2100
rpm.
High idle speed is configured within the ECM

program data.
Low Idle Speed
Engine idle speeds less than 1200 can lead to

premature drive component failure.
Engine low idle speed settings are 1200 rpm.

As of 2006 Caterpillar Tier III engines will rev to
1400 rpm during the bypass mode - start cycle.
The low idle speed will drop to 1200 rpm when
the bypass switch is released.
Low idle speed is configured within the ECM

program data.
Page 10
HIGH PRESSURE This section will show oil circulation through
these components.
COMPRESSOR OIL
Standard factory fill compressor oil is Shell
LUBRICATION Corena PAO 32 series synthetic oil.
Air Receiver Tank

GENERAL
The model shown may be referred to as a tee
Two-stage high pressure application machines tank, air oil receiver tank. Fluid levels are to be
utilize contained air pressure to direct circulat- checked 2 minutes after machine shutdown or
ing oil through hoses, valves, oil coolers and when the fluid is at rest.
the two stage air end.
Apply new clean compressor oil through the fill
plug port. As a safety device the fill plug has a
DESCRIPTION drilled vent passage to release residual air
pressure upon loosening.
Components of the compressed air system are
common throughout the Sandvik Mining and Fluid level shall be in the middle sight glass.
Construction high pressure drill applications.
Condensation or water can develop in the air
• Air receiver tank system during normal run modes.
• Fluid level sight glasses
• Synthetic compressor fluid
• Air/oil receiver safety relief valve

FILL PLUG
• Minimum pressure valve
• Separator element filter
• Separator differential indicator

560art.tif
• Scavenge oil return system
• Oil temperature thermostats
• Oil cooler bypass valves
• Oil cooler
• Oil stop valve
• Temperature safety switches
• Pressure safety switch
• Two stage air end Drain water and oil sediment daily through the
drain valve.
• Discharge check valve
• High temperature hoses
Oil Lubrication Page 11

Park the machine with the front of the machine
slightly lower than the rear so that draining con-
densation can be achieved.
! WARNING
The cap is under spring pressure. Use
The air receiver tanks for high pressure drill extreme caution when removing the cap
applications is a pressure vessel. It is tested from the housing.
and certified by the manufacturer for pressure
and temperature. When testing the minimum pressure
High pressure application air/oil receiver tanks 1. Operate the machine at the rated high idle
have one non adjustable safety relief valve pre- speed.
set for a maximum pressure that will vent to
atmosphere 400 psi (27.5 bar) 2. Turn the working air on and observe the air
receiver pressure gauge on the operator
If a air/oil receiver tank is damaged it must be console.
repaired by a local registered and certified pres-
sure vessel repair center. The vessel must be 3. Gauge ports are available to install a 500 psi
recertified prior to reinstating it into service. (35 bar) pressure gauge on the air receiver
tank separator element indicator.
Minimum Pressure Valve
Air pressure inside the air receiver tank should
A minimum pressure valve is positioned on the never drop below the preset spring value of the
vertical section of the air receiver tank. It’s main minimum pressure valve.
function is to maintain air pressure inside the
tank during the run mode. Separator Element Filter
The minimum air pressure is 140 psi (9.7 bar) The vertical section of the air receiver tank sup-
and is responsible for pushing the compressor ports one single air/oil separator filter.
oil through all the lubrication parts.
minimum pressure
PISTON AND SPRING
DRY AIR IN
CHECK separator element

VALVE
VENT
DRY AIR OUT
MINIMUM PRESSURE VALVE
This valve is on the dry side of the air/oil sepa-

rator element so it should not be saturated with
oil. It offers a vent to atmosphere. If air is vent-
ing it is a indicator of minimum pressure valve Separator filter elements are not dirt holding fil-
seal failure. ters
Page 12
The air oil separator filter concept is to slow Expect one cup (236 ml) to one quart (.94 l)
down the air movement that contains compres- during a drilling condition.
sor oil. Oil mist will be trapped on the inside fil-
ter diffusion casing. Air and microscopic oil will No oil or a flood of oil in the sight glass is a indi-
pass through the paper pleated filter media. cator of potential separator filter problems.
Perform a daily inspection of the separator filter

indicator when the machine engine is running at SCAVENGE LINE
TO COMPRESSOR
high idle speed. GEAR HOUSING
• yellow indication means the filter is OK
• red indication means the filter requires

maintenance
Refer to separator maintenance section of this

manual.
Separator elements in a high pressure applica-

tion pass air through the element from the inner
to outter air flow direction. Oil carry over
through the filter will evacuate through the Compressor main oil filters and scavenge filter
scavenge oil return system. maintenance is required at 250 service hour
intervals.
The separator element has a static ground
device (spring or staple type). This ground Perform maintenance with the machine in a
device is used to eliminate the static electricity shutdown condition.
inside the element filter.
For safety purpose allow a minimum of 2 min-
Gasket seals are used between the top plate utes or more after machine shutdown prior to
and air receiver tank. Clean the surfaces well starting maintenance.
and use new gaskets. Do not use silicone seal-
ant with the gaskets. Compressor Main Oil Filters
Scavenge Oil Return A 1/4 inch bleed port on the filter cover may be
opened prior to filter removal. This port will vent
A oil return system referred to as a scavenge the filter canister of any residual pressure
system enables oil carry over that passes trapped inside the filter assembly after machine
through the paper pleat separator filter to be shutdown.
returned to the compressor stator housing or
compressor gear housing. The original filter micron rating is identified on
the filter container cover. There are two permis-
The scavenge return line will have a strainer sible filters that may be installed in the
screen filter, sight glass, with a inline orifice that Schroeder filter canister.
controls the return oil flow.
• KS15 applicable 1992 thru 2002
Oil mist will be present in the sight glass during
unload and loaded conditions. This oil carry • KZ25 current filter application
over is dependent on receiver tank pressure.

Use OEM replacement filters. Failure to utilize The thermal valves and cooler bypass valves
Schroeder OEM type filters will affect compres- are threaded into a manifold. Test ports are
sor warranty. available on the manifold to test oil pressure
drops through the cooler.
Replace the plastic connector as needed when
it appears to be worn or damaged. Failure to Thermal valves require one seal ring upon
maintain the plastic connector can allow poor installation into the thermal housing port. Do not
filter sealing areas enabling contamination into use more than one seal ring per thermostat
the compressor oil lubrication system. upon installation.
COMPRESSOR VENT PORT OIL COOLING MANIFOLD

OIL FILTERS TWO THERMAL VALVES
FIL
TWO BYPASS VALVES
184°F 184°F
RETAIN 2 FILTER FC
SEALS PER FILTER X
50
X
PLASTIC FILTER BYPASS ART
CONNECTOR VALVE TC
Oil cooling is dependant on the position of the

thermal valve position.
• ART air receiver tank
• TC to oil cooler
• FC from oil cooler

When performing routine maintenance observe
filter condition. Be sure to retain all seals on • FIL filters (KS15 or KZ25)
both filter elements.
• X test ports
Use caution when installing new compressor oil
The thermal valves extend approximately 5/8
filters into the housing not to unseat the filter
inch (15 mm) to seat into the manifold bore. As
seal and push the seal into the filter.
the valves extend they restrict free flowing oil,
and force compressor oil into the oil cooler.
Loose or missing seals should be located prior
to reinstating the machine into service.
For cold ambient conditions when cold oil or
Thermal Manifold With Bypass fluid viscosity is high during the cold start cycle,
two 50 psi (3.5 bar) valves can open that allows
Two thermal valves direct compressor oil to the free flow cold oil 4 flow paths to the filter assem-
compressor through filter assembly and com- bly and two stage compressor.
pressor oil cooler depending on fluid tempera-
tures. There are seven applicable thermal In extreme cold ambient conditions it will be
valves suitable for use according to ambient necessary to cover the external surface area of
operating conditions. the oil cooler to establish oil flow in the cooler.
Page 14
900/350 Thermal Valve Upgrade Flow through the oil cooler is dependant on sys-
tem pressure, thermal valve position, oil tem-
A upgrade temperature control was added to perature, oil viscosity and bypass valve
900/350 high pressure air compressors effec- position.
tive 9/03.
This thermal valve is a single 185° F thermostat

and a 50 psi bypass relief valve.
The 027842-055 cooling manifold kit is adapt-

able for field installation.
TEST PORT
FROM
COOLER oilcooler.tif
TO
FILTER
COMPRESSOR
SECTION (AKG)
TO
COOLER
FROM
RECEIVER It may become necessary during cold ambient
TANK
operating conditions to cover the entire cooler
cores with a curtain.
027842-055 COOLING MANIFOLD KIT
A cooler curtain restricts external ambient air-
This field upgrade is only applicable to 900/350 flow through the oil cooling fins. The restricted
two stage high pressure air compressors. air can aid oil flow through the internal turbula-
tor tubes of the oil cooler therefore decreasing
Oil Coolers oil cooler pressure and temperature drops.
High ambient oil coolers are high quality alumi- Expected oil cooler pressure drop, measured
num header and turbulator tube design. as differential pressure drop through the oil
cooler.
Low ambient oil coolers are high quality steel
with re placable turbulator tubes sealed at the Pressure may be taken from the thermal valve
top and bottom headers. manifold test ports.
Pressure in the oil cooler is dependant on regu- • less than 5 to 15 psi (.3 to 1 bar)
lated system pressure. When testing oil cooler • less than 15 to 35 psi (1 to 2.4 bar)
pressures the gauge readings will be >140 psi
up to 375 psi (9.7 to 25.8 bar) • above 35 to 50 (2.4 to 3.4 bar)

Expected oil temperature drop, measured as The first stage has one male and one female
differential temperature drop through the oil rotor supported in a stator housing by radial and
cooler. thrust bearings.
• 20° to 40° F (+ 4.4° to - 6° C) The second stage has one male and one
female rotor supported in the stator housing by
Oil Stop Valve radial and thrust bearings.
Oil stop valves are positioned after the oil filter Each unit is dependant on the gear ratio, a
assembly mounted on the compressor bearing driven speed and designed oil lubrication.
distribution block. The oil stop valve receives a
pilot pressure signal equal to the discharge
pressure from the air end.
DISCHARGE INTAKE
CAT SWITCH
IN
2ND STAGE
1ST STAGE
OUT
OIL STOP VALVE
U-TUBE
X CIT SWITCH
The primary function of the oil stop valve is to X
02/99 SULLAIR
maintain compressor oil in the hoses and
related components after machine shutdown.
New and remanufactured air end units are
The oil stop valve is direct mounted to a oil available from Sandvik Mining and Construction
manifold that in design delivers compressor oil regional spare parts departments.
to required lubrication points of the air end.
Verify machine model and serial number for
This bearing distribution manifold is last point proper compressor specification.
oil injection. A compressor oil pressure switch
COP is rated to open with pressures below 90 During the machine run mode the compressor
psi (6.2 bar). This safety switch will shut the oil temperatures should be maintained at a min-
machine down. imum of 100° F (37.7° C) above the ambient
condition.
The manifold hoses are sized for flow require-
ments to the desired points of oil injection per Operators should be aware of compressor
the compressor manufacturer. operating temperatures. A sensor on the com-
pressor discharge elbow and a gauge on the
Two Stage Air End operators panel allows visual reference to air/oil
temperatures.
High pressure compressed air is made avail-
able from two sets of rotating rotor assemblies.
Page 16
It is common to see compressor temperatures
operating between 195 and 210° up to 230° F
(90.5 - 98.8° up to 110° C) during the loaded DISCHARGE
GASKET CHECK VALVE
drilling cycle. Compressor operating tempera-
tures 220 to 240° F (104 t0 115° C) are com-
mon in extreme environments. HOUSING
Operating the machine in extreme ambient con- STOP PLATE

ditions may require special operating compo-
nents or adjustments to suit the local SPRING
environment. It may be necessary to:
RETAINER RING
• upgrade the fluid viscosity using either ISO
32 or ISO 46 grades
GASKET
• change thermal valve temperature values
• modify the cooling fan system by slowing or

increasing the fan rpm to spec Discharge check valves are a one way check
valve. Free flow oil out the discharge hose with
• restrict air flow over the oil coolers with a hot oil returning to the air receiver tank under
cooler curtain high pressure. Air pressure may be as high as
375 psi (25.8 bar) with oil temperatures capable
Discharge Check Valve of 240° F (115° C).
One discharge check valve is mounted on the Compressors are a major investment. It is rec-
outlet flange discharge elbow from the second ommended to protect the investment with pres-
stage stator housing. sure and temperature safety switches.
Discharge check valves stop oil from the To protect this investment two temperature
receiver tank from draining into the compressor switches a pressure switch and a shutdown
after machine shutdown. relay are in electrical series without drill monitor
systems and the same switches are in parallel
Without a discharge check valve air pressure circuits when the drill monitor system is sup-
inside the air receiver tank could run the com- plied.
pressor reverse at shutdown.
90 PSI
Failure of a discharge check valve could allow
COMPRESSOR SAFETY
oil collection on the air cleaner elements, as RELIEF VALVES
well as fluctuating oil level and a reverse run
condition at shutdown.
250R
265R
SAFETY SWITCHES

Sandvik Mining and Construction machine Compressor Test Pressures
options allow the compressor systems to be
monitored with one common circuit panel that is Normal compressor gearbox pressure will
cabin mounted on the operator station. range from 35 to 65 psi (2.4 to 4.5 bar). Pres-
sure may be taken from a test port on the com-
The option is a drill monitor system (DMS). pressor gearbox.
Compressor monitoring using pre set switches Air venting through the safety relief valve gen-
includes: erally means compressor repair and or replace-
ment is required.
• CFP compressor air filter restriction indica-
tor @ 25 in vacuum (manual and electric) Follow compressor system cleaning procedures
as needed during compressor system overhaul.
• CSP compressor separator pressure @ 10
psi (.68 BAR)
Normal interstage pressure will range from 45
• CIT compressor interstage temperature @ to 55 psi (3.1 to 3.8 bar) during high pressure
250°F (121° C) tagged as 250R mode in a drilling condition. Pressure shall be
taken from the interstage U - tube adapter.
• CAT compressor air temperature @ 265°F
(129° C) tagged as 265R Interstage pressure creates working loads on
the engine. Excess pressure will pull the engine
• COP compressor oil pressure @ 90 psi idle speed down during a drilling condition.
(6.2 bar) tagged as 90F
Interstage pressure above 80 psi means com-
Compressor Safety Relief Valves
pressor repair and or replacement is required.
All two stage high pressure application com-
pressors come equipped with 1 or 2 each 140
psi (9.7 bar) valve(s) mounted on the compres-
sor gearbox.
Safety relief valve(s) are an integral part of a

new or replacement compressor, air end unit.
These valves are designed to vent the com-

pressor gearbox in the event of compressor
wear and or failure. These valves should not
vent air under normal operating conditions.
Air pressure will vent to atmosphere from these

safety relief valves and is an indication that
bearing or housing wear or failure has
occurred.
! CAUTION
Do not continue to operate the machine with
air venting from the compressor safety relief
valve(s).
Page 18
HIGH PRESSURE COMPRESSOR SYSTEM FLOW CHART
(COOL OIL)

HIGH PRESSURE COMPRESSOR SYSTEM FLOW CHART
(WARM OIL)
Page 20
AIR COMPRESSOR LUBRICANT RECOMMENDATIONS
Sandvik Mining and Construction encourages the user to participate in an oil analysis program with
the oil supplier. This could result in an oil change interval differing from what is stated.
NOTE!
Mixing synthetic oils with ATF or other petroleum products may lead to operational problems, foam-
ing, or plugging of orifices. Do not mix different types of fluids.
AMBIENT CHANGE LUBRICANT

ISO
TEMPERATURE INTERVAL DESCRIPTION
-40°F to +95°F (-40°C to +35°C) 1000 Hours 32 Mobil SHC-624, 924 & 1024
-40°F to +100°F (-40°C to +38°C) 500 Hours 32 Mobil Rarus 424
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Chevron HiPerSYN
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Chevron Tegra Synthetic
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Shell Corena PAO
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Royco 432
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Conoco Syncon R&O
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Texaco Cetus PAO
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Valvoline Syn Guard CP
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Petro-Canada Super SCF32
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Chevron HiPerSYN
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Citgo CompressorGuard
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Conoco Syncon R&O
+30°F to +100°F (-1°C to +38°C) 500 Hours 46 Mobil Rarus 425
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Petro-Canada Super SCF46
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Royco 446
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Texaco Cetus PAO
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Valvoline Syn Guard CP
+80°F to +120°F (+27°C to +49°C) 1000 Hours 68 Conoco Syncon R&O
+80°F to +120°F (+27°C to +49°C) 1000 Hours 68 Mobil SHC-626, 926 & 1026
High Pressure Compressors
When operating between +80 and 100°F (+27 and 38°C) with a relative humidity above 80%, syn-
thetic hydrocarbon type fluid Mobil SHC or equivalent as recommended above should be used.
All lubricant recommendations are based on 1200 rpm maximum WARM-UP speed.

Page 22
COMPRESSOR OIL CHANGE Draining Oil
PROCEDURE Depending on the ambient temperature, it may

be necessary to start the machine and warm the
compressor prior to changing fluid.
GENERAL 1. Once compressor oil is warm, shut off the

machine and remove the key from key
This procedure is to be used: switch.
• When a total system cleaning is necessary. 2. Utilize 2 each 50 gal (190 liters) containers
to collect used oil.
• Severe duty applications.
3. Connect a hose to the drain valve on the
• Changing brand name, type or viscosity of bottom of the receiver tank.
compressor fluids.
4. Open the ball valve to drain used compres-
Sandvik Mining and Construction D45KS and sor oil into the containers. Follow applicable
D50KS drilling machines are shipped from the laws prescribed for waste oil recovery.
factory with Shell Corena POA 32 in the com-
pressor system.
! CAUTION
In certain areas of the world, this oil may not be Starting the engine when the compressor oil
available. If this is the case it will be necessary has been drained will damage the compres-
to change to the local available oil. When this sor. Do not allow the engine to start!
occurs it is mandatory to clean the system of the
original oil. 5. Apply the key switch on, engage the emer-
gency stop push button and roll the engine
Mixing of two different oils can cause the follow- and compressor over two (2) or three (3)
ing problems: times. Do not allow the engine to start! This
procedure will push any residual oil that was
• Oil Foaming, big air bubbles can cause cav- left in the compressor back to receiver tank.
itation on components and make air pockets
in the oil cooler restricting oil flow 6. Remove top and bottom hose from com-
pressor oil cooler. This enables oil to drain
• Overheating, compressor fluids not flowing out of cooler.
through the oil cooler will not dissipate heat
7. Remove separator filter. Replacing the sepa-
• Excessive Oil Carry Over through the sep- rator element is dependent on service hour
arator element wasting the oil down the drill interval. When in doubt or service hours are
pipe. unknown, replace the separator element.
When the following procedure is utilized, these 8. Remove scavenge return line and allow to
problems can be reduced or be non existent. drain, remove and clean strainer screen,
replace screen and tighten.
DESCRIPTION 9. Remove the main compressor filters. The fil-
ter canister may be unthreaded from the
The Lubrication section of this manual lists housing in order to drain oil from filter canis-
approved compressor fluids compatible for Sul- ter.
lair warranty.
10. Remove and drain the pilot hose at the oil
stop valve.
Compressor Oil Change Procedure Page 23
11. Remove all oil cooler and tank lines from 10. Connect pilot hose to the oil stop valve.
compressor to drain any oil that may have
been left in system. 11. Fill air receiver tank with new clean oil to the
required level sight glass port, install the fill
12. HIGH PRESSURE APPLICATIONS ONLY plug and tighten.
Remove discharge check valve from the dis-
12. Engage the emergency stop push button,
charge port of the compressor, (location is
roll over compressor and check for any
underneath compressor) to drain any oil that
leaks. If evident, repair prior to running the
may be left in that area.
machine.
13. Remove intake piping at compressor inlet.
13. Start engine and run at low idle and check
NOTE! for any leaks. If evident, repair.
New flange O-rings will be needed for connect- 14. Permit compressor to run until compressor
ing hose ends that have been removed for this temperature comes to operating tempera-
procedure. ture. (Approximately 160° to 200°F).
Adding Oil 15. Shut machine down and recheck compres-
sor oil level after 15 minutes.
1. Pour some new clean compressor oil into
the top of the oil cooler permitting it to push 16. Add oil as needed to the proper fluid level
any of the existing oil from cooler. Once new sight glass.
oil is coming through oil cooler, attach the
top cooler hose. 17. After several hours of operation and if a
foaming problem exists, you may need to
2. Pour some new clean compressor oil into drain the oil from the separator tank and
the intake of the compressor to flush out any refill.
original oil. Once this is done, install the dis-
charge check valve high pressure applica- Oil may be transferred from air receiver tank to
tions and all other hoses that were clean drums using a portable filtration cart as
removed. shown.
3. Pour some oil into the receiver tank to push
out any existing oil. PORTABLE FILTRATION CART
P/N 023912-001
4. Close the drain valve.
5. Install separator filter, with a new gasket, do
not remove the static staple that is clipped in
the separator gasket. No additional sealants
are necessary.
6. Mount the receiver tank cover, torque bolts
to spec.
7. For low pressure applications install the
scavenge return tube and tighten adapters.
8. Connect scavenge return hose to appropri-
ate ports.
9. Install compressor filters making sure the
plastic connection piece is installed between
the two KZ25 series filters.
Page 24
AIR RECEIVER RESERVOIR only be performed with a qualified test proce-
dure and a qualified engineering firm.
SEPARATOR MAINTENANCE
Due to the complexity of such laws worldwide
GENERAL Sandvik Mining and Construction ask that the
customer bare this responsibility as a company
Routine maintenance on air receiver reservoirs standard operating procedure.
require a skilled maintenance person using safe
operating principals and clean working habits. Static Discharge
DESCRIPTION Sandvik Mining and Construction drill machines

will use a static discharge spring or staple as a
Sandvik Mining and Construction drilling equip-
electrical ground for the separator filter element.
ment use compressed air during the drilling
cycle. Air pressure will be contained in the air
• High pressure applications require a spring
receiver tank during the machine run mode.
installed on the bottom end filter holddown
bolt.
When performing routine maintenance it is
essential that the machine be turned off for a
• Low pressure applications require a static
minimum of 2 minutes prior to starting compres-
staple installed on the sealing gasket for the
sor system maintenance. Longer periods may
top cover.
be beneficial to allow oil temperatures to drop.
Do not operate the machine with the static
It is recommended to use the appropriate
spring or gasket staple removed.
machine maintenance manual when performing
the 250, 500, 1000 and 2000 hour maintenance
Compressor oil under heat from compression,
programs.
and velocity may develop static electricity inside
the air receiver tank during operating condi-
The details given in this section are relating to
tions.
air receiver reservoir air/oil separator element
service specs.
The contained static electricity may have the
capacity to ignite the oil and cause the com-
The figures given will be noted for machine(s)
pressor to flash. A machine fire will occur.
specific data.
MACHINE MODELS APPLICATION
T25KW HIGH PRESSURE
D25KS, D245S HIGH PRESSURE
D45KS HIGH PRESSURE
D55SP, D75KS HIGH PRESSURE
There are different reservoirs for high pressure

versus low pressure applications. Therefore the
maximum pressure ratings and operating tem-
perature specs differ.
It may be a written law that pressure vessels

require recertification. This recertification may
Separator Maintenance (HP) Page 25
AIR RECEIVER RESERVOIRS
D25KS, D25KX, D245S

T35KS, TM40KW, D40KX
T40KS, D40KS, D45KS
HIGH PRESSURE APPLICATION
COVER TORQUE
3/4 10 UNC GRADE 5 190 - 210 FT LB (256 - 283 Nm)
FILTER HOLDDOWN COVER TORQUE
3/4 10 UNC 50 FT LB (67.5 Nm)
Page 26
HIGH PRESSURE Cooling fan systems are designed to draw air
through heat exchangers. Engine coolant, turbo
COMPRESSOR COOLING air, compressor oil, hydraulic oil and diesel fuel
are being air cooled by the speed of the cooling
SYSTEM fan and ambient air temperature.
GENERAL
High pressure application drilling will generate

higher than normal operating temperatures.
The two stage compressor is under maximum

load during the drilling mode and receiver air oilcoolers.tiff
pressure is 345 to 350 psi (24 bar).
The engine is under 60 to 80 percent load,

depending on available receiver air pressure.
During the drilling cycle the hydraulic system

will be working hard also.
• rotation pump delivery for drill pipe rotation
• feed pump delivery for advancing drill pipe

into and out of the blasthole
When cooling problems occur, question which
• cooling fan pump delivery to turn a deter- systems are overheating.
mined fan dimension.
If there is a true cooling fan speed issue, all the
As noted in troubleshooting procedures it may fluids and the air will be influenced by the
become necessary to check the machine higher than normal operating condition.
parameters that may allow high operating tem-
peratures during the drilling modes. Experience on the machine will enable visual
identification when a cooling fan is not turning
the correct speed.
DESCRIPTION
When cooling fans are spinning the correct
The current cooling fan systems are described speed and direction (CCW), the ambient air is
in detail in the Hydraulic Systems Training Mod- sucking through the cooler assembly.
ule Book 5, Start Up And Setting Procedures.
Determine the cooling system concept as ! DANGER

described.
Fan blades can cause serious injury or
• closed loop system death. Always use caution when testing
cooling fan speed.
• open loop system
When testing the fan speed hot air will rush
• locate the components
past the motor. Depending on fan speed the air
Compressor Cooling Systems Page 27

will be forceful enough to blow personnel cloth- FAN SPEEDS
ing and personnel protective equipment.
The following performance chart will detail cool-
Cooling fan motor and assemblies are mounted ing fan speeds for current model machines
on support beams. available for high pressure applications.
The piston type motor is mounted to the female Cooling fan speeds are checked with the
end of a oil filled over hang adapter. engine at high idle speed.
OVERHANG ADAPTER
BREATHER AND MODEL DIAMETER STEEL
FILL PORT
D45KS 48” 700 -1200
PLACE TAPE
pfanmtr.tif ON FAN HUB D50KS 48” 700 -1200
Fan speeds vary due to fan system concepts.
The 700 to 1200 fan speed are the closed loop

application cooling system available on Sandvik
Mining and Construction D45KS and D50KS
machines.
CLOSED LOOP FAN SYSTEM • 700 rpm is low fan speed, cool engine
• 1200 rpm is fast fan speed, hot engine

The overhang adapter requires periodic mainte-
nance and oil change intervals of 250 hours. Re
New pumps and new motors are not preset for
placement oil can be machine grade compres-
the spec speeds required for proper cooling.
sor oil.
When fan speeds are not sufficient additional
Approximate capacity 12 oz. (355 ml).
hydraulic system troubleshooting may be
required.
To determine fan speed it will be necessary to
place a piece of reflective tape on the fan hub.
Refer to hydraulic system book 5 for cooling fan
• apply the tape with the machine shutdown system specs.
and the fan at rest.
• clean the surface prior to placing the reflec-

tive tape.
• it may be necessary to prepare the fan hub

with non reflective paint.
• use a photo cell or a hand held photo

tachometer
High idle engine idle speeds should be verified.
Page 28
HIGH PRESSURE
PILOT
COMPRESSOR CONTROL
REGULATION SYSTEM
GENERAL VENT
This section describes the Sandvik Mining and

Construction high pressure compressor regula-
tion system.
DESCRIPTION
High pressure drill application machines have SHUTDOWN BLOWDOWN VALVE

two regulation systems.
At this point, air will start to build in the air
The primary system is high pressure air regu-
receiver tank. It should take approximately 40 to
lated up to 350 psi (24 bar). DTH down the hole
60 seconds to build low regulator unload pres-
hammer tooling is required to enable 350 psi
sure.
(24 bar).
Control air from the air receiver tank is directed
The secondary system is low pressure air regu-
to the normal open (NO) low pressure regulator
lation up to 160 psi (11 bar). Rotary drill tools
‘PR’ and ‘IN’ ports.
are used for this mode of compressor pressure.
Thus high pressure machines are equipped with LP REGULATOR

two air pressure regulators to maintain receiver 100 TO 250 PSI
air pressure at designated system pressure. CLO
ICC AIR IN
RBV
Machines should be in low pressure mode for
start up and shutdown purpose. reg2.tif
Low Pressure
VENT 4 EA
SHIMS
At start up, a slow rise in air pressure will be
noticed on the operator station receiver air pres-
sure gauge.
ADJUSTMENT
SCREW
Filtered air is directed through the inlet control
valve (butterfly plate) into the compressor for
the compression cycle. Compressed air and oil Regulators adjustment procedures are on page
is discharged into the air/oil receiver tank. 33 and 34 of this manual.
Discharged compressor oil pilots the shutdown Air passing through the LP regulator and it’s
blowdown valve to close the receiver air vent to energized compressor low solenoid (CLO) is
atmosphere. directed to the inlet control cylinder ‘attached to
the butterfly inlet valve’, and to the pilot port of
the normal open (NO) running blowdown valve.
Compressor Control Regulation System Page 29
Pilot air pressure from the regulator closes the
(NO) running blowdown valve.
REG ICC AND ORIFICE

PILOT AIR
airinletparts.tif
runningbd.tif
ORIFICE
AIR OUT AIR IN
RUNNING BLOWDOWN VALVE Air for the running blowdown valve pilot piston
will be vacuumed through the 3/32 (.94) orifice.
At approximately 90 psi the inlet control cylinder
will extend to open the butterfly inlet valve. The inlet control cylinder spring will close the
When the receiver air pressure reaches the low butterfly plate, restricting incoming air.
pressure regulator setting of 150 -160 psi (10.3
- 11 bar) the LP regulator will pilot closed at the With the inlet valve closed the (NO) running
pr port closing the inlet to outlet supply air. blowdown valve will open air above the mini-
mum pressure spring setting < 140 psi to vent to
atmosphere. This operating condition is com-
pressor unload.
AIR RECEIVER The drilling application requires the drill opera-

TANK PRESSURE
tor to open the service valve for flushing air. The
service valve consists of one ball valve
reg1.tif threaded to air pipes, it is cylinder actuated by
lever and linkage connections. Locate these
parts on the mast pedestal frame.
CONTROLLED AIR
INLET CONTROL
CYLINDER AND
RUNNING BLOW- AIR RECEIVER PILOT
DOWN VALVE AIR PRESSURE (PR)
The air signal trapped in the control hose is vac-

uumed out through a 3/32” (.94) orifice inside
the intake manifold directly below the butterfly
inlet valve.
Page 30
At low pressure regulated air and a proper
AIR PIPING GROUP machine shut down it is expected that all air
007892-006 pressure inside the air receiver tank will vent to
atmosphere through the blowdown valves within
2.5 minutes.
AIR HOSE
RESTRAINTS
High Pressure
When high pressure air is needed for the DTH

airpiping.tif drilling tools, the operator will switch the com-
pressor toggle switch from the low setting to the
SERVICE MAST high setting.
VALVE PEDESTAL
The compressor low solenoid (CLO) will de-

energize and the compressor high solenoid
CHECK
(CHI) will energize.
VALVE AUXILIARY
AIR MANIFOLD NOTE!
Both CLO and CHI solenoid valves are normal
closed, toggle switch controlled by the operator
When the drilling cycle is started the receiver air to energize with 24 volts to open. Only one sole-
pressures drop below a regulator valve setting noid is energized by the toggle switch.
at the pr and in ports.
The air control process will repeat to the high
When air is passing through the regulator(s) the pressure regulator setting. The air signal to the
inlet control cylinder extends, and the running control cylinder at the butterfly inlet valve can be
blowdown valve pilots to close receiver tank up to 350 psi (24 bar).
pressure from atmosphere;
Receiver air pressure during drilling cycle will be
• Air should not vent through the running dependant on the selected DTH hammer and
blowdown valve to atmosphere during the altitude conditions.
drilling cycle.
It is recommended that the operator move the
• Air will vent to atmosphere when the high/low compressor switch to the low setting
machine is at idle, in low or high pressure between drilling cycles and at desired shutdown
mode(s), not drilling. times.
When the operator shuts off the machine the NOTE!

compressor stops turning. Problems can arise if the machine is shut down
with compressor at the high pressure regulator
Compressor oil stops circulating in the system. setting of 350 psi (24 bar).
The normal open (NO) shutdown blowdown Air regulation components are manifold
valve will loose it’s pilot signal of oil. The valve mounted and protected under a cover. To
spring will lift the piston off the seat permitting access the valves for setting remove the cover.
all air pressure from the receiver tank to exhaust
to atmosphere.

• CLO compressor low solenoid
REMOVE • CHI compressor high solenoid
COVER
• HI REG high pressure regulator
• ICC inlet control cylinder @ butterfly plate
• LO REG low pressure regulator
• MPV minimum pressure valve
• RBD running blow down valve
• SBD shutdown blow down valve
System schematics labeled HP1 a,b,c detail air

direction for drill run modes.
NOTE!
High pressure regulation is used with DTH
down the hole drilling tools and carbide button
Remove the cover to expose the regulating type drill bits
valves, air control manifold, solenoid valves and
connecting hoses. Low pressure regulation is used for rotary type
drill tools. Rotary drill bits come in many forms
ICC
such as roller, claw, drag or blade types.
MPV PILOT OIL
SBD
Regulators (HP and LP) vary due to internal
AIR IN
spring force. They are different pressure rates.
RBD
CHI
CLO ICC AIR IN
LP REG RBV
HP REG
CHI reg2.tif
ATM
HIGH PRESSURE AIR REGULATION
VENT 4 EA
SHIMS
Compressor components have repair kits and
may be rebuilt with minimal tools. Recom-
mended service intervals vary due to operating
conditions, expect between 2000 to 4000 ADJUSTMENT
machine hours. HP REGULATOR SCREW
200 TO 400 PSI
Nomenclature for the air system:
• ATM atmosphere vent muffler

• AIR IN air from receiver tank
Page 32
Calibrating Regulators 10. Actuate the compressor switch to low mode,
the receiver air pressure will vent through
Perform air pressure regulator calibration. Start the running blowdown valve to atmosphere
the calibration with the machine shut down and to the low pressure regulator calibration.
receiver air pressure is zero.
11. Lower engine idle speed allow adequate
Pressure regulators may be calibrated in place engine cool down period prior to stopping
on the machine with standard hand tools. It is machine.
advisable to install a 500 psi (35 bar) pressure
gauge and hose to the test port provided at the 12. Stop the machine per standard operating
air/oil separator indicator. principals.
1. Start the machine. 13. Allow approximately two to three minutes

for the air pressure in the receiver tank to
2. Operate the machine at low engine idle empty to atmosphere. Air will blow to atmo-
speed to warm fluids and air. Warm com- sphere through a frame mounted vent muf-
pressor oil and air temperature is recom- fler.
mended prior to regulator calibration.
14. Check receiver air pressure on test gauge
3. Compressor selector switch shall be in the for a zero indication prior to service.
low air mode.
15. Remove test pressure gauge from air/oil
4. Operate machine to specific rated high separator indicator location and cap test port
engine idle speed. adapter.
5. Check air pressure gauge for actual air Do not operate the machine at either idle speed
receiver tank air pressure. and high air pressure mode without performing
the actual drilling application.
6. Adjust low pressure regulator adjustment
screw in to increase air pressure to achieve Operating the machine at high receiver air pres-
150 - 160 psi (10.3 - 11 bar) unload air pressure and not drilling:
sure.
• robs engine horsepower and diesel fuel
NOTE! • generates additional heat in the compressor
If air pressure over runs the value reduce the system components
regulator setting and slowly adjust the regulator
to the rated pressure value. • leads to separator filter failures and exces-
sive oil carry over
Inlet control cylinder alignment can affect regu-
lator control. If low pressure cannot stabilize Vacuum Test
install a vacuum gauge in the compressor inlet.
A vacuum test port on the compressor inlet
7. Actuate the compressor switch to high mode housing enables diagnostic testing of inlet con-
trol butterfly position and/or adjustment.
8. Check air pressure gauge for actual air
receiver tank air pressure. 1. Install one negitive reading or vacuum
gauge to the vacuum test port.
9. Adjust high pressure regulator adjustment
screw in to increase air pressure to achieve 2. Remove inlet control cylinder from the inlet
350 psi (24 bar) unload air pressure. control butterfly linkage.
3. Start the machine.
4. Allow approximately 1 minute operation at

low idle for air pressure to raise in the air
receiver tank.
5. Set engine to high idle speed.
6. Expected vacuum shall be 26 inches hg.
7. Adjust unload stop screw to meet 26 inches

hg at high idle no load condition.
8. Connect inlet control cylinder to the linkage,

adjust banjo bolt thread according to linkage
position.
9. Lower engine idle speed to 1200 rpm. Air pressures shown are low pressure mode
blowing air through the bit. This would be the
10. Perform a proper engine shutdown. start of drilling and/or blowing the hole clean.
11. Remove test equipment. Air pressure will increase with bit contact to the
ground. Air pressure will increase according to
12. Plug inlet vacuum test port. hammer size, machine operating altitude and
the condition of the hammer.
Machine options may enable a normal open air Air pressures may increase as high as 350 psi
pressure switch to be added in the working air (24 bar) during high pressure mode drilling with
pressure piping. a good hammer.
This option will require the working air pressure Air pressure equals production during DTH drill-
be blowing to the drill bit before receiver air ing. Higher air pressures enable the hammer to
pressure can be switched to the high pressure function with greater forces to break rock.
mode.
Final note:
This option is intended to save engine fuel and
horsepower due to compressor loads when air The compressor lubrication system is depen-
pressure is at the 350 psi (24 bar) value. dant on operating air pressures. Compressor
system air and oil components are subject to
Operator Station Monitoring receiver tank air pressure.
Operator station gauges indicate receiver and When testing oil coolers, test pressures are rel-
working air pressures. ative to air regulated pressures. With the excep-
tion of lubrication component pressure drops
In a non drilling mode the working air pressure test pressures will be greater than the low pres-
gauge will read zero and the receiver air pressure regulator and less than the high pressure
sure gauge will be regulated pressure specific regulator values.
to the low pressure regulator calibration.
Page 34
Page 36
Page 38
VOLUME CONTROL Inlet vacuum shall be as low as zero during high
idle loaded blowing air to atmosphere condition.
The inlet control cylinder is at full stroke and the
GENERAL butterfly pate is full open.
Air inlet variable volume limiting options may be
Inlet vacuum may be restricted by the load stop
fitted to most compressor intake mechanisms.
screw of the 010368-001 slide bar.
This option may be factory mounted or added
after-market as a field installation package. Mechanical Adjustment Type Volume Con-
trol Mounted On A Butterfly Inlet Valve.
ADJUSTMENTS
The volume control is a simple limit screw

VACUUM
adjustable type bar. This section will detail the TEST
specific components. GAUGE
• Butterfly inlet valve mechanical adjustment

volume control
A butterfly inlet valve will be limited on its open-

ing value with a mechanical stop. Adjustments
are necessary when installing this application. LOAD STOP ADJUSTABLE
SCREW MOUNTING SCREWS
Test equipment required:
• vacuum gauge
• adapter, connection hose
• 9/16 (15mm) wrench UNLOAD STOP

SCREW
• ambient temperature gauge 010368-001
Vacuum shall be monitored upon startup and The 010368-001 tool limits the compressor inlet
during rated high idle engine operation. thus limiting the compressor output. The effect
is approximate 0 to 30% drop in compressor
The engine must be at high idle speed to enable efficiency.
full inlet air for the compressor vacuum test.
Volume controls are used when the compressor
It is recommended to remove the inlet control capacity is too much for the selected DTH drill
cylinder linkage from the inlet control cylinder tool.
prior to testing vacuum. Manual control allows
tuning the inlet butterfly plate to the correct inlet Example:
vacuum. A Mission 55 DTH hammer requires 790 cfm
• Inlet vacuum shall be 26” to 28” hg. (22.37 m3 /min) to maintain 350 psi (24 bar) air
pressure.
Replace the inlet control cylinder linkage prior to
setting the volume control. If the machine is equipped with 1000 cfm
(28.31 m3 /min) the hammer can’t use all the
The compressor must be in a loaded condition available air and the compressor system cycles.
for calibrating the volume control bar.
Volume controls Page 39

Page 40
AUXILIARY AIR Dust collection systems have to be tuned for
the ground conditions and material being
COMPONENTS drilled. Certain applications require special
attention to customize the dust collecting com-
ponents. One size dust collector will not fit all
GENERAL applications.
Sandvik Mining and Construction earth drilling Dust Collection And Dust Suppression
machines are specified to meet the customer’s
needs.
The following optional equipment is made avail-

able to assist the drilling or maintenance func- dustoptions.tif
tions of most of the drill product line:
• Dry Dust Collecting Systems
• Automatic Thread Greasing System
• Hydraulic Tank Pressurization
• Bit Lubrication System
• Automatic Lubrication Systems

The typical dust collector on a blasthole drill
• Blow Down Cleaning Attachments machines is the Tipton model with 4, 5, 6 or 8
filter elements.
• Chain Lubrication System**
DESCRIPTION
Suppressing drilling dust is a mandatory part of

equipment operator safety. The two available
means for suppressing drill dust are:
• DRY DUST COLLECTING systems by way

of seals, curtains, suction fan, filter media,
collection box with a manual drop vent
• WATER INJECTION systems with seals,

curtains, various water tank sizes and a
water pump with relief valve
Daily and when required maintenance for either Dust filters must have a good seal to the hous-
system is the responsibility of the end user. ing. Each filter must be hand tightened with a
sealed wing nut.
Dry dust collection systems are one means of
suppressing fine drill dust particles omitted dur- A loose filter, bad filter seal or damaged filter
ing the drilling cycle. element will emit dust out the fan housing. Dust
blow by will damage dust collector fan and fan
There are many sizes and styles of dust collec- housings.
tors used in the industry.
Auxiliary Air Components Page 41
Maintain good door seals. Tighten each door to
maintain adequate vacuum inside the dust col-
lector.
The filters are purged with regulated air from

the machines air system. Dust collector regula-
tion is adjustable and set to 50 psi (3.5 bar).
NOTE! RELIEF SOLENOID

FLUSHING
The dust collector air regulator may be backed VALVE VALVES
VALVES
out to zero air pressure for transportation pur-
pose. Adjust the regulator during the pre deliv-
ery checks prior to drilling and dust collecting.
LP APPLICATION Maintain good door seals. Tighten each door to

REGULATOR maintain adequate vacuum inside the dust col-
lector.
Flushing valve repair kits are available. Electric

power to the solenoids is a timed system by
means of a sealed circuit board.
HP APPLICATION
REGULATOR
x
DCT
50 A
PSI
This sealed dust collector timer junction box
F houses the circuit board. The timer distributes a
A
off time and on time sequence to one filter at a
90 time.
PSI F
A • adjust on time to enable a quick burst of air
to purge the dust filter. The on time shall be
F
300 ms
)( • adjust the off time according to material col-
DUST CONTROL SYSTEM lected. Typical setting is 6 seconds off time
Regulated air is directed to flushing valves and

electric solenoids inside the dust collector.
Page 42
The circuit board powers one solenoid and LED
per flushing valve. The LED illuminates to indi-
cate when the solenoid receives a on cycle.
Maintain good junction box door seals. Tighten

door to minimize dust and water entry.
A hydraulic motor and fan enable vacuum

inside the dust collector housing. The motor
speed is partially responsible for dust control.
Angle drill dust hood skirt lengths may need to

be modified to suit the ground conditions.
Fan speed shall not exceed 3000 rpm. Faster

fan speeds may over load the filters and not let
the filters clean adequately.
Adjust the speed according to ground material.

Skirt extensions can be added to make a good
Turn the dust collector fan control off between ground seal. This is required so the fan suction
rod changes. Better filter cleaning occurs when from the dust collector can draw dust and the
the fan is not turning. drill cuttings can be contained under the skirt.
Dust Hood
Cylinder actuated dust hoods and dust hood

doors allow adequate seals for dust suppres-
sion under most drilling conditions.
Depending on application, dust skirts may need

to be modified.
It may be necessary to use two dust skirts and

overlap them at the corners to enable a relief
for drill cutting accumulation.
Vertical drill dust hood skirt lengths may need to

be modified to suit the ground conditions.

Operators use a cab mounted control lever or Metered air directs thread grease to drill pipe
electric switch to turn the dust collector or water threads near the table bushing.
injection system on. Additional controls allow
dust hood and dust hood door options.
POSITION GREASE NOZZLE

TO DRILL PIPE THREAD
Add thread grease to the container, position the

follower plate and pump into the grease and
secure the container cover.
The drill dust collecting system with fan motor

speed, air pressurization, and electrical timed
pulse settings are detailed in service literature
007702-000. ckthrgrsr.tif
Automatic Thread Greasing System
The old method of operators applying thread

grease to the drill pipe with a brush still exists.
New concepts allow the operator to remain in

the operator cab and still apply thread grease
the drill pipe.
Special drill pipe thread grease can be pumped

by air actuation through hose and adapters Adjustable flow control valves at this pump to
onto the drill pipe thread box or pin ends. meter regulated air pressure to the grease
pump and to the injector nozzle located near
Brand name thread grease: the table bushing.
• Texaco Threadtex
Lock flow control valve position.
• Kopper Koat by Jet lube
Regulated air pressure for this pump is
• J89 by Jet lube between 80 up to 100 psi (5.5 - 6.9 bar)
• Driltech Copper 024178-003
Page 44
Machines operating in altitudes above 4000
feet (1200 meters) will need to alter the stan-
THREAD GREASE SYSTEM
dard air pressure spec of 5 psi (.3 bar).
x
Service literature 004756-000 details the
adjustment setting procedure for hydraulic tank
air regulation parts.
100
PSI
x
)(
)(
)(
ADJUSTFLOW
CONTROL VALVES RAP
FOR AIR AND GREASE
DELIVERY 10u
Daily and when required maintenance for the 40u

x
thread grease system is the responsibility of the HYDRAULIC TANK 5u
end user. 5-7 12
AIR REGULATION
PSI PSI
Hydraulic Tank Pressurization

Daily, when required and 500 hour mainte-
All Sandvik Mining and Construction blasthole nance for hydraulic reservoir pressurization
products have air regulation components on the system is the responsibility of the end user.
top cover of the hydraulic reservoir.
When servicing the hydraulic reservoir with new
Hydraulic tank pressurization serves two main oil open the ball valve to vent residual air pres-
features. sure. This is recommended practice to prevent
• maintain a positive pressure into the pump gasket or seal damage to the cover and inlet
inlet supply connections.
• assist in contamination control
Bit Lubrication System
High pressure application machines may be fit-

ted with 2 sizes of reservoirs holding 10 gallon
(38 liter) or 30 gallon (114 liter) of special lubri-
cant oil referred to as rock drill oil.
REGULATOR
RELIEF VALVE
When selecting an oil to lubricate DTH ham-
mers and drill bit it is recommended to consider
the following;
• ambient operating condition
• operating temperature
HYDRAULIC TANK
PRESSURIZATION The lubrication cycle may be adjusted for oil
quantity or flow and a timed cycle to inject. Oil is

injected into the air system after the service
valve.
x
TIMER
(LTR)
RDOregulation.tif
FILTER AND
SOLENOID 60
PSI
REGULATOR
5u LTR
LS
PUMP
DTH LUBRICATOR SYSTEM
Daily maintenance is required. Use sealed and

approved clean containers for transporting rock
drill oils.
Service literature 011362-000 details the adjust-
ments available to operator and mechanical
Contaminants inside the lubricator tank may
personnel. Tune the oil injection rate to provide
block oil flow to the pump supply port.
a fine mist or a slight visual film of oil inside the
drill pipe or drill bit rollers.
Lubricator pump service literature 011353-000
details the pump service procedures.
With the machine running the lubricator air reg-
ulation system should be stable at 60 psi (4 bar)
Notes:
Allow adequate pump chamber fill time for the
Factory setting on the flow control valve is 10
viscosity of rock drill oil being used.
turns out or 1/2 piston volume.
To fast pump cycle times will not allow some
grades of rock drill oil (due to viscosity and tem-
Lubricator timers have adjustable on and off
perature) to completely fill the pump chamber.
time cycles. Timer relays are located in the
lubricator junction box or cab junction box.
To fast cycle times will over load the piston
• ON cycle is the duration of time regulated air springs. Spring breakage may occur which will
pressure is directed to the lube pump and lead to loss of oil flow to the DTH hammer.
should be set for 2 second intervals
During normal operating rock drill oil will be
• OFF cycle is the time between oil injecting visual inside the drill pipe connections. It is nor-
and should be set for 6 to 10 second inter- mal to use 1 quarts (.95 liters) per hour of oil
vals during the drilling cycle.
Page 46
Automatic Grease System
All point lubrication grease systems are avail-

able to lubricate cylinder pins, bushings, and x
(HP)
rotating bearings for sprockets.
(LP)
Points that are not lubricated by the automatic 60 -80
system and require manual lubrication are: PSI
• rotating drive shaft yoke and u-joint assem-

blies
• feed system traveling carrier sprockets
• air swivel joint on rotary head air piping

)( LT
This system may be manual, electric or progra-
mable.
LS
autogreaseparts.tif
AUTOMATIC
GREASE SYSTEM
Daily and when required maintenance is the

responsibility of the end user.
Open the water separator drain tap daily to

empty collected condensation.
It is recommended to fill the lubricator bowl

daily with a quality air line lubricant, SAE 10w or
an equivalent air line lubrication oil.
Depending on compressor application the items
shown here may be configured slightly different. Chain Lubrication System
The grease pump requires air line lubricant and Chain manufacturers prefer to lubricate moving
reduced air pressure. A solenoid will open air to chain sections with a low volume of chain lubri-
the grease pump from either the electric timer cant.
or the program module.
The chain lubricant can be petroleum based,
Electrical power is 24 VDC and may be cali- engine, machine or chain oil proper for the
brated to inject grease on a preset timed inter- ambient operating condition. Synthetic oil may
val. be utilized in sever operating conditions.
Service literature 006113-000 details grease In normal conditions a SAE 20 to SAE 40

system components. weight lubricant is sufficient.

Daily inspection of oil capacity is a must to
assure lube pump does not draw air and loose
prime. Fill the reservoir as needed based on oil
consumption.
PUMP
REGULATED AIR
SUPPLY
SOLENOIDS
IMMERSION
HEATER 023182 CHAIN LUBE GROUP
023192 RESERVOIR ASSEMBLY

The feed system must be free to travel full
travel up and down the mast to perform proper
Chain lubrication systems are air activated with chain maintenance.
reduced air pressure from the reservoir.
Expected control air pressure shall be 60 to 80 1. Control the toggle switch to air mode while
psi to operate the lube pump. operating feed full travel. This cycle pre-
cleans the chains with compressed air.
Four nozzles positioned in the mast are pointed
toward pull-down and hoist chains to spray 2. Control the toggle switch to oil mode while
lubricant according to operator control. operating feed full travel. This cycle lubri-
cates the chains with oil.
Operators may control the chain lube cycles
with a cab mounted console toggle switch. 3. Operate the toggle switch to air mode while
operating feed full travel. This cycle purges
Note! oil from the mast hoses.
Chains do not require daily lubrication.
Maintenance personnel must control the chain Air Line Filtration

lube cycles from the same toggle switch. Lubri-
cate the chains at 500 hour intervals. Arctic and cold ambient conditions may require
air line filtration to separate condensation mois-
ture in the dry air supply lines.
Page 48
Coalescing filter spare part number 022462-001
COALESCING FILTER
022462-001
A coalescing filter may be connected in line for

any of the mentioned auxiliary air regulated
components.
Drain Condensation
Many of the auxiliary air components have

manual drain ports that when opened allow
moisture and condensation to vent to atmo-
sphere.
In severe climactic applications it is recom-

mended to manually open the drain ports on a
regular basis. This is a maintenance task that
when utilized minimizes moisture and conden-
sation from the pneumatic component.

Page 50
TROUBLESHOOTING HIGH PRESSURE COMPRESSOR
SYSTEMS
SYMPTOM PROBABLE CAUSE ACTION

Machine shuts down with air demand Air end low oil pressure and/or high air/ Check air/oil discharge temperature
present oil temperature switch may be defective switches.
Check low oil pressure shut down switch

on lube manifold
Airflow through cooler insufficient Check fan RPM, system pressure and
flow
Low oil level in receiver tank Check center sight gauge on receiver
tank and see if oil is in center
Dirty oil and filters and clogged filters Change oil and filters
Incorrect oil for ambient condition
Faulty thermostats Remove thermostats and check
Faulty safety shut down circuit Check shut down switches
Pressure by-pass valves open Remove and check by-pass valves
Machine will not build up full discharge Check service lines for external leaks,
pressure open valves and/or bad hoses in control
circuit
Dirty air filter Check air intake filters, change if needed
Pressure regulator(s) Check pressure regulator diaphragm(s)

low or high pressure for damage, repair and adjust if needed
Hose size changes may affect full dis- Maintain original hose size for air regula-
charge air pressure tion and discharge applications
Machine will not build up full discharge Defective pressure regulator Repair or replace regulator
pressure (cont)
Faulty minimum pressure valve Remove and inspect minimum pressure
valve for movement, check seal and
repair as needed
Running blow down valve Remove, inspect and repair as needed
Shutdown blow down valve Remove, inspect and repair as needed
Air demand greater then supply Compressor not sized correctly for drill
application
Stuck inlet valve Check free movement, stroke adjust-

ment and settings of inlet valve
Check inlet vacuum with machine run-

ning at rated high idle speed
Check orifice in bleed muffler on control

cylinder
Troubleshooting High Pressure Compressor Systems Page 51

Improper unloading with excess pres- Pressure regulator(s) Check pressure regulator(s) setting.
sure buildup causing tank safety relief Repair or adjust as needed
valve to open
Air inlet Check adjustment and settings of inlet
valve
Jammed control linkage
Control cylinder sticking or loose
Adapter plate Plugged 3/32” orifice in adapter plate
Unload stop screw Unloaded stop screw adjusted too far

“in” allowing intake valve to be open too
much
Vent muffler restriction Clean or replace vent muffler do not use

solvents to clean vent muffler
Insufficient air delivery Intake filter Check filter and change as needed
Separator filter Plugged air/oil separator, change as

needed
Pressure regulator Check, adjust or replace as needed
Engine Check rated high idle speed (TEL)
Inlet valve Check inlet adjustment. Inlet valve may

be stuck closed
Check inlet linkage/shaft
Running blowdown valve Air vents to atmosphere during the drill-

ing cycle. Check, clean, rebuild as
needed
Shutdown valve Check, clean, rebuild as needed
Control line Check for plugged, loose or leaking con-

trol line(s)
Excess oil consumption Separator element Plugged scavenge line strainer or fixed
orifice
Damaged separator element
Damaged O-ring(s) on separator ele-

ment
Hold down nut on element not at 50 FT

LB (37 Nm) torque
Oil Incorrect oil
Foaming of oil
Oil level too high
Contaminated oil, drain, flush and refill

complete system per procedure
Page 52
Compressor overheating Oil cooler External surface dirty
Plugged or partially plugged with dirt

build-up
Weather Oil jelling in cooler due to cold weather

conditions.
Cooler may need covered or a oil viscos-
ity correction for the ambient conditions
Thermostats Broken or incorrect temperature rating

for ambient condition
Single seal ring for each thermostat, do

not use two seals rings
Worn out, replace as needed
Oil Low sump oil level
Incorrect oil for ambient condition
Oil contaminated with water or other

matter
Mixing of two different oils
Filter Filter seal stuck inside filter or filter hous-

ing
Incorrect filter capacity in beta ratio or

micron rating
Cooling fan Low fan speed, check RPM
Low fan system pressure
Fan pump oil flow to fan motor low
Bad fan motor
Worn out fan blades
Engine RPM low
Fan direction is CCW acting as a

“sucker”
Fan shrouding on cooler letting air

around fan blade slip
Faulty hydraulic hoses from fan pump to

fan motor
Faulty oil stop valve
Compressor Plugged bearing injection lines
Collasped hose or restriction in oil cool-

ing hosing
Troubleshooting High Pressure Compressor Systems Page 53

Compressor system will not shift to dif- Control circuit Defective solenoid valves or dirt in
ferent pressure settings Electric solenoid control valves (CLO - CHI)
Environmental conditions Air line restriction by condensation add

022462-001 coalescing filter
Frozen condensation
Operator controls Defective “high/low” toggle switch
Defective wiring from switch to sole-

noid’s
Defective air pressure switch
Pressure regulator adjustments
Inlet control cylinder, linkage or mounting

hardware
Compressor oil dumps out air filter dur- Improper shutdown procedure Machine shut down with compressor at
ing shutdown “HIGH” pressure setting. Must be set in
“LOW” position and engine at low idle for
Machines that share compressor and proper shutdown
engine air filters require both primary
and secondary filter replacement and Machine shutting down at high idle RPM
intake pipe cleaning prior to starting the during drilling at high pressure
engine
Run engine out of fuel
Compressor components Faulty oil stop valve
Faulty discharge check valve
Excessive foaming oil
Oil level in sump over full
Engine high idle speed drops Poor fuel Replace fuel filters as needed
Turbo boost Inspect turbo and air to air cooling sys-

tem components, replace silicon hose as
needed
Air venting through the safety relief valve Normal gearbox pressure will range from
generally means compressor repair and 35 to 65 psi (2.4 to 4.5 bar). Pressure
or replacement is required may be taken from a test port on the
compressor gearbox
Interstage pressure creates working Normal interstage pressure will range

loads on the engine. Excess pressure from 45 to 55 psi (3.1 to 3.8 bar) during
will pull the engine idle speed down dur- high pressure mode in a drilling condi-
ing a drilling condition, pressure above tion. Pressure shall be taken from the
80 psi means compressor repair and or interstage U - tube adapter
replacement is required.
Page 54
SERVICE LITERATURE 006307-000 Air Cleaner Engine/compressor
006477-000 Compressor Clutch Assembly

GENERAL 007702-000 Dust Collector Service (Driltech)
This section will give reference material specifi-
008674-000 Taperlock Bushing Installation
cation numbers for high pressure and low pres-
sure air systems that are available in Sandvik
010119-000 Air Inlet Valve Adjustment
Mining and Construction D45KS and D50KS
service procedures.
010756-101 Dust Collector Service (Tipton)
DESCRIPTION 011060-000 Centralized Lubrication
When component adjustments or repairs are 011353-000 DTH Lube Oil Pump Instructions
needed it is advisable to use service proce-
dures. 011362-000 Lube Oil Injection Instructions
This section may be updated as new proce- 012457-000 Lp Air End Shaft Seal Instructions
dures are written.
015702-000 DMS Instructions/troubleshooting
001036-000 Air Cleaner
016708-000 Air Cleaner Engine/compressor
001044-173 Lp Air End Shaft Seal Instructions
017144-000 Connector Expansion Instructions
001111-000 Swivel Seal Housing Packing
017239-000 Air End Shaft Seal Instruction
001217-000 Air Piping Swivel (Chiksan)
001217-001 Air Piping Swivel (Dover)
0019602-052 Turn Valve Assembly 90 Series
001658-000 Hydraulic Tank Pressurization
020247-000 Dust Collector Service (QMP)
001670-002 Pressure Relief Vent
020845-001 Dual Poppet Inlet Valves 90 Series
001958-121 Hp Air End Shaft Seal Instructions
020965-000 Drill Monitor System DMS
002428-000 Air Filter/regulator Instructions
003751-000 Side Mount Swivel (CRS) Instruc-
tions 021531-001 DMS - DIP Switch Chart
004320-000 Air Inlet Valve Adjustment 021740-000 Cooler Assembly
004756-000 Hydraulic Tank Pressurization 023260-01A Variable Speed Control
006113-000 Centralized Lube Systems
006113-010 Centralized Lube Systems
Appendix 1 - Air Systems Service Literature - Page 55

2-14-97
COMPRESSOR SHAFT SEAL 2. Check the oil seal retainer and shaft and
remove any burrs or sharp edges.
KIT (001958-121)
3. Clean the shaft thoroughly with a fine emery
cloth to remove any dirt, grime, metal particles,
etc.
! CAUTION
Disconnect the battery and tag the ignition NOTE !
system to warn others of the servicing being For units serial no. 5DH20-1 to 7DH20-150 the
performed. seal must slide over the keyway. Be sure to
round off all sharp edges on keyway before
installing the seal.
Disassembly
1. Remove the outer segment of “V” ring (2) Assembly and Installation
from the shaft.
1. If necessary, press spring pin (6) into the oil
2. Remove the six 1/4” capscrews and the seal retainer.
dust shield. Slide the inner segment of “V” ring
(2) off of the shaft. ! CAUTION
3. Remove the six 5/16 capscrews and Keep fingers off the dry lapped surfaces.
remove the oil seal retainer. The finish of the lapped face is easily dam-
aged and must be handled very carefully.
4. Remove the remaining components of shaft The lapped face can be identified by the
oil seal assembly (1) from the shaft. The rubber highly polished surface.
bellows (1D) are bonded to the shaft and have
to be broken loose by pushing the whole seal 2. Lightly coat the bore of the oil seal retainer
further down the shaft. If tools are used, care with light clean oil, such as 10W-30 motor oil.
should be taken that the shaft is not scratched Unwrap seat (1A) and take care so the lapped
or damaged in any way. surfaces do not get damaged.
5. Remove retaining ring (5), seat (1A) and 3. Lubricate and install O-ring (1B) in the
spring pin (6) from the oil seal retainer. groove in seat (1A).
4. Align the hole in seat (1A) with pin (6) and

! CAUTION gently press the seat into the bore, taking all
Do not remove, loosen or tamper with the precautions necessary so lapped face of seat
1/2” bearing retainer screws. These screws does not get damaged.
maintain the factory set axial end play of the
shaft. 5. Install retaining ring (5) into groove to hold
seat (1A) in place.
Inspection
1. Clean all parts thoroughly and remove all

old sealants, gasket material and other foreign
matter from and around the bearing, retainer
(1F) and oil seal retainer.
001958-121 SHEET 1 OF 3
2-14-97
1/2” BEARING RETAINER SCREWS

OIL SEAL RETAINER DO NOT REMOVE
5/16” CAPSCREWS, 6 EA.
1/4” CAPSCREWS, 6 EA.
DUST SHIELD
SPRING
HOLDER
.10 INCH DEFLECTION AFTER

ASSEMBLY
ITEM QTY. DESCRIPTION

1 1 SEAL ASSEMBLY - shaft
1A 1 SEAT
1B 1 O-RING - 4-1/2 X 3/32
1C 1 RING - primary
1D 1 BELLOWS
1E 1 BAND - drive
1F 1 RETAINER
1G 1 SPRING
2 2 V - RING
3 1 GASKET - dust shield
4 1 O-RING
5 1 RING - retainer
6 1 PIN - spring, 1/8 X 3/8
001958-121 SHEET 2 OF 3
2-14-97
6. Coat the shaft with light clean oil, such as 11. The seal will then be at its proper operating
10W-30 motor oil. height. Install the six 5/16” capscrews and
torque to 18 ft. lbs. or 2.5 kgm.
NOTE !
If the new shaft seal is furnished with spring
holder, it should be discarded.
! CAUTION
Inner “V” ring (2) must not touch the oil seal
7. Coat the inside diameter of bellows (1D) retainer.
and the lapped face of seal with motor oil.
12. Lubricate the inside of “V” rings (2). Adjust
the inner ring (2) axially with the lip of the ring
! CAUTION facing out, to obtain a dimension of .10” from
The seal assembly must be started squarely the surface of oil seal retainer on which the dust
over shaft by hand force against lapped car- shield and gasket (3) are being mounted.
bon face. If the seal assembly becomes
locked on the shaft, remove carefully and 13. Install gasket (3) and the dust shield using
start over. Excessive force should not be six 1/4” capscrews and torque to 11 ft. lbs. or
necessary for assembly. 1.5 kgm.
8. Install spring (1G) and seal assembly over 14. Install the outer “V” ring (2) with the lip
the shaft with the lapped carbon surface facing toward dust shield and slide onto shaft until
out. Carefully slide seal down until contact with compressed to .35 dimension.
spring is made.
9. Lubricate and install O-ring (4) over the oil

seal retainer.
! CAUTION
Oil leakage will occur if the seal the seal
assembly is pushed on the shaft too far,
causing the rubber bellows to grip the shaft
and not allow the spring to exert pressure
between the lapped faces.
10. Install the oil seal retainer over the shaft and
line up bolt holes. Push the retainer down
squarely and slowly against spring force until
the oil seal retainer contacts bearing retainer.
001958-121 SHEET 3 OF 3
2-14-97
001958-121 SHEET 4 OF 3
2-20-97
INSTALLATION OF
TAPER LOCK BUSHINGS
(008674-000) ENGINE COUPLING
FLYWHEEL
GENERAL SETSCREW
The following procedures describe the
removal and installation of part number KEY
004785 taper lock bushings used on the
compressor flex coupling. GAP (FROM
PARTS MANUAL
COMPRESSOR
GROUP) BUSHING
Removal
1. Remove the setscrews from the bushing.
2. Insert one of setscrews into the threaded

hole in the bushing. Tighten the setscrew to BUSHING TO DRIVESHAFT GAP
remove bushing.
3. Insert the bushing into the hub. Match
the hole pattern. Two (*) of the taper bush-
Installation ing holes placed 180° (*) apart will not be
threaded and they should align with holes in
1. Clean the shaft, bore, ane the outside the hub that are threaded.
of the bushing and hub of all oil, lacquer,
and dust. DRIVE HUB
(THREADED
2. Apply Loctite #RC/609 to shaft keyway FOR BUSHING
REMOVAL)
and insert the key. Tap the key to ensure it
is seated.
NOTE !
If the compressor shaft is equipped with a SHAFT KEY
locational spacer, the taper lock bushing
COMPRESSOR
must be seated against the spacer. If DRIVESHAFT
spacer is not used, refer to the Parts Manual
(Compressor Group) for the proper dimen- UNTHREADED
sion from end of air end driveshaft to the SETSCREWS (FOR BUSHING
INSTALLATION)
face of the taper bushing.
TAPERLOCK
BUSHING
4. Apply Loctite #242 to the setscrews

and thread them into the half threaded holes
in the hub. Install the hub and bushing on
the shaft.
008674-000 SHEET 1 OF 2
2-20-97
5. Alternately torque the setscrews to the

recommended torque shown in the setscrew
torque table. BUSHING WRENCH
PART TORQUE
NUMBER. Nm (FT-LBS)
6. Use no more than a 6 lb. (**) hammer to
drive a block, sleeve, or drift against the large 004785-001 49 (67)
end of the bushing. 004785-002 49 (67)
004785-003 49 (67)
! CAUTION 004785-004 26 (36)
Do not hammer on the bushing or the 004785-005 18 (24)

compressor shaft. 004785-006 49 (67)
004785-007 26 (36)
7. Repeat Steps 5 and 6 until torque 004785-008 26 (36)
wrench reading after hammering is the same 004785-009 62 (84)
as before hammering.
004785-010 49 (67)
8. Fill all cavities with grease. 004785-011 62 (84)

004785-012 49 (67)
* On 004785-011 bushing - holes are 004785-013 105 (142)
120° apart, (3 untapped holes equally
SETSCREW TORQUE TABLE
spaced).
** On 004785-011 bushing - use a 12 lb.

hammer.
008674-000 SHEET 2 OF 2
5-6-97
COMPRESSOR AIR INLET

CONTROL (010119-000) CONTROL CYLINDER LEVER
GENERAL
This topic contains procedures for the removal,
installation and adjusting of the compressor air
inlet control and it’s linkage.
VOLUME
CONTROL
REMOVAL
To remove the air inlet valve assembly proceed 3. Remove the two socket head capscrews
as follows: which hold the bracket to the inlet valve.
1. Loosen the clamps that connect the air inlet 4. Remove the hardware securing the inlet
piping to the air inlet adapter. control cylinder to the bracket.
2. Label the air hoses at the inlet control

cylinder before removing. Cap and plug the ASSEMBLY and INSTALLATION
cylinder and hoses.
Assemble and install the inlet valve assembly as
INLET ADAPTER follows:
CAPSCREWS
INLET VALVE 1.Remove any traces of gasket from the sealing

surfaces of the air inlet manifold, the inlet valve
AIR INTAKE and the inlet adapter.
MANIFOLD
2. Mount the bracket assembly to the inlet
valve with the two socket head screws.
CONTROL
CYLINDER
3. Mount the inlet control cylinder to the
3. Remove the capscrews securing the air inlet bracket assembly.
adapter to the air intake manifold. Remove the
adapter and the inlet control assembly. 4. Slide the cylinder lever onto the shaft of the
inlet valve.
DISASSEMBLY 5. Connect the control cylinder to the cylinder

lever (hand tighten the hardware).
Disassemble the inlet valve assembly as follows:
6. Recalling the approximate gap of the inlet
1. Note the approximate gap of the inlet valve
valve, tighten the hardware securing the cylinder
before removing the hardware securing the inlet
lever to the inlet valve shaft.
control cylinder to the cylinder lever.
7. Adjust the valve closing adjusting screw so
2. Loosen the hardware securing the cylinder
that it touches the cylinder lever.
lever to the shaft of the inlet valve and slide the
lever assembly off of the shaft.
010119-000 SHEET 1 OF 2
5-6-97
side of the air intake manifold.

CLOSING
SCREW ADAPTER
CLOSING
SCREW
MANIFOLD VACUUM
TEST PORT
8. Apply a gasket adhesive to one side of the

inlet valve gaskets before installing the gaskets
on the valve.
3. Start the machine and adjust the valve
9. Position the inlet assembly on the air intake closing adjusting screw until a reading of 28
manifold. Remove the hardware securing the inches (1 kgs/cm²) is achieved on the vacuum
cylinder to the lever and operate the lever to gauge.
determine that there is no interference between
the valve and the intake manifold. 4. Check the groove in the inlet valve when the
valve fully opens. When fully opened the angle
10. Install the air inlet adapter and secure it to should be between 15 to 20° from perpendicular.
the manifold. Tighten the capscrews in a
diagonally opposing pattern.
11. Recheck the movement of the valve before 15° - 20°

tightening the cylinder to lever hardware.
12. Reconnect the air inlet piping.
15° - 20°
ADJUSTMENT
Adjust the inlet valve assembly as follows:
1. Before beginning to adjust the inlet valve,

note the position of the groove in the inlet valve
shaft. The angle of the groove equals the angle 5. Adjust the cylinder rod extension as
of the inlet valve. If the groove is horizontal the necessary.
valve is closed and should be opened slightly.
INLET
VALVE
GROOVE
2. Install a vacuum gauge to the fitting on the
010119-000 SHEET 2 OF 2
3-4-98
AIR END SHAFT SEAL KIT INSPECTION AND CLEANING
(012457-000) 1. Clean all parts thoroughly and scrape off any

gasket material or other foreign debris from the
parts.
GENERAL
2. Check the bore edges of the seal retainer
The components of the seal kit are numbered (S1) and the bearing retainer (S2) for burrs and
S4 through S12 in the figure shown. Item S4 is break any sharp edges. Make sure the oil sup-
ply passage in these parts are open and clean.
the seal which includes a seat with O-ring, the
carbon ring, a rubber bellows, and a spring.
The seal itself is non-serviceable. 3. Remove all burrs and break all sharp edges
on the shaft.
DISASSEMBLY ! WARNING
1. Remove screws (S8) and remove V-ring New seals must slide over the shaft and any
cover (S3) and two V-rings (S5). Discard the V- sharp edges will cut the seal. Therefore, the
rings. edges MUST be rounded off or broken!
2. Remove screws (S9) and remove shaft seal 4. Clean the shaft thoroughly with fine emery
retainer (S1). cloth to remove any dirt, metal particles, etc.
3. Remove and discard O-ring (S11) from seal

retainer (S1).
INSTALLATION
4. Remove retaining ring (S6) and shaft seal
seat from shaft seal retainer (S1). 1. If a new pin (S12) is required, install it in the
seal retainer (S1) flush with the outside surface
5. Check roll pin (S12) to see if it is sheared or by tapping it gently with a hammer.
bent. If it is damaged in any way, remove it and
discard it. 2. Lightly coat the bore of the seal retainer (S1)
with lubricant provided in the kit.
! WARNING 3. Unwrap the seat.
DO NOT loosen or tamper with 1/2” cap-
screws (S10). These hold the bearing
retainer (S2) in place which maintains the
! WARNING
axial end plays of the shaft. The finish of the lapped surface is easily
damaged and must be handled carefully.
6. Remove seal assembly (S4) from the shaft. The lapped face can be identified by it’s
The rubber bellows is bonded to the shaft and highly polished surface. Fingers should
has to be broken loose by pushing the whole NOT come in direct contact with the lapped
seal further down the shaft. If tools are used, surface. Coat the lapped surface of the seal
care should be taken that the shaft is not seat with lubricant provided in the kit.
scratched or damaged in any way. When the
bond is broken, the seal may be removed eas-
ily.
012457-000 SHEET 1 OF 3
3-4-98
S10
S9 12457S.TIF
S8
SPRING
S12
BELLOWS
S4
CARBON FACE
S5
SEAL SEAT
S7
S3
S1
S6
S11
S2
4. Align pin (S12) with the slot in the seal seat. NOT use it along with the seal ring (S7).
Install the seal seat in the seal retainer (S1) with
the lapped surface facing the inside of the com-
pressor. Check to make sure that the seat is
! CAUTION
evenly seated. The carbon is easily damaged and must be
handled carefully. Fingers should NOT
5. Coat the shaft with lubricant provided in the come in direct contact with the lapped sur-
kit. face of the carbon face.
6. Unwrap the seal assembly. Coat the inside 7. Coat the lapped surface of the carbon face
of the rubber bellows with lubricant provided in with lubricant provided in the kit.
the kit.
8. Install seal assembly (S4) on the shaft, with
NOTE! the carbon surface facing out, just far enough to
The compressor unit may have a seal ring (S7) assure that the tail section is past the shaft
installed. If the seal assembly comes with a chamfer.
sheet metal spring holder, throw it away. DO
012457-000 SHEET 2 OF 3
3-4-98
! CAUTION ! CAUTION
The seal assembly must be started squarely Seal retainer (S1) must be held in position
over the shaft by hand force against the car- until the two screws (S9) are installed since
bon face and protecting the face with card- releasing the assembly may NOT allow the
board. If the seal assembly becomes locked spring to exert the correct pressure between
on the shaft, remove it and start over. the lapped faces of the seat and carbon.
Excessive force should not be necessary. This will result in seal failure within a short
period of time.
9. Lubricate and install O-ring (S11) in the
groove on seal retainer (S1). 11. Coat the shaft and I.D. of V-rings (S17) with
the lubricant provided in the kit.
10. Coat the lapped surface of the seal seat with
lubricant. Install seal retainer (S1) over the 12. Install V-rings (S17) on the shaft with the lips
shaft and line up the bolt holes. facing as shown.
NOTE! 13. Install V-ring cover (S3) with four screws

The 1/8 inch NPT hole located in seal retainer (S8)
(S1) must be positioned down toward the feet of
the unit to allow oil to drain out. Push down
squarely and slowly against the seal assembly
until the seal retainer (S1) contacts the bearing
retainer (S2). The seal will then be at proper
operating height. Hold the seal retainer (S1) in
position with one hand while installing two
screws (S9) opposite each other. After tighten-
ing screws down to 18 ft.-lbs (24 Nm) of torque,
assemble the other four screws (S9) to the
same torque.
012457-000 SHEET 3 OF 3
3-4-98
012457-000 SHEET 4 OF 3
2-20-97
AIR PIPING SWIVEL-JOINT 3. Secure female component in vise with ball

plug hole positioned over a suitable container.
CHIKSAN
4. Rotate male component. Ball bearings
(001217-000) should drop out.
NOTE !
It may be necessary to thin hardened lubricant
OVERHAUL with petroleum solvent.
Tools Required: 5. Separate male and female components
after ball bearings have been removed.
Adjustable wrench, pliers, screwdriver, and
vise. ! CAUTION
Do not damage machined surfaces when
separating components. Protect sealing
Disassembly surfaces at all times.
1. Remove the dust cap on the ball plug. 6. Carefully remove old packing from female
packing chamber using screwdriver.
2. Remove ball plug and o-ring using adjust-
able wrench. ! CAUTION
Use extreme care in removing old packing to
NOTE ! prevent damage to sealing surfaces.
If castellated ball plug is used, first remove the
cotterpin using pliers. 7. Remove grease retainer from male com-
ponent.
DUST CAP COTTER PIN

MOLDED PACKING
LUBE FITTING
BALL
O-RING PLUG
BALL RACES ANTI- BALL
GREASE RETAINER EXTRUSION BEARINGS
RING
PACKING
CHAMBER
PACKING
MALE COMPONENT SEALING
SURFACE FEMALE COMPONENT
001217-000 SHEET 1 OF 3
2-20-97
8. Clean all parts with petroleum solvent. ball races.
9. Inspect the parts for excessive wear, cor- 4. Secure female component in vise with ball
rosion or other damage. plug hole on top.
A. Inspect ball races for dents, grooves, 5. Insert male component into female com-
or other damage. ponent.
B. Check male and female components 6. Look through ball plug hole to align ball
for excessive erosion or corrosion. races.
C. Carefully inspect the inside surfaces of 7. Drop balls into races. Rotate male compo-
elbows for evidence of erosion or corrosion. nent, adding balls until both races are filled with
the proper number of balls.
! CAUTION • Air Swivel - 1-1/2 inch requires 54 steel
Replace all parts that show evidence of dam- balls 1/4 diameter
age in the ball races, packing seal surfaces,
or other areas. • Air Swivel - 2 inch requires 48 steel balls
3/8 diameter
10. Sealing surfaces must be completely
smooth. Remove minor scratches or pitting by • Air Swivel - 3 inch requires 66 balls 3/8
polishing with fine abrasive. inch diameter
11. Reclean all parts after polishing to remove NOTE !
metal particles and abrasives. Count the number of balls installed in each race
to be certain that exactly the right number are
installed. Incorrect number will cause binding or
excessive wear and reduced pressure or struc-
Assembly
tural capacity.
1. Apply a thin coat of lubricant to ball races, 8. Install a new O-ring on ball plug.
sealing surfaces, and new packing.
9. Insert the ball plug.
NOTE !
Make sure correct lubricant is used for intended NOTE !
service conditions. For castellated ball plug, tighten until snug.
Then, loosen one-quarter turn and insert cotter-
2. Install the new grease retainer on male pin. For hexagon ball plug, tighten to approxi-
component by gently stretching it over the ball mately 50 ft. lbs.
races.
10. Lubricate bearings as follows:
NOTE !
Retainer lip must face away from ball races. A. Use a small, hand-held grease gun to
force small amount of lubricant through fitting.
3. Install new packing in female component
packing chamber. NOTE !
Standard lubricant is Chiksan No. 7.
NOTE !
Anti-extrusion ring must face outward, toward B. Rotate male component 90° (quarter
001217-000 SHEET 2 OF 3
2-20-97
turn) and add more grease.
C. Repeat step b (above) two more times,

lubricating at each quarter turn.
D. Check smoothness of rotation.
! CAUTION
Excessive lubrication can cause swivel to
bind, distort the anti-extrusion ring and dis-
place the packing. Use only enough lubri-
cant to obtain smooth rotation. If the swivel
is more difficult to rotate after greasing than
before, or if lubricant is detected on inside
of primary packing, or if distortion of pack-
ing is noted on inner diameter, dissemble
joint and carefully inspect all seals for dam-
age. Replace damaged seals and any pack-
ing which has been distorted or displaced
into the bore.
11. Install the dust cap.
001217-000 SHEET 3 OF 3
2-20-97
001217-000 SHEET 4 OF 3
02-06-97
AIR SWIVEL
(001217-001)
2. Clean the bearing and seal
surfaces of the swivel joint tail, then install
GENERAL dust seal (2) around in the groove.
The following instructions apply to a OPW/
Dover type swivel joint only.
3. Insert the tail into the

ASSEMBLY
swivel body holding dust seal (2) snug in
groove. Slight hand pressure is required to
force the tail into O-ring (3).
4. Ball grooves in the tail

must be in line with ball holes in the swivel
body to allow easy entry of balls (1) into the
bearing races. Slowly rotate the tail back
and forth as balls are dropped through the
individual holes to fill each bearing race.
5. Thread in ball retainers (5)

until contact is made with the ball, back off
ITEM QTY. DESCRIPTION
slightly.
1 48 BALL - bearing - 3/8”
2 1 SEAL - dust, felt
3 1 O-RING
4 2 NUT - jam
6. Thread jam nuts (4) on
5 2 RETAINER - ball
retainers (5). Hold ball retainers (5) in posi-
6 1 FITTING - grease
tion with an allen wrench while locking the
jam nuts with an open end wrench. Lubri-
cate.
NOTE!
1. Clean the inside of the To disassemble swivel joints, reverse proce-
swivel body carefully. Grease O-ring (3) and dure.
install it in the swivel joint body.
001217-001 SHEET 1 OF 1
02-06-97
001217-001 SHEET 2 OF 1
2-21-97
HYDRAULIC CYLINDER .
(001690-001)
EXTERNAL
GROOVE
GENERAL
This hydraulic cylinder is used in several
applications. Therefore, the Removal and ROD PRY
CARTRIDGE
Installation topics are not included.
NOTE !
The following procedures are for the cylinders
manufactured by Hydro-Line.
F. Place the new cartridge on the rod end,

OVERHAUL being sure to use a twisting motion as you start
it onto the rod.
Complete disassembly of this cylinder is not
G. Insert the cartridge (now mounted on rod)
required if replacing the rod cartridge or the tube
into head recess.
end seals.
H. Replace the rod cartridge retainer. Tighten
the tie rod nuts to 10 ft-lbs (13.5 Nm) of torque.
1.Replace the rod cartridge seal as follows:
A. Remove the tie rod nuts.
2. To replace the tube end seals proceed as
B. Remove the rod cartridge retainer.
follows:
.
TIE ROD NUTS A. Remove the tie rod nuts at end of cylinder.
B. Separate the head and cap from the ends
of the cylinder.
C. Discard the used seals and clean all parts
thoroughly, including the inside of the tube and
the seal grooves in the head and cap.
D. Lubricate the new tube seals with
TUBE petroleum jelly to hold them in place before
ROD installing them. Make certain the seals are
CARTRIDGE
RETAINER HEAD seated fully into their grooves and against outer
groove diameter.
C. Remove the rod cartridge by inserting a
screwdriver in the external groove. Pry carefully. NOTE !
See illustration. When installing continuous ring type seals, avoid
D. Clean the cartridge recess in the head. stretching the seal.
E. Lubricate the inside of the rod cartridge and When installing split ring type seals, insert the
the outside of the new cartridge prior to seals with CAUTION to avoid stretching. Be
assembly. sure to butt the ends of the seals together as you
begin to seat a seal in a groove. Hold the ends
together and in place with one finger while
seating the rest of the seal with your other hand.
001690-001 SHEET 1 OF 2
2-21-97
E. Let parts dry.

CONTINUOUS RING SEAL F. Apply Uniloc #571 to threads of piston (or
piston nut) and rod. All threads must be
thoroughly wetted by adhesive.
G. Assemble the piston onto the rod. Back off
2 turns and look to be sure threads are covered
with adhesive. Retighten snugly.
PISTON ROD
PISTON
STUD
SPANNER
WRENCH OFF
HOLES
ON
SPLIT RING SEAL
E. Reassemble the cylinder. Tighten tie rod H. Allow adhesive to cure for 30 minutes
nuts hand tight only. before applying test pressure to assembled
F. Torque tie rod nuts in the order shown. cylinder.
G. Recheck the torque 10 ft-lbs (13.5 Nm) in
the same order.
3. To disassemble and assemble the

piston and rod assembly proceed as follows:
A. Heat the piston and rod to 400°F - 450°F

(205°C-233°C).
B. Using a spanner wrench, remove the piston
by turning counter-clockwise.
C. Unthread the stud from the end of the rod if
necessary.
D. Clean the threads of the rod and piston (or
piston nut) thoroughly with a solvent and a bristle
brush.
001690-001 SHEET 2 OF 2
TYPICAL SYSTEMS Cooling Systems
Required for engine coolant, compressor and

hydraulic oils, and as of 1996 intake air for the
GENERAL engines. Two types of cooling fan systems are
available.
This section describes the main hydraulic
systems and their design parameters.
• Vane pump and motor driving 36" 42" 48"
and 52" OD aluminum fan.
DESCRIPTION
• Vane pump and motor driving 42" and 48"
Systems are classed as closed loop and open and 54” OD steel fan.
loop. The systems are separated and do not
inter-relate with each other. • Piston pump and motor, hydraulic controls,
48" and 54” OD steel fan.
Propel or Tram Systems
• Piston pump and motor, electronic controls,
Provide crawler mounted machines with 48" and 54” OD steel fan.
mobility.
Drilling Accessories
• Piston pump and motor(s) are in a closed
loop configuration. Needed for the drilling cycle require a fixed
volume of oil. We refer to the following systems
Rotation Systems as accessories.
Turn drilling accessories, drill pipe and drilling • Vane pump through directional control
tools such as DTH (down the hole hammers valves, return filtration, reservoir.
and drill bits) or roller type drill bits.
The application is lower, middle, and upper
• Piston pump and motor(s) are in the closed stacker valves directing oil to actuators.
loop configuration.
When accessory pumps are in the free flow
Feed Systems condition, they are used as a charge system,
thus giving adequate oil for cylinder
Feed systems differ from one product to replenishment.
another in the Driltech family of drills. Four
applications are used throughout the product. Relief valves or individual compensator valves,
depending on the component manufacturer
• One is a piston pump with cylinder(s) in an protect systems noted.
open loop circuit.
Back-Pressure
• One is a vane pump and a piston pump with
cylinder(s) in an open loop circuit. Back pressure is an elevated return pressure
system, and may be used as a charge pressure
• One is a piston pump with cylinder(s) in a on some Driltech products. When the vane
closed loop circuit. pumps are in the free flow condition the back-
pressure setting is the pump(s) relief valve.
• One is a piston pump and motor, in a closed
loop circuit. • Return oils generating back-pressure are
contained in our high-pressure return mani-
fold (HPR).
Typical Systems Page 3
Hydraulic schematics have abbreviated Throughout this manual the terms noted here
nomenclature to give details for porting and and systems described above will be used to
manifolds within the hydraulic system. explaining the specific systems in detail. Flow
and pressure values will be specified in the
Mud pump systems appropriate sections.
Well drill applications may use the option of mud Review the specific model machine hydraulic
assisted drilling. Mud pump is the application, system schematic.
the hydraulic systems are simple closed loop
components attached to the mud pump assem- • Major hydraulic omponents are:
bly. • Denison hydraulic piston pumps and motors
• Piston pump and motor are in a closed loop • Denison vane pumps and motors
configuration.
• Sundstrand piston pumps and motors
This application is generally limited to the
• Hydramatic - Rexroth motors
T40KW drill machine used in the well drill mar-
kets. • Sun hydraulic cartridge valves
• Denison directional valves
• Denison relief valves
• General Engineering cylinders
Page 4
START-UP PROCEDURE
NEW PUMP INSTALLATION ISOLATION

PLUG
Denison piston pumps require specific set up

and run in procedures.
As any hydraulic system; Driltech systems

require total cleanliness from all fluid power
components. Adequate time for proper
installation, proper refilling of the pump, hoses
and components, proper setting of the system EXTERNAL 3
14 IN /REV PUMPS
pressures are all vital to new pump longevity. FILTRATION
CLOSED LOOP PUMP WITH OFFLINE

Working conditions are a factor many times FILTRATION USE ISOLATION PLUG
PLUG IN PORT SHOWN
forgotten during a machine service and new
component installations. Prepare the work area
to suit the service work being performed. Isolation plugs force the gerotor pump oil flow
to fine filtration. The main valve block requires
The guide described herein is the the fine filtration.
recommended procedure, for competent
service and mechanical personnel performing NOTE!
new or reconditioned pump service, installation Failure to use the isolation plug in the
or start-up in the field. It is preferred that work designated port will at some point enable
be performed in a controlled environment such contaminants to flush into the valve resulting in
as a protected shop. irratic system controls.
Install isolation plug in described port location The control valve block consists of relief
as noted in packaged instructions. valves and control features. It is not
recommended to open the control valve block
OPEN LOOP FEED PUMP in the field.
DO NOT USE ISOLATION
PLUG INSIDE H PORT
The unit is sold seperate. Care must be taken
during removal and replacement that dirt or any
3
form of contaminants do not get into the open
6 AND 7.25 IN /REV PUMPS pump cover.
CLOSED LOOP PUMPS When installing the adapters in the Denison

WITH OFFLINE FILTRATION
DO USE ISOLATION PLUG piston pump, ports ‘V’ and ‘KG’ two items are
INSIDE H PORT protected.
The 6 and 7.25 cubic inch pumps reguire the • The ‘KG’ port uses a special drilled boss
plug installation in the H port as described. oring adapter P/N 002144-001. It threads
over a strainer/filter inside the ‘KG’ port.
The 14 cubic inch pumps require the isolation
plug installed in the port cover SAE plug noted • The ‘V’ port has a modulating pin inside an
herein. This plug does not have a port offset drilled passage. A flat bottom boss
designation. oring adapter is used in the ‘V’ port.
Start-Up Procedure Page 5

4. Fill hydraulic tank to the full mark on the
SERVO STRAINER sight glass, taking into account to where the
PIN
cylinders are positioned. Do not over fill the
hydraulic tank. All oil entering the system
shall be via the hand pump or the optional
service center wiggins quick filling adapter
port. Oil entered through these ports will be
fine filtered to 10 micron absolute filtration.
5. Use shop air or equivalent compressed air

source to pressurize the hydraulic tank
MAIN PRESSURE through the reservoir mounted air pressur-
COMPENSATOR ization system. Air pressure at the reduced
ADJUSTMENT value of 5 psi should be approximately 10
minutes duration. This time enables all man-
1. Drain all air from the new pump when filling ifolds and any air entrapped in hoses to be
the hydraulic system with new, clean purged prior to start-up.
hydraulic oil from the hydraulic tank. Locate
the highest plugged port on the Denison SHOP SUPPLY AIR TO
replacement pump. 5 PSI REGULATION
2. Pumps from 1996 and newer have one plug

on the mounting flange end. Open and drain
oil until a steady stream of oil exits the open
port. Refit the plug after all air is purged
from the pump in question.
6. Install appropriate pressure gauges at G,

KG or extension hose from KG and V, VA or
VB ports. Reference pump port locator
drawing to identify gauge locations.
VENT PORT 7. Copies of performance charts are available

in the setting procedure for specific hydrau-
lic systems. Performance charts detail all
applicable hydraulic pressures required dur-
ing the pump testing procedures.
3. Older pumps need air drained as well.
Remove the highest SAE plug available, or 8. Refer to the appropriate performance chart
remove one input stroker cover bolt. for pump set-up.
NOTE! Servo pressure readings are from the Denison

When bolt removal is the only alternative it will pump G port and require inline connections for
be necessary to replace the nylite washer rotation and propel pumps. Do not deadhead
001330-128 and loosen all bolts. Torque the the servo pressure in these applications.
mounting bolts to spec 30 ft. lb. (40.8 Nm.) in a
cross pattern. 9. Connect a swivel tee and reduce to appro-
priate hose adapters. Common G port
Page 6
access is at the inlet port of the off line filter
(CC3 or CC7 micron servo filter housing). 3
14 IN /REV PUMPS
V DG
10. Feed pumps in the open loop configuration KG
(without off line filtration) may be accessed VB
at the G port directly, without a swivel tee
connection. In this application it is possible
to deadhead a gauge at the G port. B
Z
ALT DG
P6P all ports Z
J A G
ALT (KG)
VA
A-PRESSURE/RETURN
H B-PRESSURE/RETURN
D DG-CASE PRESSURE
VA A G-SERVO PRESSURE
DG J-REPLENISHMENT TO FILTER
V KG-SERVO STRAINER, REPLENISHMENT PRESSURE
V-MAIN PRESSURE BOTH PORTS A&B
KG
VA- MAIN PRESSURE A PORT
B VB- MAIN PRESSURE B PORT (NOT SHOWN)
Z- CASE PRESSURE IN NEUTRAL
Z-BRAKE/SERVO PRESSURE ON STROKE
A-PRESSURE/RETURN
B-PRESSURE/RETURN
Applicable pumps may vary slightly in compo-
C-INLET nents such as compensator adjustment, neutral
D-CASE DRAIN
adjustment, cross port piping and input con-
DG-CASE PRESSURE trols.
FB-CONTROL VENT B SIDE (FEEP PUMP ONLY)
The 14 cubic inch series pumps use a 500
G-SERVO PRESSURE, TO FILTER (NOT SHOWN) series stroker on the input control side of the
H-SERVO PRESSURE, FROM FILTER pump.
K-AUXILLARY REPLENISHMENT
KG-SERVO STRAINER, REPLENISHMENT PRESSURE Refer to Hydraulic Systems Book 4 for details
V-MAIN PRESSURE BOTH PORTS A&B on set up and hydraulic adjustments of the 500
VA- MAIN PRESSURE A PORT series stroker unit.
VB- MAIN PRESSURE B PORT (NOT SHOWN)
Z- CASE PRESSURE IN NEUTRAL Refer to Electrical Systems Book 2 90 series

Z-BRAKE/SERVO PRESSURE ON STROKE machines for electrical set up and adjustments
of the 500 series stroker unit.
Applicable pumps may vary slightly in compo-
nents such as compensator adjustment, neutral
adjustment, cross port piping and input con-
trols.

PUMP RUN-IN AND PRESSURE SETTING 7. For detailed pressures refer to the specific
system performance charts provided with
1. Replenishing pressure readings are from system set-up procedures. Actual pressures
the KG adapter or extension hose posi- are noted with engine at high idle speed
tioned at the propel pump brake and bypass after adequate run in periods are performed.
input stroker.
NOTE!
2. Main pressure reading from the common Due to machine applications, follow your
port V or system port VA and VB. Rotation machine model engine high idle speed. Typical
and feed pumps have pressure gauges and high idle no load engine speeds are 1800, 1900
remote pressure valves on the operator con- and 2100 rpm according to machine model.
sole connected with hoses to the V ports.
Typical propel pump applications do not 8. The main system compensator is factory set
have main pressure gauges. Machine to the minimum pressure value, approxi-
options may be fitted to propel pump V ports mately 500 psi.
for pressure testing and possible venting
when interloc systems are added. 9. Adjustments should be slow increments in
500 psi intervals over a 10-minute time
3. Center all pump controls and control cables frame. Maximum pressure values are noted
on the drill console to lessen any hydraulic in the performance chart spec, and are set
load during the engine hydraulic startup by stalling the function.
mode.
10. After the ‘run in’ period and pressures are in
4. When the machine engine is started the low spec, lower the engine idle speed to 1200
engine idle speed is at minimum 1200 rpm. rpm. Allow adequate cool down period and
An engine speed meter on the drill console shut engine off.
enables a visual check of engine rpm. When
in doubt use a photo tachometer and reflec- 11. Remove any pressure gauges installed for
tive tape on the engine front pulley. the system pressure checks.
5. Allow engine to idle at low speed and no 12. Re-connect system hoses and hydraulic
load for approximately 20 minutes. Do not adapters used during tests per system con-
use the pump controls during this time of run figuration.
in. The gerotor pump has to fill hose and
pipe connections and valves in the circuit. 13. Expected new pump run in process will
Air trapped in the components will purge to require between 30 minutes to (1) one
the hydraulic tank through case drain hoses, service hour depending on work environ-
drain ports or normal circulation during this ment, and ambient conditions.
critical run in period.
6. Pressures on the servo range between This procedure does not include Denison pump
(330-580 psi) and replenishing pressure removal and installation to gearbox.
range between (200-300 psi) for rotation
and propel pumps in a closed loop applica-
tion. At low idle these pressures will be NEW PUMP INSTALLATION
slightly lower than actual spec. Allow ade-
quate run in time prior to checking the actual Sauer Sundstrand axial piston pumps require
servo and replenishing pressures. specific set up and run in procedures.
Page 8
As any hydraulic system; Driltech systems The A port relief valve is a non-adjustable shim
require total cleanliness from all fluid power type valve preset for 3675 psi (250 bar) posi-
components. Adequate time for proper tioned under the HP plug.
installation, proper refilling of the pump, hoses
and components, proper setting of the system Note:
pressures are all vital the new pump longevity. MPV046 pumps with the B port relief valve
installed is evident upon hydraulic system shut
Working conditions are a factor many times down. The cooling fan and motor rotation stops
forgotten during a machine service and new abruptly at shutdown. Damage to the hydraulic
component installations. Prepare the work area motor can result operating with this condition.
to suit the service work being performed.
Bypass plug
The guide described herein is the recom-
mended procedure, for competent service and Bypass plug should be full closed, turned in cw
mechanical personnel performing new or rotation maximum torque 7 to 10 ft lb, (9.5 to
reconditioned pump service, installation or 13.6 Nm).
start-up in the field. It is preferred that work be
performed in a controlled environment such as Charge system relief valve
a protected shop.
The charge pump relief valve is a shim type
Driltech crawler mounted machines utilize two cartridge positioned under the CH plug. Plug
models of Sundstrand pumps in a closed loop torque is 30 to 70 ft lb (41 to 95 Nm). Charge
single direction application. pressure test port can be utilized at the offline
filter connection inlet port or M3 pump port.
The 40 series MPV046 is applicable to the
D40KS, D45KS, D50KS and early model Gator Adjustable volume limiters
machines.
Adjustable volume displacement stroke limit
MPV046 screws are on either side of the pump. The
M1 sealing lock nut requires a 5/16 hex wrench and
CHARGE
PUMP a flat blade screw driver. Final torque on the nut
should be 4 to 7 ft lb (5.4 to 9.5 Nm).
L1
mpv040 MPV046 VOLUME DISPLACEMENT SCREWS
BP L2
HP CH
HDC
X1 X2
HP A PORT RELIEF
ADJUST SCREW IN
CH CHARGE RELIEF FOR INITIAL START UP
ADJUST OUT FOR FINAL
FAN SPEED SETTING
The Driltech application MPV046 pump is used
in a single direction output flow. Only one multi
Upon new pump start-up it is required to turn
function relief valve is used. Be certain that the
the screw in (cw rotation) 3 revolutions. This
B port relief is removed prior to start-up.
step assures that the pump will not have full
volume output oil flow during the critical start
Main port multi function relief valve
and run in procedure.

In order to prevent damage to the volume lim- PUMP RUN-IN AND PRESSURE SETTING
iter parts make initial adjustments of this screw
with the machine turned off and zero charge 1. Install the inlet supply line to port S. Be cer-
pressure. tain to allow adequate time to fill the pump
with clean hydraulic oil. Open the upper
Note: most adapter during the filling process in
The volume limiter setting will be calibrated dur- order to allow air to bleed from the pump.
ing the pump final adjustments to allow a maxi- Generally the M1, M2 or case drain L ports
mum fan rotation speed. are the upper most ports.
Refer to cooling fan system setting and perfor- 2. Install a 1000 psi (60 bar) pressure gauge in
mance charts. the charge pressure pot M3 or the offline fil-
ter inlet port.
The 90 series MPV090 is applicable to the
D55SP, D60KS, D75KS D90KS and as a 3. It is recommended that the hydraulic lines
upgrade for the Gator machines. for the hydraulic displacement control
(HDC) be disconnected at the X1 and X2
ports until after initial start-up.
CHARGE FILTRATION AND PRESSURE PORT
A PORT RELIEF
4. Start the machine and operate at low engine
idle speed (1200 rpm).
mpv090
B PORT RELIEF
5. Allow approximately 3 to 5 minutes run time
M1
X1
with the HDC hoses disconnected. Monitor
the machine fluid temperatures during this
CHARGE PUMP X2 run in period as the cooling fan will not be
turning during this time. Do not let the
HDC machine operate to shutdown temperatures.
A B
MPV090 S
6. When charge pressure stabilizes in the 180
to 210 psi (12.5 to 14.5 bar) and the run in
The multi function relief valve is adjustable
period is sufficient stop the machine.
through a pressure range 0 to 3600 psi (0 to
250 bar).
7. Connect the X1 and X2 pilot control hoses
to the hydraulic displacement control. If the
The MPV090 pump is operating in a single
pilot control hoses are connected to the
direction output flow also. The B port multi func-
wrong ports the fan motor will motor rotate.
tion valve is backed out (ccw) it’s limit and
locked secure.
8. Connect a 5000 psi (350 bar) gauge to the
M1 pressure port in order to monitor the
Back out (ccw) the A port multi function valve in
main loop pressure during the fan set up
order to start from zero. Turn the valve adjust-
procedure.
ment in (cw) 2.5 to 3 turns. This will allow the
MPV090 some operating pressure to turn the
9. Restart the machine and notice the cooling
fan motor a slow rotation during the initial start
fan direction of rotation. With correct
up procedure.
hydraulic connections the fan rotates (ccw).
Final adjustment to the A port multi function
If fan does not rotate check the hydraulic hose
valve will be made during the pump setting pro-
connections at pump ports A and B or pilot
cedure.
ports X1, X2 and multi function valve setting.
Page 10
Pressure settings vary depending on machine Service literature 008172-000, 008610-000 and
specific components. Refer to the cooling sys- 021434-000 detail vane pumps.
tem section of training module book 5 for per-
formance data. Vane and gear type pump applications used on
Driltech hydraulic systems are simple compo-
During the new or remanufactured pump start nents. The pumps are valve free and without
up and run in procedure it is necessary to moni- need for pressure gauge installation on pump
tor charge pressure only. ports.
The charge and system pressures noted in Internal parts of this pump are lubricated by the
training module book 5 will reflect actual work- operating fluid. It is essential to keep the fluid in
ing pressure for the machine specific system. the system clean. Dirt should not be allowed to
accumulate on the pump or around the shaft
Knowledge of the closed loop cooling fan sys- seal.
tem is the final step in setting the external pilot
vales used on Driltech Mission cooling fan sys- It is important that the supply or inlet piping and
tems since late 1995. fittings be tight and in good repair to prevent air
from being drawn into the system.
Pump service, pressure adjustments, and sys-
tem diagnostics should be performed with prop- Restrictions and air entering the pump supply
erly trained, qualified service technicians. will damage the pump during short term opera-
tion. Clean and replace supply lines under rou-
This procedure does not include Sundstrand tine maintenance intervals.
pump removal and installation to gearbox.
After new or remanufactured pump installation
and all hoses are secure it is necessary to fill
NEW PUMP INSTALLATION the pump with oil. Only clean hydraulic oil shall
be used. When adding new oil to the reservoir
Denison vane pumps and a Sundstrand gear the supply manifolds may have air trapped
pump are used for drill related accessories. inside.
As with any hydraulic system, Driltech systems Use filtered shop air to pressurize the hydraulic
require total cleanliness from all fluid power tank through the reservoir mounted air pressur-
components. Adequate time for proper ization system. Air pressure at the reduced
installation, proper refilling of the pump, hoses value of 5 psi should be approximately 10 min-
and components, proper setting of the system utes duration. This time enables all manifolds
pressures are all vital the new pump longevity. and any air entrapped in hoses to be purged
prior to start-up.
Working conditions are a factor many times
forgotten during a machine service and new
component installations. Prepare the work area SHOP SUPPLY AIR TO
5 PSI REGULATION
to suit the service work being performed.
The guide described herein is the recom-

mended procedure, for competent service and
mechanical personnel performing new or
reconditioned pump service, installation or
start-up in the field. It is preferred that work be
performed in a controlled environment such as
a protected shop.

After the air pressurization precharge cycle is system theory and system pressures that
complete disconnect all service tools and require checks and/or adjustments.
reconfigure to original spec.
Install one 500 psi (35 bar) pressure gauge on

the manifold referred to as HPR. Refer to back
pressure systems performance chart in training
module book 5.
FAN SYSTEM
PUMP RUN-IN AND PRESSURE CHECKS TEST PORT
1. Start machine and operate at low idle speed

(1200 rpm) for 3 to 5 minutes. Leave all con-
trols in neutral, do not operate functions.
2. Check hydraulic pressure on HPR at low

engine idle speed. Pump service, pressure adjustments, and sys-
tem diagnostics should be performed with prop-
3. After 5 minutes of operating at low idle erly trained, qualified service technicians.
speed engage engine speed to high idle.
This procedure does not include Denison or
4. Confirm HPR pressure to the back pressure Sundstrand pump removal and installation to
performance chart. the gearbox.
NOTE!
Under severe operating conditions it may be VACUUM MODULES AND PUMPS
necessary to extend the run in period to as
much as 30 minutes. When performing routine maintenance on
hydraulic systems it may be permitted to use a
5. Monitor fluid temperatures during the run in air or electric powered vacuum accessory.
cycle.
The intended use would be for O-ring or hose
6. Operate a function that is a drill accessory replacement and adapter sealing.
(holding wrench, dust hood door, tong
wrench). Due to the many variations that a hydraulic
pump would need to be replaced it is not advis-
7. Look and listen to the new pump as it is run- able to use the vacuum module.
ning. Look for apparent oil leaks. listen for
abnormal noises as it is cycled. The best practices to follow during pump
replacement:
8. Lower the engine idle speed to 1200 and
allow adequate cool down cycle. • Drain all fluid into suitable containers.
9. Stop the engine, remove HPR gauge and • Use appropriate service tools for the job.
prepare machine to operate.
• Inspect components including hoses.
Vane pumps used in a open loop cooling fan
system should be started in this same manner. • Evaluate and clean the system.
It will be necessary to understand the open loop
• Replace components as needed.
Page 12
• Reassemble components to manufacture’s • Allowing the proper time stated during the
specifications. pump run in procedure pages 8, 10, 12 will
assist the motor filling procedure.
• Follow recommended start up procedures
and safe operating principals. MOTOR RUN-IN AND PRESSURE CHECKS
NOTE! • When applicable vent the pump via the

After utilizing a vacuum module or pump and all remote pressure valve or the pump compen-
components are correctly installed it will be sator.
necessary to precharge the hydraulic system
with the allowable 5 psi air pressurization stated • Turn the remote pressure valve open (ccw).
on pages 6 and 11 of this manual. Turn the pump compensator out (ccw) to
lessen the circuit pressure upon start up.
NEW MOTOR INSTALLATION
• When applicable install a charge or servo
The following is a guide relating to new hydrau- pressure gauge in the appropriate pump
lic motor installations. port.
It will be in summary form to apply to the Deni- • When applicable install a pressure gauge in
son, Sundstrand and Rexroth models currently the appropriate main loop port.
in use on Driltech Mission products.
• When applicable place the pump controls in
As previously stated hydraulic service, pressure the neutral position.
adjustments, and system diagnostics should be
performed with properly trained, qualified ser- 1. Start the machine and operate the engine at
vice technicians. low idle speed (1200 rpm) for the predeter-
mined time.
• Read and understand the instruction manu-
als. Identify components and their functions. 2. The longer the system hoses are the longer
the run in time should allow.
• Visually inspect components, related hoses,
machine tools and devices for potential haz- 3. For applications that allow operator controls
ards. turn the pump supply forward and reverse
for 3 to 5 minutes each way without a work-
• Secure drill related accessories such as drill ing load.
pipe, undercarriage components, feed drive
gears and chains prior to hydraulic compo- NOTE:
nent removal. The entire run in should take between 10 to 30
minutes.
• Have the system hoses been cleaned or
replaced properly? 4. Check the pump servo, charge, and replen-
ishment pressures during the forward and
• Make all necessary hose connections using reverse cycles. Pressures should be stable
new O-rings on flange adapters. in the ranges noted in the specific perfor-
mance charts.
• Do not secure the replacement motor to the
application component. Leave the motor 5. Lower the engine idle and stop the machine
shaft free to turn during the run in process. in order to make final installation(s) of the
hydraulic motor to the drive component.

6. Inspect or replace the drive coupling device. 7. Adjust the remote pressure valve or pump
compensator (cw) in slow increments to the
NOTE! desired stall pressure stated in training mod-
It is recommended to use a lithium-molybde- ule book 5 performance charts.
num disullfied or similar grease as a shaft and
coupling lubricant for the new components. 8. Secure pressure compensator adjustments
(Mobilux EP111 coupling grease By Mobil) and center pump control(s).
7. Follow manufactures specifications when 9. Disengage the locking device.

mounting the motor to the drive assembly.
10. Lower engine idle speeds allowing ade-
NOTE! quate cool down period.
The final torque specification for motor mounted
hot oil shuttle valves on applicable propel 11. Stop engine, relieve residual hydraulic pres-
motors is 125 ft lb (92.5 Nm). sures, remove test and diagnostic equip-
ment.
8. Hydraulic motors with external mounted hot
oil shuttle valves require the installation of a 12. Reconfigure machine to spec.
flow meter in the case drain hose connec-
tion.
NOTE!
NOTE! Overall this procedure may take 15 to 30 min-
Final setting for external mounted hot oil shuttle utes to perform safely and accurately.
valves are 3 to 4 gpm (11.4 to 15.2 lpm).
The Sundstrand cooling fan motor will not be
operated to a stall condition. The motor pres-
FINAL MOTOR PRESSURE CHECKS sure seen will be a working pressure as stated
in the specific performance chart.
1. Start engine and run at low idle (1200).
2. Rotate the component without load in order

to align a locking device. This procedure is
stated in the specific system set up proce-
dures of training module book 5.
3. With the device locked the hydraulic system

will be stalled. Maximum pressures can be
calibrated.
4. When applicable center the pump to neutral

and back out remote pressure control valve
(ccw) for minimum system pressure.
5. Engage the engine to the rated high idle

speed.
6. Operate the pump control on 20% and mon-

itor the main loop system pressure gauge.
Page 14
SUPPLEMENTAL PUMP The O-ring part no. 002174-030 is 90-225
series buna n material.
COMPONENTS
Gator, D25KS, D245S manifolds.
GENERAL PART NUMBER MOUNTING TORQUE
016175-001 125 FT LB
This section describes valve and manifold
170 Nm
assemblies mounted to pump ports ‘A’ or ‘B’.
016175-002 125 FT LB
170 Nm
DESCRIPTION 016175-004 125 FT LB
170 Nm
The following products Gator, D25KS, D245S,
TM40KW, D55SP(H), D75KS(H) use specific The manifolds shown have been used on said
manifolds positioned on Denison pump(s) A products since 1990. There has been a manu-
and/or B ports. facturing change with regards to sequence
action for the directional valves.
Proper mounting is essential for the valve posi-
tioned in the manifolds to work or shift correctly.
002174-030
Proper valve installation into the bore so that P1 O-RING
the valve seats properly and seals the working
ports per design is essential to allow oils to
move the intended flow path. GA1
D2 GB1
As a rule oil takes the path of least resistance. If D1

valves are not properly seated or cannot shift V1
A PORT
correctly, the system oil may drain or return to DRILL
hydraulic tank pressure. B PORT
PROPEL
The following pictures are views along with 016175-002
mounting torques required when working with
the component in question. Regardless of sequence operating characteris-
tics the valves have to be seated properly into
the manifold bores.
Identify the drill or propel valves via A or B man-

ifold ports. Proper valve torques into the
016175-000 manifolds are common.
PROPEL (NC) DRILL (NO)

016175-058 016175-059
150 -160 ft lbs 150 - 160 ft lb

203 - 217 Nm 203 - 217 Nm
Supplemental Pump Components Page 15

Feed systems on high pressure D55SP and
D75KS model drills require a ‘slow feed’ system
(DTH applications). 002174-030 O-RING
• C55SP2H
• C75K6H FFV
One fine feed manifold p/n 017954-001 is

mounted on the ‘B’ port of the feed pump and
one O-ring p/n 002174-030 seals the manifold FFS
to the pump port. Discard and replace this O- D55SP D75KS
ring anytime the manifold is removed from the FEED PUMP
feed pump port ‘B’.
017954-001 FINE FEED MANIFOLD

BOLT TORQUE 125 FT LB (170 Nm)
The feed pump is used in an open loop applica-

D55SP, D75KS
FINE FEED
tion. The feed pump ‘A’ port is 2’’ diameter and
MANIFOLD acts as a supply port. The ‘B’ port is 1.5 “ thus
the fine feed manifold can only be mounted on
D55SP FEED VALVE
the ‘B’ port.
Feed systems for the TM40KW have a fast

feed pump with a directional control manifold on
the B port of the piston pump.
CONTROL CARTRIDGES
002174-030 O-RING
Manifold mounting torque is essential for

correct cartridge and solenoid operation.
TM40KW FAST
FEED PUMP
When installing the fine feed manifold onto the
feed pump ‘B’ port, torque the bolts in a cross
pattern to 125 ft lbs (170 Nm).
One control cartridge p/n 016175-054 fits into

016175-002 FAST FEED MANIFOLD
the fine feed manifold and requires a final BOLT TORQUE 125 FT LB (170 Nm)
torque of 150 -160 ft lb (203 -217 Nm). This car-
tridge is used to limit the feed pump output to
the feed cylinder(s) to a 10 gpm (38 lpm) deliv- When installing the fast feed manifold onto the
ery. feed pump ‘B’ port, torque the bolts in a cross
pattern to 125 ft lbs (170 Nm).
The two control cartridges fit into the fast feed

manifold and requires a final torque of 150 -160
ft lb (203 -217 Nm)
Page 16
Propel systems and track drive motors on the Other applications
Caterpiller 330, 330L, 350 and 375 require addi-
tional oil cooling and oil filtration in excess of the Driltech equipment manufactured during 1988
normal motor case drain oils. In order to allow through 1994 with Caterpiller 235 series track
this function in the closed loop applications one frames and Rexroth bent axis motors have a dif-
aluminum manifold with two hydraulic valves ferent style hot oil shuttle valve than the one
are mounted to the motor ports shown herein.
Always use a new set of O-rings to seal Call the Driltech Mission Service Department
between the manifold, motor ports and flange when servicing rigs built between 1988 and
adapters. 1994 models D40KS, D45KS, D50KS, D55KS,
D60KS and D75KS with the 235 D6 series track
drive motors and hot oil shuttle valves.
The following products use external mounted

manifolds with the hot oil shuttle valve and con-
necting hoses frame mounted.
• Gator products with the 320 series track

have shuttle valves mounted on a central
valve plate above the left side track frame
• D25KS, D245S products with the 325 series

track have the shuttle valves mounted on
angle iron support between the mast pedes-
tal frame.
NOTE!
The torque values are very important when rein-
stalling the shuttle valve manifold onto the
motor ports or the shuttle valve spool and relief
valve into the manifold.
COMPONENT VALUE
MANIFOLD 100-110 Ft.Lb.

ONTO MOTOR PORTS (135-150 Nm)
SHUTTLE VALVE SPOOL 45-50 Ft.Lb.

INTO MANIFOLD (60-68 Nm)
RELIEF VALVE INTO 30-35 Ft.Lb.

MANIFOLD (40-48 Nm)
Supplemental Pump Components Page 17

Page 18
PROPEL SYSTEM • When applicable remove, cap and plug ‘Z’
port brake hose at the pump output stroker.
CLOSED LOOP
CAUTION! ROTATING DRIVE LINE
A main concept of a drill machine is to be
mobil. Due to ground conditions in the mining ‘DG’
PORT
environment and the duration of time spent
drilling vs. propelling (tramming) excavator
tracks are the primary undercarriages delivered
on drill machines today.
‘VA’
PORT
A track drive system in a closed loop
configuration consists of one axial piston pump,
hoses and steel pipes, connecting a fixed
displacement motor. Each track assembly has propel pump ‘Z’ PORT
BRAKE PORT
a spring applied hydraulic released brake and a HOSE
reduction drive inside the final drive assembly.
The Denison piston pump has four (4)

pressures, which may need monitored when
setting and diagnosing the track drive ‘KG’ PORT
REPLENISHING
components. Refer to the propel performance HOSE
chart for machine model pressure
specifications. 1. Start machine engine or motor.
The track components will need to be locked in 2. Set the engine to high idle speed.
order to stall the pump when checking or
setting the system to spec. One method in 3. Warm hydraulic oil to > 100° F (37.7° C).
locking the track drive is to remove the 1/4
hose connection to the brake port of the final If solid pin method is used, slowly rotate the
drive. This is the preferred method. Some track sprocket so solid pin rests against track
undercarriages do not have an external brake frame.
port. With these type track assemblies a large
solid pin positioned on one tooth of a drive 4. Place propel pump control on stroke approx-
sprocket will serve as the track lock medium. imately 20% (manual or electric).
Equipment and operator safety should be a 5. Check pressure gauge value.

primary concern when connecting any locking
medium to the final drive sprocket assembly. Tram interloc features vent pump pressures
(check for auxiliary valves near the propel
PUMP PRESSURE CHECKING: pump gearbox, or mast pedastal).
No Pressure Adjustment Required.
6. Refer to propel performance chart for appro-
• Install 5000 psi (350 bar) pressure gauge to priate pressure.
VA port of propel pump. Hydraulic test sta-
tions have guage connections on HPS1. 7. De-stroke propel pump control to neutral.
• Remove propel cable end from pump input 8. Counter rotate track and remove solid pin
stroker (Optional). from drive sprocket.
Propel Systems - Page 19

9. Lower engine idle, stop machine. 7. Place propel pump control on stroke,
approximately 20% (manual or electric).
10. Reconnect brake hose to pump port ‘Z’ if
applicable. 8. Check main pressure gauge value.
11. Disconnect pressure gauge(s) from pump 9. Check servo pressure gauge; compare to
ports. neutral pressure reading.
Confirm the machine options prior to propel 10. Servo pressures increase with working pres-
pump diagnostic procedures. sures.
Machine options such as tram interloc, jack/ 11. Check replenishing pressure gauge; com-
brake interloc, rotary head/brake interloc, and pare to neutral pressure reading.
electronic depth counters may interrupt the
tram pump pressures by means of pump vent 12. Pump replenishing pressure decreases
solenoid and brake solenoids. depending on components such as hot oil
shuttle valve settings or hydraulic motor con-
PUMP PRESSURE CHECKING: dition.
Diagnosing Troubleshooting
DRAIN
HOSE
• Install a swivel tee and 1000 psi, (70 bar) RELIEF
pressure gauge to the ‘G’ or ‘H’ port for the VALVE
servo pressure test. Hydraulic test stations HYDRAULIC
MOTOR
have guage connections on LPS 1 or 2.
• Install a 500 psi (35 bar) pressure gauge at hot oil shuttle
the ‘KG’ or ‘port or connecting hose with
swivel tee or ‘alternate KG’ for the replenish-
ing pressure test. Hydraulic test stations
have guage connections on LPS 1 or 2.
• Remove, cap and plug ‘Z’ port brake hose at TEST

PORT BRAKE
the pump output stroker if applicable. HOSE
SHUTTLE
VALVE
1. Start machine engine.
2. Set the engine to high idle speed. When main, servo, and replenishing pressures
are in spec.
3. Warm hydraulic oil to > 100° F (37.7°C).
1. Counter rotate track and remove solid pin
4. Slowly rotate the track sprocket so solid pin from drive sprocket.
rests against track frame.
2. De-stroke propel pump control.
5. Check servo pressure gauge, note the neu-
tral pressure value. 3. Lower engine idle, stop machine.
6. Check replenishing pressure gauge, note 4. Reconnect brake hose to pump port ‘Z’ if
the neutral pressure value. applicable.
Refer to propel performance chart for pressure

specifications.
Page 20
PROPEL PERFORMANCE CHART
NEUTRAL CENTER BRAKE
ADJUSTMENT ALT DG PORT
PORT ‘Z’
Main Servo Replenishment
Model psi psi psi ‘KG’ PORT
(bar) (bar) (bar) REPLENISHING
TEST PORT
GATOR* 3000 330/580 200/300

(207) (23/40) (14/21) P6P test ports
‘VA’ PORT
‘A’ PORT
D25KS 3500 330/580 200/300
MAIN
(242) (23/40) (14/21)
PRESSURE
‘H’ PORT
D245S 3500 330/580 200/300 SERVO
(242) (23/40) (14/21) PORT
D40KS 4200 330/580 200/300

(290) (23/40) (14/21)
D45KS 4200 330/580 200/300

(290) (23/40) (14/21)
‘V’ PORT
D50KS 4200 330/580 200/300 MAIN PRESSURE
(290) (23/40) (14/21) BOTH DIRECTIONS
D55SP* 4200 330/580 200/300 MAIN PRESSURE

(290) (23/40) (14/21) COMPENSATOR
D60KS* 4200 330/580 200/300

(290) (23/40) (14/21) Diagnosing pump and motor(s) require case
T60KS 3500 psi 330/580 200/300 pressure gauge, flow meter installation to case
(242) (23/40) (14/21) drain connections. Case pressures should not
D75KS* 4200 330/580 200/300 exceed 75 psi. Typical pump case pressures
(290) (23/40) (14/21) range between 8 to 45 psi.
D90KS 4200 330/580 200/300
(290) (23/40) (14/21) All pressures are checked with the engine at
high idle speed and hydraulic oil > 100° F
D90KSP 4200 330/580 200/300
(290) (23/40) (14/21) (37.7° C)
1190E* 4200 330/580 200/300
Servo pressure for closed loop applications
(290) (23/40) (14/21)
range between the spec noted. Typical servo
pressure at neutral range is 390 to 410 psi (27/
The propel pumps are manual or electric type 28.5 bar) increasing through the servo range
automatic brake with neutral bypass control according to maximum system pressure.
features.
Replenishing pressure for closed loop
Neutral centering adjustments may be made if applications range between the spec noted.
the pump has unwanted motion in the A or B Typical replenishing pressure at neutral range
working ports. Disengage cable end prior to this is 210 to 220 psi (14.5/15 bar) and will
adjustment. decrease when the actuator is turned on.
Absolute lowest replenishing pressure for a
The Z port hose connects to the track final drive rotation system is 180 psi (12 bar) during
brake assembly. This hose may be interrupted propel mode.
with a solenoid valve for tram interloc features.
NOTE!
The Z port is case pressure while the pump is Main pressure * may be slightly higher than
in neutral. When the pump is controlled on the noted for additional power due to final drive
Z port becomes servo pressure. selection and overall machine weights.
A typical left or right propel system without tram • ‘Z’ port track brake connection is not applica-
interloc options. ble to the Gator, D25KS and D245S product.
SPRING APPLIED The Gator, D25KS and D245S equipment use

BRAKE ASSEMBLY directional control manifolds with cartridge or
HYDRAULIC RELEASE poppet valves that enable the propel pump to
> 271 PSI (18.7 BAR) act as the feed or rotation pump.
LPR
MDS
HOS
HOS
x
LPD
HOS
MCS
LPR
Z PORT
TCS
HPS
LPR
X
LPR LPS
LPS
MDS
Current model D25KS/D245S use a constant

Nomenclature regarding the propel system supplied hydraulic pressure as a pilot to shift
components shown here. These names are the cartridge valves from propel to drill modes.
common throughout the product range. The pilot is fan system pressure typically above
2200 psi (152 bar). The fan system pressure is
• LPS low pressure supply separate from the propel system.
• LPR low pressure return
Refer to the supplimental component section of
• HOS hot oil shuttle valve this manual to mount the manifold and valves
correctly to the specific pump application.
Page 22
Tram interloc systems The proper operating sequence for using the
tram foot switch (deadman) feature is essential
Machine specific options may allow additional for hydraulic component longevity.
solenoid operated valves to control brake and
pump pressures of propel pump systems. The sequence of operation is:
• Machine ready to tram

SPRING APPLIED
BRAKE ASSEMBLY • Both propel pump control levers in neutral
HYDRAULIC RELEASE
> 271 PSI (18.7 BAR)
• Step on the tram foot switch pedal
• Actuate propel pump control levers forward

or reverse as needed
(
24 VDC • Center the propel pump control levers to
neutral when ready to stop machine
O
TFS • Step off the tram foot switch pedal
O
Failure to apply the tram foot switch before

x operating the propel pump control levers or
randomly stepping on and off the tram foot
switch with the propel pump control levers
actuated will lead to hydraulic seal and relative
LBS hydraulic component problems.
RBS
Troubleshooting propel systems with tram
interloc components may require
PUMP V PORTS
Z PORT
T T
• #4 hydraulic cap and plugs
T T
• Electrical meter or test light
PVS
• Tram interloc bypass switch actuation
X
KG PORTS • Understanding of the component locations

OR Z PORTS and pump porting
MACHINE GRADIENT LIMITATIONS
Pump vent solenoid (PVS) vents the propel The following sample and performance chart
pumps main system pressure until actuated by are available in a single format relative to the
either the tram foot switch or control relays. machine model in every operator manual
published from Driltech Mission.
Left (LBS) and right (RBS) brake solenoids
dead head propel pump servo brake pressure
until actuated by either the tram foot switch or
control relays.

GRADES PERCENT
9° 15.8%
11° 19.4%
26° 12° 21.3 %
15° 26.8%
16° 28.7%
17°
17° 30.6%
18° 32.5%
20°
19° 34.4%
20° 36.4%
20° 21° 38.4%
22° 40.4%
23° 42.4%
D55SP GRADIENTS
25° 46.6%
26° 48.8%
27° 51%
29° 55.4%
GRADE IN DEGREES
12°
10
= 10% SLOPE
100
21° VERTICAL RISE DISTANCE

SLOPE DEGREES =
HORIZONTAL DISTANCE
TAN x SLOPE = DEGREES
15° GRADE IN PERCENT
10’
15°
100’
D55SP GRADIENTS 100 X VERTICAL RISE

% GRADE IS 100 x SLOPE OR
HORIZONTAL DISTANCE
Page 24
ROTATION SYSTEM 2. Set the engine to high idle speed.
3. Warm hydraulic oil to > 100° F (37.7°C).

CLOSED LOOP 4. Slowly rotate drill pipe to align drill pipe flats
and holding wrench.
The drill rotation system consists of one axial
piston pump, hoses and steel pipes connecting
5. Lock the drill pipe rotation with holding
fixed displacement or variable displacement
wrench/deck wrench.
motor(s).
6. Adjust (manual or electric) pressure torque
The Denison piston pump has four (4)
control valve ccw to minimum setting.
pressures which may need monitored when
setting and diagnosing the rotation
7. Place rotation pump control on stroke
components. Refer to the rotation performance
approximately 20% (manual or electric).
chart for specific machine model pressures.
8. Check rotation pressure gauge on drill con-
The rotating components will need to be locked
sole panel.
in order to stall the pump when checking or
setting the system to spec. When ever possible
9. Adjust (manual or electric) pressure - torque
position the top flats of the drill pipe in the
control valve cw, checking rotation pressure
holding wrench to lock the rotation.
gauge for pump compensator value.
Equipment and operator safety should be a
10. Refer to rotation performance chart for
primary concern when connecting any locking
appropriate pressure
medium to the rotating drill accessories.
11. If pump pressure is to spec, lessen pressure
Approved locking tools are the holding wrench/
torque control valve setting ccw.
deck wrench, jay wrench and flange plugs of
adequate port sizes.
12. Place rotation pump control to neutral.
13. Unlock holding wrench from drill pipe flats.
Drill operators may set the pressure control

valve at any value between 100 psi up to
maximum pressure of the pump due to drill
pipe, drill bit sizes and ground conditions. It is
recommended to be at the higher range.
PUMP PRESSURE CHECKING:
Diagnostic And Troubleshooting
• Install a swivel tee and 1000 psi (70 bar)

pressure gauge to the ‘G’ or ‘H’ port for the
PUMP PRESSURE CHECKING:
servo pressure test.
No Pressure Adjustment Required.
• Install a 500 psi (35 bar) pressure gauge at
the ‘KG’ port for the replenishing pressure
test.
Rotation Systems - Page 25
1. Start machine engine. When main, servo, and replenishing pressures
are in spec.
2. Set the engine to high idle speed.
18. De-stroke rotation pump control.
3. Warm hydraulic oil to > 100°F (37.7°C).
19. Unlock holding wrench from drill pipe flats.
4. Check servo pressure gauge, note neutral
pressure value.
ROTATION PERFORMANCE CHART
5. Check replenishing pressure gauge, note
neutral pressure value. MAIN SERVO REPLENISHMENT
MODEL PSI PSI PSI
6. Refer to rotation performance chart for pres- (BAR) (BAR) (BAR)
sure specifications. GATOR 3000 330/580 200/300

(207) (23/40) (14/21)
7. Slowly rotate drill pipe to align drill pipe flats D25KS 3500 330/580 200/300
and holding wrench. (242) (23/40) (14/21)
D245S 3500 330/580 200/300

8. Lock the drill pipe rotation with holding (242) (23/40) (14/21)
wrench/deck wrench.
D35KS 3000 330/580 200/300
(207) (23/40) (14/21)
9. Adjust (manual or electric) pressure - torque
control valve ccw to minimum setting. D40KS* 3500 330/580 200/300
(242) (23/40) (14/21)
10. Place rotation pump control on stroke D45KS 3500 330/580 200/300
approximately 20% (manual or electric). (242) (23/40) (14/21)
D50KS 3500 330/580 200/300

11. Check rotation pressure gauge on drill con- (242) (23/40) (14/21)
sole panel. D55SP* 4200 330/580 200/300
(290) (23/40) (14/21)
12. Adjust (manual or electric) pressure - torque D60KS* 4200 330/580 200/300
control valve cw, checking rotation pressure (290) (23/40) (14/21)
gauge for pump compensator value.
D75KS** 4200 330/580 200/300
(290) (23/40) (14/21)
13. Check servo pressure gauge, compare to
D90KS** 3500 330/580 200/300
neutral pressure reading.
(242) (23/40) (14/21)
14. Servo pressures increase with working pres- D90KSP** 3500 330/580 200/300
(242) (23/40) (14/21)
sures.
1190E** 3500 330/580 200/300
15. Check replenishing pressure gauge, com- (242) (23/40) (14/21)
pare to neutral pressure reading.
Diagnosing the pump and motor(s) require
16. Replenishing pressure decreases depend- case pressure gauge(s) and a flow meter
ing on component condition. installation to case drain connections.
17. Refer to troubleshooting chart if either pres- Typical rotation pump case pressures range
sures are out of spec. between 5 psi at neutral up to 45 psi (.4 to 3
bar) at stall. Case pressure should not exceed
75 psi (5.2 bar).
Page 26
All pressures are checked with the engine at Flange plugs are available from Driltech
high idle speed and hydraulic oil > 100° F Mission spare parts department and may be
(38.6° C) used to stall a pump for diagnostic purpose.
Servo pressure for closed loop applications

range between the spec noted. Typical servo FLANGE PLUG PN FLANGE PLUG SIZE
pressure at neutral range is 390 to 410 psi (27/
28.5 bar) increasing through the servo range 004762-001 .50 #8-8
according to maximum system pressure. 004762-002 .75 #12-12
004762-003 1.00 #16-16

Replenishing pressure for closed loop
applications range between the spec noted. 004762-004 1.25 #20-20
Typical replenishing pressure at neutral range
004762-005 1.50 #24-24
is 210 to 220 psi (14.5/15 bar) and will
decrease when the actuator is turned on. 004762-006 2.00 #32-32
Absolute lowest replenishing pressure for a
rotation system is 180 psi (12 bar) during Rotation pumps may be stalled at the A and B
drilling mode. work ports during diagnostic testing. It is
recommended to turn the compensator valve
NOTE! out (ccw) prior to stalling the pump.
* models may be fitted with dual motors for
high torque low speed drilling. 001330-000 = 6 cu in
002764-000 = 7.25 cu in
** models are fitted with dual motors for high AVAILABLE PARTS
torque low speed drilling.
CASE DRAIN New pump/motor installations

CHECK VALVE
When replacing pump(s) and motor(s) it is
recommended to inspect or replace the shaft
coupling.
ALIGNMENT ADJUSTMENT
SCREWS AND NYLATRON
GUIDE SHOES A lithium - molybdenum disullfied or similar
coupling grease is recommended for new
component shafts. (Mobil EP111)
Maintain pressure/return and case drain hoses
as needed. Inspect hoses for wear at all points
for rubbing. Replace worn hoses as needed
and prior to failure.

Rotation motors have a spring washer • LPR low pressure return
positioned between the motor flange and the
drive coupling. Do not operate the rotary drive • LPS low pressure supply
system without the spring washer as excessive • HPS high pressure supply
coupling travel will damage the rotary drive
components. • HOS hot oil shuttle valve(s)
Typical one or two motor rotation system. • LPD low pressure drain
Rotation motors are two bolt or four bolt flange

OPTIONAL mounting with different part numbers for the
2ND MOTOR applications.
)(
)(
HOS
LPR
USE ONE NEW

002713-001 OR
002713-002 WHEN
PLANETARY IS OPENED
)(
)(
MOTORS
HOS 001329-000 = 6 cu in
002746-000 = 7.25 cu in
Rotary Speed And Torque
Motor and planetary are matched as sets to

LPD achieve a desired rotation speed and torque for
the ground condition.
Planetary sets are identified by part number:

LPR
• 001004-001 = 4.89 reduction
X
LPS • 001079-001 = 3.27 reduction

HPS
Pump output flow, number of motors, motor
displacement and planetary reduction are the
main elements when selecting correct drill pipe,
Nomenclature regarding the rotation system drill bit rotation speed.
components shown here. These names are
common throughout the product range.
Page 28
PLANETARY 50 GPM 60 GPM 75 GPM 113 GPM
# DISPLACEMENT
REDUCTION MAX RPM MAX RPM MAX RPM MAX RPM
3
1 6 IN 3.27 160 192 240 ****
3
1 6 IN 4.89 106 127 160 ****
3
2 6 IN 3.27 80 96 120 175
3
2 6 IN 4.89 53 64 80 118
3
1 7.25 IN 3.27 132 158 198 ****
3
1 7.25 IN 4.89 89 106 132 ****
3
2 7.25 IN 3.27 61 79 99 145
3
2 7.25 IN 4.89 45 53 66 97
Match motor(s) and planetary reduction with • electrical adjustable control

pump output flow to achieve a desired drill pipe
rotation speed. ELECTRICAL CONTROL (VP01)
The examples shown are some of the most

common applications.
Maximum torque is available through the

pressure range of the pump and motor
selection.
A remote pressure control valve and a pressure

gauge connected to the rotation pump main
pressure enables torque to be set for drill pipe
and bit control in various ground conditions. P T
Two valve applications are typical on drill

machines: Remote pressure valves may be removed from
the pump port during diagnostic checks. When
• manual adjustable control a valve seat is open or damaged due to low
input power or common wear, the pumps
pressure will take the path to low pressure
MANUAL CONTROL (003500-001)
drain.
Removing the P or T port hose and securing

T the hose with a pressure type hydraulic plug
allows the remote pressure valve to be
bypassed. Install a hydraulic cap over the
exposed valve port.
P

Two Speed Rotary Applications
SERVO SUPPLY
High rotation torque becomes a concern when
drilling through different ground formations.
RDS
The two speed rotation system allows the
operator to change the motor torque and speed
output when encountering different ground
conditions. Pump volume output remains
standard, the motor displacement changes
according to operator need.
SINGLE MOTOR TWO SPEED APPLICATION
Under normal operating conditions motors are

set to the maximum angle which give a slow
speed as standard. when selected servo oil
through the rotatary displacement solenoid
directs the input control to change cam angles.
Page 30
HIGH PRESSURE RETURN • HPR high pressure return
• LPD low pressure drain

BACK-PRESSURE All Driltech reservoirs use the elevated return
pressure from HPR as a replenishment charge
Vane pump systems free circulate oils through pressure for feed pumps.
directional valves known in our systems as
(stacker valves). Hydraulic oils are directed Maintaining this pressure on regular intervals
through these valves during actuation to (500 hour maintenance) will extend feed pump
operate accessories that assist the drilling service life.
cycle.
A few of the drill related accessories are:

RELIEF
VALVE
• drilling air
• mast locking (LPR)

MANIFOLD TEST
PORT
• drill pipe loader(s)
• dust control and water injection
• angle drill options
After free circulating oil or actuation of stacker

valves the hydraulic oil is directed to a return fil-
ter canister for fine filtration.
After filtration this oil under pressure is available SUPPLY

LINES
for the feed pump and rotation pump as replen- (LPS)
ishing oil.
LPD (HPR)
HYDRAULIC RESERVOIRS MANIFOLD
Current Driltech Mission machines have 4

variations of the hydraulic reservoir. D25KS/D245S HYDRAULIC RESERVOIR
(T25KW - T35KS)
• GATOR, D245SP, D560
• D25KS, D245S, T25KW, T35KS Pressure spikes from the vane pump stacker
valves and feed systems occur during normal
• D40KS, D45KS, D50KS, D55SP, D60KS, operation. Mid-range machines may have one
D75KS, T40KS, T60KS 2.5 gallon accumulator on a mounting plate
• D90KS, D90KSP, 1190E inside the mast pedestal. One hose will connect
the accumulator to the HPR manifold return
All reservoirs use the following nomenclature: pipe.
• LPS low pressure supply Charge accumulator to specs noted in service

literature 004695-000 using (N2) nitrogen gas
• HPS high pressure supply
only as the filling compound.
• LPR low pressure return
High Pressure Return - Page 31
125-150 PSI
LPR HPR
TEST
PORT
125 O
HPS
150 HPR LPR
CHECK
LPD VALVE
LPS
LPD
D40KS, D45KS, D50KS, D55SP, D60KS, D75KS
D40KS D90KS 1190E

D45KS
D50KS
D55KS
D60KS
D75KS
! CAUTION
HPR/HPS pressure should be lower than
012446 SERIES pump replenishment pressure. It is recom-
RPKC mended that the pump replenishment and
RPKE HPS pressures maintain a 30 to 50 psi
(2 - 3.5 bar) differential.
PUMP SPEEDS
Mid range machines back pressure may be The vane pumps are specific for the machine
taken at the HPS manifold 2 inch (52mm) high models and the operating systems. Primary
pressure supply manifold positioned between pumps utilized for drill accessories are the T6C
mast pedestal diagonal supports. and T6CC series from Denison hydraulics.
Gearbox ratios determine the pump(s) actual

LPS output when the engine is at high idle speed.
This feature is factored into the design of a
HPS specific model of drill machine.
Low engine speed will generate oil flows

however the actuator speed will not be to
specifications. Pump output flows should be
metered, and any pressure checks or setting of
the back-pressure valve should be performed
with the engine at the rated high idle speed.
Page 32
Three pressure ports are made available for
testing the back-pressure.
• At the back-pressure valve manifold before

the filter.
• In the supply pipe referred to as (HPS) after

the filter. Most common test port.
• In the return pipe referred to as (HPR)

before the filter.
CHECKING HPR/HPS PRESSURE:
No Pressure Setting Adjustment Required. TEST PRESSURE

HPR/HPS GATOR
• Install 500 psi (35 bar) gauge at either of
three ports noted.
3. Warm hydraulic oils to > 100° F (37.7° C). Photo shows a Gator machine test port on the
HPR/HPS back pressure manifold. The relief
4. Check gauge pressure at selected port posi- valve setting is 150 psi (10 bar) using a 500 psi
tion. (HPS manifold) (35 bar) gauge for the test.
5. Operate feed pump control and feed system
directional control valve. CHECKING HPR/HPS PRESSURE:
6. Check gauge pressure during feed pump oil Backpressure Adjustment Required.
consumption.
• Install 500 psi (35 bar) pressure gauge at
either of three ports noted.
7. Refer to HPR/HPS performance chart.
8. If pressure maintains the desired pressure
during feed pump utilization no pressure
adjustments are required.
3. Warm hydraulic oils to > 100° F (37.7° C).
Pressure may be unstable during the feed sys-
tem actuation. Gauges may bounce during oil
4. Check gauge pressure at selected port posi-
demands.
tion.
During feed system actuation HPR/HPS pres-
5. 9/16 (14mm) wrench, 5/32 (4mm) allen
sures vary from 30 to 100 psi (2 to 6.9 bar)
wrench required to adjust. Tools may vary
above the neutral pressure setting. Pressure
depending on machine model.
spikes in HPR/HPS above 250 psi (17 bar)
could cause damage to hydraulic components.
High Pressure Return - Page 33

6. Loosen lock nut on back pressure valve HPR/HPS
thread. MODEL
psi (bar)
7. CW adjustments increase, CCW adjust- GATOR 150

(10/10.5)
ments decrease pressures.
D25KS 175
(12)
8. Refer to high pressure performance chart for
pressure values. D245S 175
(12)
9. Upon desired pressure range, tighten lock D35KS 150
nut on valve thread. (10/10.5)
D40KS 125/150
10. Operate feed pump and directional control (8.5/10.5)
valve, checking HPS pressure.
D45KS 125/150
(8.5/10.5)
11. HPS pressure should not drop below speci-
D50KS 125/150
fied pressure. (8.5/10.5)
D55SP 125/150
(8.5/10.5)
NOTE!
D60KS 125/150
• During (feed, mast raise, leveling jack) cylin- (8.5/10.5)
der actuation and the feed pump on full vol- D75KS 125/150
ume output, the back-pressure noted may (8.5/10.5)
rise above the spec pressure. This is due to
D90KS 175/230
variations in oil volumes returning to the (12/16)
back-pressure valve from the operated cylin-
D90KSP 175/230
der(s). (12/16)
• When said cylinders are operated in an abu- 1190E 175/230

sive manner pressure spikes are witnessed (12/16)
in this back-pressure system. In turn these
pressure spikes will damage hydraulic com- See troubleshooting procedures in the event
ponents. that back pressure cannot be adjusted and/or
maintained during feed pump actuation.
Examples of abusive cylinder actuation are, and
not limited to: Consult the Driltech Mission factory technical
support team for help in the event pressure
• Rapid feed cylinder directional changes, up spikes are present at HPR/HPS manifolds
and down. during your drilling application.
• Stopping mast raise cylinders with full vol- Operating principals and/or additional spare
ume oil, lowering or raising mast.
parts may be required.
HPR PERFORMANCE CHART
Pressures noted herein are static pressures.

The pressures will raise an lower according to
loads within the systems.
Page 34
2-18-92
ACCUMULATOR 7. The bleeder valve can be used to let out any

gas pressure in excess of desired precharge.
(004695-000)
8. Replace dynaseal and valve guard.
RECHARGING
The accumulator charges should be pressure
checked at approximately 100 hour intervals. If
! CAUTION the bladder charge cannot be maintained, , the
complete accumulator must be replaced.
Overcharging the accumulator bladder can
damage the accumulator and hydraulic com-
ponents. Extreme temperatures can result in
incorrect pressure readings. Accumulator
charging should only be done when the
ambient temperature is between 70 and
100°F (21 and 38°C).
1. Exhaust all hydraulic pressure from the sys-

tem.
! CAUTION
DO NOT use oxygen as a charge gas. Dry
nitrogen gas should be used.
2. Remove valve guard and dynaseal.
3. Mount hose assembly gland nut to pressure

regulator.
4. Attach a swivel connector to the gas valve.

Hand tighten sufficiently to compress gasket
swivel connector in order to prevent gas leak-
age.
5. Precharge bladder slowly to about 10 PSIG

before completely tightening the valve stem nut.
Use a second wrench on the valve stem flats to
react the torque applied to the stem nut.
6. Proceed to inflate accumulator to 100 psi (7

bars) by slowly opening the pressure regulator
valve on nitrogen cylinder, closing it occasion-
ally to allow needle on pressure gauge to stabi-
lize (thus giving accurate reading of precharge
pressure). When correct precharge has been
reached, close pressure regulator valve on
nitrogen cylinder securely.
Accumulator - Page 35
2-18-92
Page 36
FEED SYSTEM
OPERATE FEED SYSTEM
SO THAT THIS ROTARY
HEAD IS AT THE UPPER-
GENERAL MOST TRAVEL
There are many different configurations of feed

systems. This manual details:
• D55SP with fast feed - Rotary application
• D55SP with fine feed - DTH application
• D40KS - DTH drill application
• 90 series cylinder pulldown - Rotary applica-

tion Operation and machine safety are of utmost
concerns during all hydraulic pressure setting
• 90 series motor pulldown - Rotary applica-
procedures. Stay clear of moving components
tion
such as chains, sprockets and table bushings
• Gator drill/propel - DTH application while feed system is in operation.
• D25KS D245S drill/propel - DTH application ! WARNING

Confirm the specific drill machine system sche- Oil under pressure can pierce the skin
matic for other applications. causing health concerns, or possible death.
Do not feel for hydraulic oil leaks with your
bare hand. Avoid skin contact whenever
FEED SYSTEMS possible.
Machine models, feed cylinders, pulldown and

hoist chains are primary considerations when
! WARNING
setting a feed system properly. A feed system Hot hydraulic oil may cause sever burns.
performance chart provides product model feed
system specifications through the Driltech When checking and setting feed pump systems
equipment product range. it will be necessary to register the pump servo
and high pressure supply pressure as well.
The Denison piston pump may be in an open
loop or closed loop application. The feed CHECKING PUMP PRESSURE:
system has to be operated on and put into a
stall setting in order to calibrate the maximum No Pressure Adjustment Required:
system pressure.
When possible test the feed system without the 2. Set the engine to high idle speed.
drill pipe connections. Rotary head empty as
shown in the following illustration. 3. Warm hydraulic oils to > 100° F (37.7° C).
The steps noted in this section are to be utilized Gator, D25KS and D245S series machines shall
for all Driltech application feed systems. have the drill propel selector (DPS) placed into
the drill mode prior to operating either of the
feed systems.
Feed System - Page 37

If pump is new allow adequate pre-charge time
per new pump start-up procedure.
3. Warm hydraulic oil to > 100° F (37.7° C).
4. Place pump control on stroke approximately

20% (manual or electric).
5. Set (manual or electric) feed pressure con-

trol ccw to minimum setting.
6. Actuate directional control valve to hoist

position.
7. When feed cylinder(s) are fully retracted and

the rotary head contacts top of mast, adjust
4. Place pump control on stroke approximately feed pressure control to maximum pressure
20% (manual or electric). setting.
5. Set (manual or electric) feed pressure con- 8. Remove pump compensator cover nut,
trol ccw to minimum setting. loosen lock nut.
6. Actuate directional control valve to hoist (for- 9. Adjust pressure compensator in to increase
ward) position. pump stall pressure.
7. When feed cylinder(s) are fully retracted and 10. Adjust pressure compensator out to
the rotary head contacts top of mast, adjust decrease pump stall pressure.
feed pressure control cw to maximum pres-
sure setting. 11. Adjust pressure to machine model spec per
feed performance chart.
8. If feed pump pressure is to spec, lower pres-
sure control setting ccw. 12. Monitor servo pressure while setting main
pressure.
9. Center directional control valve to neutral
position. 13. Monitor HPS pressure during setting main
pressure.
10. De-stroke feed pump.
position.
CHECKING PUMP PRESSURE:
When main, servo and HPS pressures are in
Diagnostic And Troubleshooting:
spec.
• Install 1000 psi (70 bar) pressure gauge to 15. De-stroke feed pump.
pumps ‘G’ port for servo pressure.
Center the feed pump controls to neutral during
• Install 500 psi (35 bar) pressure gauge on propel, machine start and shutdown modes.
HPS manifold (replenishment pressure).
All pressures noted are with hydraulic oil > 100°
F (37.7° C) engine speed at high idle, auxiliary
2. Set the engine to high idle speed. pressure gauges installed to appropriate ports.
Page 38
FEED PERFORMANCE CHART • Open loop pump servo pressure 160 to 280
psi (11 - 19 bar) range. Servo pressure
HPS Or increases with working pressure.
Main Servo
Replenishment
Model Psi Psi
Psi
(Bar) (Bar) SERVO
(Bar)
PRESSURE
GATOR * 3000 330/580 200/300
(207) (23/40) (14/21)
D25KS * 3500 330/580 200/300

(242) (23/40) (14/21)
D245S * 3500 330/580 200/300

(242) (23/40) (14/21) CASE
PRESSURE
D35KS 3000 N/A N/A
(207)
D40KS 3000 160/280 125/150 OPEN LOOP

(207) (11/19) (8.5/10.5) APPLICATION
D45KS 3000 160/280 125/150
(207) (11/19) (8.5/10.5) • Closed loop pump servo pressure 330 to
D50KS 3000 160/280 125/150 580 psi (23 - 40 bar). Servo pressure
(207) (11/19) (8.5/10.5) increases with working pressure.
D55SP 3200 160/280 125/150
(220) (11/19) (8.5/10.5) • Closed loop pump replenishment pressure
200 to 300 psi (14 - 21 bar). Replenishment
D60KS 3500 160/280 125/150
(242) (11/19) (8.5/10.5)
pressure decreases due to the condition of
the system components.
D75KS 3500 160/280 125/150
(242) (11/19) (8.5/10.5)
Piston pump case pressure 5 to 40 psi (.4 - 2.8
D90KS * 3500 330/580 200/300 bar) dependent on main pressure. Pump case
(242) (23/40) (14/21) pressure increases with system pressure and
D90KSP * 3500 330/580 200/300 should not exceed 75 psi (5.2 bar).
(242) (23/40) (14/21)
1190E * 3500 330/580 200/300

MACHINE LIFT-OFF
(242) (23/40) (14/21)
A machine safety system designed to limit
drilling capacity and over pressure conditions is
Products * have closed loop feed systems
connected to all feed system applications. The
therefore servo and replenishment pressures
extend side of feed cylinder(s) are monitored
will differ between models with the open loop
during drill conditions.
feed system.
Lift off components consist of
Auxiliary pressures to be checked when
performing feed system set-up, diagnostic, and • one manifold mounted adjustable relief valve
troubleshooting.
• interconnecting #4 hoses
• High pressure supply (HPS) adjustable from
125 to 150 psi (8.5 - 10.5 bar) on mid range • inline check valve positioned on open loop
machines and 175 psi (12 bar) other applica- feed pump port FB
tions noted in the HPR performance chart.
This pressure is a open loop pumps replen- • inline needle valve connected to open loop
ishment oil at prescribed pressure. feed pump port DG.

Machine lift off relief valve setting can limit the cylinders when deep hole drilling applications
machines down pressure capability. are used.
The inline check valve on open loop feed pump The cylinder maximum sequence valve setting
applications stops feed pump servo pressure is 4200 psi. Pump pressure have to be altered
from venting to pump case drain thus affecting prior to setting the cylinder maximum sequence
pump control. valve. Upon proper calibration return feed
pump to feed system specs.
The needle valve on open loop feed pump
applications limit system pressure and derates The feed distribution manifold for high pressure
the feed pump internally. The needle valve drill applications may have a additional 3/4 way
must be open 1.5 to 3 turns so the pump will control valve with cable connections and the
derate. additional maximum pressure relief valve.
NOTE! CYLINDER MAX

LIFT OFF
For open loop feed pump applications lift-off SEQUENCE VALVE SEQUENCE VALVE
relief valve is positioned on the feed distribution
manifold inside the hydraulic cabinet lower left
inside corner.
The typical machine lift-off pressure value is

200 psi less than the feed pump main pressure
setting for the specific model machine.
MACHINE LIFT-OFF
RELIEF VALVE SET
200 PSI < FEED SYSTEM
PRESSURE
FRS
D40KS, T40KS, D45KS

HIGH PRESSURE APPLICATIONS
FOS
FVS
Feed override solenoid FOS and feed vent
solenoid FVS part number 002006-101 are
shown mounted to support. These hydraulic
T T
solenoids are common valves typically used to

w
vent a system pressure or allow pilot pressure

D45KS HYDRAULIC CABINET
to be applied.
NOTE! Consult machine specific electrical schematic

On D40KS and D45KS high pressure drill for options.
applications the feed distribution manifold may
support a retract side cylinder maximum
sequence valve. This valve is protecting feed
Page 40
• FOS Feed Override Solenoid
SINGLE CYLINDER OR • FF Fine Feed Adjustment
DUAL CYLINDERS
• FFS Fast Feed Solenoid
• FVS Feed Vent Solenoid
• CIS Centralizer Interloc Solenoid
HVS
• HVS Holding Valve Solenoid
FFS • HV Holding Valve

• MLO Machine Lift Off (200 psi< feed pump)
• LSV Lower Stacker Valve (2500 psi)
• LPS Low Pressure Supply (5 psi)
• LPR Low Pressure Return (8 - 20 psi)
MLO
• LPD Low Pressure Drain
• HPS High Pressure Supply (125 - 150 psi)
• LS Load Sensing
LSV
• FFS Fine Feed Solenoid
FINE FEED
MANIFOLD
MLO
HPS DG FB
HPS
DG FB
FFS
LPR
LPS LPR
LPS
FVS LS
CIS FVS
FOS CIS
FOS
D55SP FEED SYSTEM SCHEMATIC

LP ROTARY APPLICATION
D55SP FINE FEED SYSTEM
Nomenclature regarding the feed system WITH LOAD SENCING
components shown here. Many of these names HP DTH APPLICATION
are common throughout the product range.
Feed systems for DTH drill applications have 90 Series Feed Systems
added valves allowing a fine feed or holdback
system. Cylinder Pulldown
Holdback is generally used when drilling deep A 90 series machine application feed system
holes with high drill string weight. Holdback uses a 14 cu in (229.4 cc) pump. Pressures are
when used allows the operator a means to stop noted in the feed performance chart.
or hold the drill string weight.
There are two feed systems applicable to the 90
series machines.
HV • Multi pass drill applications will use the cylin-

der pulldown system
• Single pass drill applications are offered with

either the cylinder or motor pulldown sys-
tems.
4.5 X 3 FAN
PRESSURE 90 series multi pass cylinder application feed
system require general maintenance of the
accumulator and auxiliary valves inside the feed
manifolds.
FF
The feed pump for 90 series machines are in a
closed loop application. Pump input controls are
calibrated with two output flow rates.
CMV
• Pulldown mode output flow rate is 113 gpm
(429 lpm) equates to 16° stroke limit.
LPD • Hoist mode output flow rate is 85 gpm (323

lpm) equates to 13° stroke limit.
MLO
When the output flow limiters exceed the spec
LSV the feed system reacts faster when controlled
on. Excess output flow may make the feed
uncontrollable when the pump is centered.
HPS
The following list of hydraulic components may
DG FB
be used to identify and set the specific valves of
a cylinder application feed system.
LPR
Holding valve: calibration specs are noted in
LPS service literature 008738. Holding valves are
counterbalance valves for feed cylinders. The
FOS TT W concept is to hold the load of rotary head and
x
LPD drill pipe during none drilling modes.
D40KS FEED SYSTEM SCHEMATIC

HP DTH DRILL APPLICATION
Page 42
Decompression pilot valve: is a two piece
component. The adjustable valve and check
valve are mounted on the feed cylinder return
pipe. Pilot hoses connect the pilot valve to a
check valve. Pressure setting the pilot valve to
600 psi enables feed system pulldown pressure
to open the decompression check valve. The
decompression check valve allows oil into the
HPS
FAN
REPLENISHMENT
feed pump return leg from HPS filtration.
PRESSURE
FILTER
• Install a pressure gauge on the decompres-
LPD
sion check valve between the pilot valve and
check valve. Expected reading to open the
check valve is 600 psi.
Replenishment check valves: are in a feed

manifold due to feed cylinder rod and case area
variations.
• It becomes necessary to allow oil into the

feed system return leg for adequate replen-
ishment during feed down conditions.
• It becomes necessary to allow oil to exit the

return leg during hoist modes. The feed
pump can be held over center if too much oil
is trapped in the return leg during hoist
modes.
HPS
ROTATION
PUMP
Replenishment pilot valve: is applied when
feed pump is in the hoist mode only. Valve set-
ting is approximately 1000 psi (70 bar) The pilot
valve opens the A port check valve to allow
return oil from the feed cylinder a exit to HPR.
• This valve is preset according to the specific

part number.
LPR
LPS
D90KS, 1190, 1190E

FEED SYSTEM

90 Series Motor Pulldown 90 series motor application feed systems
require maintenance of accumulator and gen-
eral hydraulic valves.
LPR
Two speed pilot control valve: is located near
the motor on the feed gearbox mount.
• Connect a pressure gauge between the pilot

valve and servo control valve. Adjust the
pilot valve for 1000 psi (70 bar) outlet pres-
sure.
Servo control valve: is located near the motor

on the feed gearbox mount. Hoses from the
pump servo system allow control oil to the
motor X or Y port.
• Motor speed will be slow when servo oil is
directed to Y port of the motor input control.
• Motor speed will be faster when servo oil is

directed to X port of the motor input control.
Motor actuation may be visible by a slight speed

increase for the hoist mode only. The motor out-
put control has a pointer that shall move from
19° to 14° during the hoist mode when the two
speed pilot control and servo control valves are
operable.
Drill/Propel Applications
The Gator, D25KS and D245S feed systems

use a Denison piston pump for propel/rotation
and propel/feed systems. Pump mounted mani-
folds require special torque discussed in the
supplemental pump component section of this
manual.
Each pump port manifold uses pilot assisted

directional control valves to switch pump port
flow to the dedicated system.
Fan system pressure in excess of 1800 psi (124

bar) enters manifold port V1 from a remote
LPS
mount solenoid valve (MCS) during the propel
tram mode only.
The directional control manifolds must have

D90KS, 1190, 1190E hoses attached to D1 or D2 ports in order to
FEED SYSTEM allow the valves to empty periodically.
Page 44
FINE FEED VALVE @ 10 GPM
LPD EXG REPLENISHING CHECK VALVES
D
GB2 A
V1
EX
B
HV
LS LSS
RE
A B
FPV FOS HPSG CBP REG
GA2 LOAD SENCING VALVE
HPR
REPLENISHMENT FILTER
GB2
V1 B
MCS W
A
T T
GA1
LPR
LPR
GATOR DRILL/PROPEL SYSTEM
The Gator machine utilizes two 001330 series

closed loop application pumps. Each pump is 6
cu in displacement and is controlled by a 900
series electronic displacement control valve.
Input voltage varies according to operator con-

trol. Expected voltage is 6 vdc for threshold and
21.5 vdc for max.
The Gator series pump may be manual con-

trolled with standard hand tools.
TEST PORTS

between the two applications with vane pump
principals.
D25KS high pressure applications use one

T6CC vane pump
SLOW FEED • shaft section - slow feed

PUMP
• rear section - fan/accessory
HVS
D245S high pressure applications use one
FOS T6CC and one T6C vane pumps
• shaft section - slow feed
• rear section - fan

HV
• single engine mounted pump - accessory
D25KS and D245S low pressure applications

MLO
use one T6CC vane pump
• shaft section - accessory
• rear section - fan
High pressure applications
B A D25KS and D245S applications with a slow

GB2 GA2
feed system maintain a slow feed relief valve
positioned on the low pressure return manifold
V1 port 9. The relief setting is 3600 psi (248 bar)
MCS set 100 psi over the fast feed pump pressure.
Fast feed pump compensator setting is 3500 psi

(242 bar). Refer to the feed system perfor-
mance chart when calibrating the fast feed sys-
tem on D25KS and D245S model machines.
FAST FEED
PUMP
MDS
D25KS, D245S FEED SYSTEMS
The D25KS and D245 machines are based on

low pressure rotary or high pressure DTH drill-
ing applications. The hydraulic systems vary
Page 46
PORT 3 SLOW FEED
RELIEF VALVE SETTING
3600 PSI (248 BAR)
hpr245
4. Actuate directional control valve to hoist (for-

ward) position.
5. When feed cylinder is fully retracted and the

rotary head contacts top of mast, adjust feed
pressure control cw to maximum pressure
setting.
6. If feed pump pressure is to spec, lower pres-

sure control setting ccw.

position.
CHECKING PUMP PRESSURE:
Slow feed application specs
No Pressure Adjustment Required:
• Slow feed pressure at 3600 psi (248 bar)
• Fast feed pressure at 3500 psi (242 bar)
• Remote pressure valve control setting from
3. Warm hydraulic oils to > 100° F (37.7° C). 0 through the range.
Gator, D25KS and D245S series machines shall Remote Pressure Controls
have the drill propel selector (DPS) placed into
the drill mode prior to operating either of the A remote pressure control valve and a pressure
feed systems. gauge connected to the rotation pump main
pressure enables torque to be set for drill pipe
and bit control in various ground conditions.
Two valve applications are typical on drill

machines:
• manual adjustable control

Remote pressure valves may be removed from
MANUAL CONTROL (003500-001) the pump port during diagnostic checks.
When a valve seat is open or damaged due to

low input power or common wear, the pumps
T pressure will take the path to low pressure
drain.
Removing the P or T port hose and securing

P the hose with a pressure type hydraulic plug
allows the remote pressure valve to be
bypassed. Install a hydraulic cap over the
exposed valve port.
• electrical adjustable control
ELECTRICAL CONTROL (VP01)
P T
Page 48
LOWER STACKER pressure with full volume oil supply dependent
on pump control position.
• D25KS and D245S machines high pressure

DIRECTIONAL CONTROL VALVES
drilling applications have a slow feed and
The lower stacker valve has two primary func- fast feed supply oil which will mix vane pump
tions. oil with a variable volume fast feed pump.
One is to provide oil supply for leveling the • D25KS and D245S machines use a drill/pro-
machine on uneven ground using (leveling jack pel selector switch (DPS) to enable the pis-
cylinders). ton pumps to independently operate both
functions.
Second is to have a sufficient oil supply for fill-
ing two (mast raise cylinders).
The components of the lower stacker valve cir-

cuit consist of:
• Pump supply oil
• Directional control valves
• Pressure control valve
• Hoses and hard line pipes
• Double acting cylinders
• Pilot check valves
• Counterbalance valves
• Midrange products D40KS, D45KS, D50KS,
The lower stacker valve sections are designed D55SP, D60KS, and D75KS utilize a opera-
to accept large volumes of oil for the purpose of tor controlled variable volume oil supply.
filling large diameter cylinders.
The control of the pump displacement from the
All Driltech equipment with the exception of the operators station can be varied to make slow or
90 series machines the lower stacker valve cir- fast cylinder travel speed.
cuit operates with oil supply from the feed sys-
tem. Lower stacker valve system pressure may be
checked during normal operation from the drill
Feed system performance is essential for the operator station.
appropriate lower stacker oil supply. Feed pump
and operator controlled remote pressure valve This system is not available on the Gator
enable lower stacker valve supply pressure. machine. The concept will differ on the D25KS,
D245S and all 90 series equipment.
Optional override features are available to allow
electrical switching that blocks feed pump oil
pressure from the remote pressure valve.
Feed override (FOS) feature when actuated

enables the feed pump to maintain maximum
Lower Stacker Valve - Page 49
CHECKING LOWER STACKER VALVE PRES- The absolute maximum pressure for lower
SURE: stacker valves and cylinders are 3000 psi (207
bar). Do not exceed 3000 psi (207 bar)
No Pressure Adjustment Required
Pressure Adjustment Required
Monitor hydraulic pressure gauge on operator
control panels. 1. Perform procedures noted.
When checking the lower stacker valve, relief 2. Locate the lower stacker valve inside the
valve setting stall a leveling jack cylinder in the hydraulic cabinet.
upper most full retract position.
Place the drill/propel mode selector to the drill

mode for D25KS and D245S machines. LOWER STACKER
RELIEF VALVE

lsv
3. Warm hydraulic oil to > 100°F (37.7° C).
4. Turn feed remote pressure valve full CCW

out for minimum pressure.
5. Place feed pump control on partial stroke.

This may be to the first stop position.
6. Move and hold the left rear leveling jack con- 3. When adjusting pressure do so with caution
trol lever forward or up for a retract cylinder and make small increment adjustments up
condition. toward the final setting.
7. Adjust the remote pressure control CW to 4. Adjusting the set screw CW increases the
obtain a system pressure. Continue to adjust system pressure. CCW decreases the sys-
remote pressure valve until the pressure sta- tem pressure available for cylinder working
bilizes at the stacker relief valve pressure pressure.
setting.
When making pressure adjustments a visual
8. Cab mounted hydraulic pressure gauge increase or decrease should be evident on a
should be at 2500 psi (172 bar) pressure test gauge. If there is no change in
pressure value troubleshooting the feed system
As stated prior the feed pump pressure(s) have and/or lower stacker valve may be required.
to be the greater pressure in order for lower
stacker pressure to be obtained.
2500 psi (172) bar is a base pressure for most

machine applications. Under certain machine
! WARNING
weights it may be necessary to increase the Opening a pressurized hydraulic line can
lower stacker relief valve pressure. result in personal injury, death or fire. Never
open a working hydraulic system line during
any phase of operation.
Page 50
The lower stacker valve consists of Leveling jack cylinders use two check valves
with a pilot section separating the extend and
• one inlet section with a relief valve typically retract ports. (POC) represents pilot operated
set at 2500 psi (172 bar) check valves.
• four or five open center manual controlled
spring centered working sections
• one outlet section with return hose to HPR
HPR
Mast raise cylinders use counterbalance valves

in the cylinder barrel base end. There are two
(CB) valves per cylinder and two cylinders per
machine mast. The valve settings differ from
extend and retract working ports.
2500 PSI
LOWER STACKER SCHEMATIC
When servicing individual valve sections inspect

spool seal surfaces, section mating surfaces, o-
ring and back-up seal or quad seal condition,
linkage or cable end alignment and adjust-
ments.
Maintain proper tie rod tension for the specific

manufacture valve assembly.
R
• Commercial Intertech 40 - 45 ft lb
(54 - 61 Nm) E
• Gresen 40 - 45 ft lb (54 - 61 Nm)
• Apitech 50 ft lb (68 Nm)

For accurate results adjustments to the mast
Refer to the appropriate service disassembly raise cylinder counterbalance valves may be
and repair literature. made with a manifold on a test bench only.
Hydraulic systems training module book 4 will
reference cylinder and valve adjustment specs.

AUXILIARY LOWER STACKER VALVE D90KS And 1190E Application
APPLICATIONS
The D90KS stacker application use fixed dis-
The D25KS, D245S and all 90 series applica- placement vane pumps with or without primary
tions differ from the mid range Driltech models. relief valves.
D25KS And D245S Application The following gearbox with vane pumps is an
example of a 1190E machine. Auxiliary gearbox
The manifolds and valve locations are shown on pump locations differ from 90 series machines
the reservoir drawing. in the cooling fan system pump(s) placement on
• Left side manifold LPR the two bottom mounting pads.
• Right side manifold HPR Pump port relief valves as shown can only be
set by momentarily stalling the output oil supply.
• Port 9 slow feed relief valve Do not run the system stalled for long periods of
time. Estimated test time less than 1 minute.
• Port 1 cooling fan relief valve
High pressure drilling applications with a slow HVP2/4

feed system maintain a slow feed relief valve
positioned on the low pressure return manifold
port 9.
This relief setting is 3600 psi (248 bar) set 100

psi (6.9 bar) over the fast feed pump pressure. 1190accpumps
Fast feed pump compensator setting is 3500 psi

ADJUSTABLE RELIEF
(242 bar). Refer to the feed system perfor- VALVE
mance chart when calibrating the fast feed sys-
tem on D25KS and D245S model machines.
When checking lower stacker pressures on

D25KS, D245S machines the highest pressure
are to be noted: PRESSURE TEST PORT
• Slow feed pressure at 3600 psi (248 bar)
• Fast feed pressure at 3500 psi (242 bar) When the pump port relief valve is used it must
be set higher than the lower stacker relief valve
• Remote pressure valve control setting from setting. External 9170 series relief valves are
0 through the range. calibrated to 2600 - 2850 psi (180 - 197 bar).
• Lower stacker relief valve pressure at 2500 In preparation for pump relief valve setting
psi (172 bar) remove the oil supply hose at the lower stacker
valve inlet port. Trace and mark hoses for
Perform the lower stacker pressure test as proper installation later on.
stated on page 50 with the left rear leveling jack
cylinder retracted. Use sufficient #12 hydraulic cap and plug sets
to plug the pump supply hose.
Page 52
Primary Relief Valve Pressure Setting And
Adjustments.
When applicable install a pressure hose and

adequate pressure gauge to the test port pro-
vided on the relief valve manifold. Use a test
gauge with at least 5000 psi (345 bar) capability.
1. Start the machine engine or
2. Start the machine electric motor when appli-

cable (Motor rpm at 1480).
3. Set the engine to high idle speed. LOWER STACKER VALVE

BYPASSING INLET SECTION
4. Quickly check the gauge pressure.
Lower stacker valves will be described in detail
5. Lower the engine idle speed. in the valves and cylinders book 4.
6. Shutdown the machine engine or motor. When setting the lower stacker valve you must
7. Adjust the relief valve in to increase and out • Locate the bypassing inlet section
to decrease the system pressure. Do this
• Identify the bypass inlet relief adjustment
adjustment in small estimated increments.
screw and nut
8. Start the machine engine. • Open the center SAE plug to access the
relief valve adjustment screw. The plug is
9. Set the engine to high idle speed. located center on the bypass inlet screw.
10. Quickly re-check the gauge pressure. • Make adjustments to the center screw
adjustments only when setting lower stacker
11. Final pressure of pump port relief valve relief pressure value.
should be 2600 - 2850 psi (180 - 197 bar)
The following picture is used to illustrate the
12. Lower engine idle speed. lower stacker valve bypassing inlet section of
the 014492 series Apitech valve.
13. Shutdown the machine engine or motor. .
Release hydraulic pressure by opening the air

pressurization ball valve on the hydraulic reser-
voir cover.
Follow safe operating principals when working

with warm oil under pressure.
14. Connect hoses to the lower stacker valve

RELIEF VALVE
inlet port as removed. ADJUSTMENT SCREW
D90KS and 1190 hydraulic cabinets have the APITECH BYPASS INLET VALVE
same valve locations.
Checking Lower Stacker Pressure On D90KS 7. 2500 psi (172 bar) is a base pressure.
And 1190 Machines Machine weight due to options may require
higher lower stacker relief valve pressure
1. Start machine engine. values.
2. Start machine motor if applicable 8. Maximum lower stacker relief valve pressure
is 3000 psi (207 bar).
3. Warm hydraulic oil to > 100°F (37.7°C)
Do not loosen the large lock nut or adjust the
4. Operate left rear leveling jack cylinder con- large thread bypassing inlet valve.
trol up until hydraulic cylinder is in full retract
position. Changing the bypassing inlet adjustment
value will result in:
• Possible loss of oil flow and speed of the cyl-
inder functions
• The loss of working pressure available to

operate the leveling jacks and mast raise
d90opcon cylinders
• Heat generation through the valve adding to

seal failures and excess noise
Test procedures written from Apitech specify the

following set up to be performed on a test bench
in a controlled environment.
Setting of the Bypassing inlet requires a 60 gpm

5. Check lower stacker relief valve setting on (228 lpm) flow meter installed on the outlet hose
operator station hydraulic pressure gauge. connection.
Setting Lower Stacker Pressure On D90KS
FM BYPASSING INLET
And 1190E Machines ADJUSTMENT
1. Follow prior procedures.
2. Remove center position SAE plug from

bypass inlet adjustment nut.
3. Insert allen wrench into bypass nut assem-

bly.
4. Actuate left rear leveling jack control up until

hydraulic cylinder is in full retract position. Install two 500 psi (35 bar) pressure gauges,
one connected into the inlet supply hose and
5. Hold the leveling jack control, monitor one into the outlet return hose.
hydraulic pressure.
When perform this test with the valve mounted
6. Turn adjustment screw in to increase, out to on the machine do so at idle speed and do not
decrease working pressure. operate the stacker valve controls.
Page 54
Adjust the bypassing inlet valve large thread nut
to obtain 200 psi (14 bar) differential deltaP from
inlet to outlet gauge pressure maintaining oil
flow through the outlet.
38 GPM LPR
LPR
#1 PILOT SECTION
PRESSURE REDUCING VALVE
#2 PILOT SECTION FILTER
#4 BYPASS PISTON ASSY 12 GPM
#5 BYPASS ADJUSTMENT
WITH RELIEF VALVE
014492 SERIES INLET VALVE
The lower stacker inlet section receives oil from

two vane pumps. There is a mixing of 38 gpm
(144.4 lpm) and 12 gpm (45.6 lpm) for a com-
bined flow of 50 gpm (190 lpm) for filling the lev-
eling jack and mast raise cylinders.
In neutral mode the 50 gpm (190 lpm) opens the

bypass inlet piston and empties to reservoir with
minimal pressure drop.
When the bypass piston is miscalibrated system

operating pressure can drain to low pressure
return limiting the leveling jack and mast raise
functions.

A reduced pilot pressure is used to enable elec-
tric coil actuation. The pilot section pressure
reducing valve is calibrated to allow 200 psi
(13.8 bar) for the pulsar coils.
Pilot pressure may be tested at the bypass inlet

section PP pilot pressure adapter. The pilot sec-
tion pressure reducing valve is a non adjustable
component.
• excess pressure will damage the pulsar coils

and seals.
• low pressure will affect coil actuation limiting

performance of all work sections.
Cleaning the pilot section filter may be required

when work port sections performance is slow or
inoperable.
Each work section may be manual controlled by

connecting a service tool to the hex screw
within each section.
Each work section have flow limit screws that

may limit spool movement to slow a specific
function.
Page 56
ACCESSORY SYSTEMS • Outlet section (*power beyond plug) with two
return lines
When middle and upper stacker valves are con-

GENERAL
nected in series the middle stacker valve will
This section describes the functions of the have a power beyond plug installed in the outlet
‘upper’ and ‘middle’ stacker valves. section.
The outlet section will have an additional return

DESCRIPTION hose which is relief valve drain to LPR manifold.
All Driltech Mission rigs are equipped with vane Two separate vane pumps supply oil to the mid-
pumps to deliver oil for non-drilling related func- dle and upper stacker valves on larger Driltech
tions. Mission products.
Directional control valves most commonly Upper stacker valve are non drilling accessory
referred to as stacker valves, are actuated by options. Sections may vary according to cus-
the machine operator to enable the vane pump tomer requested options or after market field
oil to run actuators. installations.
Upper stacker valves consist of any combina-

tion of the following options:
• Inlet section with relief valve
• Vee block cylinder (angle drilling)
• Drill pipe support swing cylinder in sequence

8 SECTION with clamp cylinder
MIDDLE STACKER
CONTROL LEVERS • Drill pipe centralizer swing cylinder in
sequence with clamp cylinder
• Dust hood door cylinder
• Dust hood cylinder

Middle stacker valve sections consist of:
• Power tong swing cylinder
• Inlet section with relief valve
• Power tong break-out cylinder
• Drilling air on/off control cylinder
• Power tong clamp cylinder
• Mast lock cylinder(s)
• Outlet section with two return lines.
• Holding wrench (deck wrench) cylinder
Operator consoles may have from 2 to 8 control
• Water injection/dust collector motor(s)
levers that move the section spools of the upper
• Loader swing cylinders stacker valves.
• Loader indexing cylinder Each directional control valve assembly has

one adjustable relief cartridge on the inlet sec-
• Loader locking cylinder tion.
• Winch motor
Accessory Systems - Page 57
Install a 3000 psi (207 bar) pressure gauge in
line or dead headed into a work section.
PRESSURE GAUGE TO
ANY WORK PORT
PRESSURE GAUGE TO
ANY WORK PORT
GRESEN SECTION
COMMERCIAL INTERTECH SECTION
• Components in the accessory system will be STACKER VALVE PRESSURE:

protected by the relief valve.
No Pressure Adjustment Required
• Load moving ability will be affected by the
relief valve and load sense check valve. When machine is shutdown install one appropri-
ate size pressure gauge at any working section
• Motor performance will be limited by the outlet adapter using approved pressure fittings
relief and load sense check valve. and hose. Gauge should be 3000 psi (210 bar).
Adjusting the relief valve CW in will create more • Machines with the hydraulic test station
pressure and may effect the hydraulic compo- option have a pressure hose connection.
nent life.
• Middle stacker pressure may be checked by
selecting HP1 control position 2
Adjusting the relief valve CCW out will decrease
the working ability of the components. It will • Upper stacker pressure may be checked by
generate heat which in turn affects seal life. selecting HP1 control position 3.
The only means of checking accessory systems

are with a pressure gauge installed inline or in a 1. Start machine.
dead head condition.
Maintain proper tie rod tension for machine spe-
cific manufacture valve assemblies. 3. Warm hydraulic oil to > 100° F (37.7° C).
• Commercial Intertech
4. Operate the control handle that has been
• Gresen 32 ft lb (43 Nm) selected as the test section
• Apitech 50 ft lb (68 Nm) 5. The pressure hose and gauge will pressur-
ize to the relief value
Refer to the appropriate service disassembly
and repair literature. 6. Lower the engine idle speed
7. Stop the machine engine or motor
Page 58
8. Disconnect test equipment rate. Adjustments to this valve require connec-
tion of a inline flow meter as shown below.
.
S/N
AIR ON/OFF
SECTION
BEING TESTED
GPM
5000 PSI GAUGE 21.5
TEST PRESSURE
2500 PSI 170 BAR
Driltech Mission products maintain relief valve 2. Set the engine to high idle speed.
settings for the middle and upper stacker valve
accessory components at a base pressure 3. Operate the control handle that has been
between 2200 to 2500 psi (150 -170 bar). selected as the test section.
• Check pressures as needed or at 2000 hour 4. Check both pressure on the gauge and flow
intervals. value through the flow meter.
5. Note the hydraulic oil temperature.

STACKER VALVE PRESSURE
Diagnosing And Troubleshooting When flow values drop 15 to 20 percent under

load it is time to remove the vane pump from
Equipment schematics represent 2500 psi (170 service.
bar). This is a base number and may differ
between drill product line. NOTE!
• Checking flow with a flow meter connected Failure to service the unit may affect other
inline between the pump and directional hydraulic systems. Vane pump oils return to the
control inlet section. HPR/HPS manifolds for feed system replenish-
ment as stated in HPR/HPS system setting sec-
• When checking flow maintain a pressure tion of this manual.
gauge on a working section.
Gator Application Accessory Systems
NOTE!
Gator, D25KS, D245S, and all 90 series The Gator machine uses a flow divider mounted
machines use a 3 port adjustable flow divider to the vane pump outlet port. The flow divider
between the pump output flow and the stacker splits the flow to the base stacker and HPR
valve inlet section. The flow divider cartridge is manifold. Base and feed stacker valves are
a preset valve for either a 21 or 26 gpm flow electro proportional type control valves.

Electrical input allows proportional oil flow for
the desired actuator speeds.
The Gator machines base stacker consists of:
)
• inlet section with relief valve
T
• boom lift - up down T
• boom swing - left right
• feed dump -
• feed tilt - left right
• feed extend - up down
• water injection dust collector
• outlet section with a pilot pressure reducing

valve and power beyond plug
The Gator machine feed stacker consists of:
• inlet section with relief valve
• power tong - swing clamp
• power tong - breakout
• holding wrench - in out GATOR BASE STACKER

• loader swing - in out
• loader lock - in out Manual override and stroke limiting features are
standard components on the Gator machine
• loader rotate - cw ccw base and feed stacker valves.
• centralizer - swing clamp Stroke limiters may be adjusted to provide

smooth speed control for a specific cylinder or
• dust hood - up down, petol wrench
motor circuit.
• outlet section with a pilot pressure reducing
valve and pressure buildup valve 018835-037
COIL RESISTANCE
Operator controls are multi function by means of REDUCED
tram relays (TR) located inside the cab junction PRESSURE
box of Gator machine cabs.
Refer to Electrical Systems Training Module

MANUAL OVERRIDE
Book 2 Gator Testing and Adjusting. SPOOL
COVER
STROKE LIMITER
Page 60
Manual override feature allows testing of the The following picture is used to illustrate the
spool section as a troubleshooting method. middle and upper stacker valve bypass inlet
Adjustment of the manual override CW will section of the 018149 series Apitech valve.
move the specific spool to direct oil into the
actuator.
Gresen 018835 series directional valves are

pilot controlled with a reduced pressure rate of
300 psi (21 bar). Excessive pilot pressure will
damage coils and seals.
The pressure reducing valve is mounted inside

the outlet section and is non adjustable. Pilot
pressure may be taken from a single pressure
MAIN RELIEF VALVE
port on the outlet section.
90 Series Application Accessory Systems

In neutral mode the 12 gpm (45.6 lpm) opens
The 90 series machines uses a flow divider the bypass inlet piston and empties to power
mounted inside the hydraulic cabinet. The flow beyond to be available for the lower stacker
divider splits vane pump flow to the middle and function.
upper stacker sections and HPR manifold.
When the bypass piston is miscalibrated system
operating pressure can drain to low pressure
FLOW DIVIDER return limiting the valve section functions.
A reduced pilot pressure is used to enable elec-

tric coil actuation. The pilot section pressure
reducing valve is calibrated to allow 200 psi
(13.8 bar) for the pulsar coils.
Pilot pressure may be tested at the bypass inlet

section PP pilot pressure adapter. The pilot sec-
tion pressure reducing valve is a non adjustable
component.
• excess pressure will damage the pulsar coils

and seals.
Expected flow to the middle and upper stacker
valve sections is limited to 12 gpm (45.6 lpm). • low pressure will affect coil actuation limiting
Excess flow to HPR is 40 gpm (152 lpm). A flow performance of all work sections.
meter is required to establish proper flow to the
stacker valve sections. Cleaning the pilot section filter may be required
when work port sections performance is slow or
Improper adjustments to the flow divider will inoperable.
lead to operational problems for
Each work section may be manual controlled by
• stacker valve sections connecting a service tool to the hex screw
within each section.
• cylinder application feed system replenish-
ment

Checking Middle Stacker Pressure On 7. 2500 psi (172 bar) is a base pressure.
D90KS And 1190 Machines Machine options differ between models.
Stacker relief valve pressure values may
1. Start machine engine. vary and should not exceed 2500 psi
(172 bar).
2. Start machine motor if applicable
3. Warm hydraulic oil to > 100°F (37.7°C) #2 BYPASS PISTON

#6 RELIEF VALVE CARTRIDGE
4. Operate a single control without pressure #7 PILOT SECTION PRESSURE
REDUCING VALVE WITH FILTER
limiters to stall a hydraulic cylinder in full
retract position.
d90opcon
All middle and upper stacker valves have com-

mon pressure limiters and flow limit adjust-
ments.
Check middle stacker relief valve setting on Dust hood functions use a individual work port
operator station hydraulic pressure gauge. pressure limiter. The dust hood cylinder work
port pressure limiter is calibrated for 1000 psi
Setting Middle Stacker Pressure On D90KS (70 bar) for extend mode only.
And 1190E Machines
1. Follow prior procedures.
2. Remove center position #2 SAE plug from

relief section plug.
3. Insert 5/32 (3.9 mm) allen wrench into

assembly.
4. Actuate control until hydraulic cylinder is in

full retract position.
5. Hold the control, monitor hydraulic pressure.
6. Turn adjustment screw in to increase, out to

decrease working pressure.
Page 62
90 Series Track And Feed Chain System
ACCUMULATOR PRESSURE
625 PSI (43 BAR) N2
TRACK TENSION
PRESSURE REDUCING
400 - 800 PSI
(27.5 - 55 BAR)
LPD
FEED CHAIN TENSION

PRESSURE REDUCING
300 - 400 PSI
(20.7 - 27.5 BAR)
CHAIN TENSION
PRESSURE LIMIT
2000 PSI
(138 BAR)
LSV
Chain tension limit valve is mounted inside the

hydraulic cabinet straight in, top panel. This is
the first pressure value to enable chain tension-
ing when the lower stacker valve is operating
above 2000 psi (138 bar).
As the lower stacker valve is actuated pressure

less than 2000 psi (138 bar) will not generate a
track or feed chain tension mode.

Track tension pressure reducing valve is Feed chain tension pressure reducing valve is
mounted on the machine frame between the mounted inside the hydraulic cabinet on the top
axle and fuel tank, under the front engine panels.
mount.
During routine service feed chain tension may
During routine service track tension may be be relieved by opening the flow control valve
relieved by opening the vent connection inside #38.
the track frame.
350 AND 375 TRACK ASSEMBLIES
Each track assembly use a single accumulator

as a shock absorber for the idler recoil. Dry
nitrogen N2 is the filling gas and should be
check on 1000 hour service intervals. extreme
ambient operating conditions may require more
frequent service intervals.
Page 64
COOLING SYSTEMS The anti-cavitation check valve allows return oil
to enter the motor inlet after the hydraulic sys-
tem stops operation.
GENERAL
Available as individual parts the 017520-001
The following section describes the two types of check valve uses adapters, hoses and swivel
cooling systems used on Driltech Mission rigs. tee adapters to connect the check valve around
A and B ports of the vane motor.
Open loop - Denison vane pump and vane
motor. This open loop system has been the pri- This addition has drastically reduced vane
mary cooling system throughout our equipment motor failure due to cavitation.
history. It has undergone numerous changes to
accommodate the bigger horsepower require- The open loop pump is shown.
ments of the drilling industry.
Closed loop - Sundstrand pump and motor with

pilot control valves. This closed loop system has
been on mid-range machines since 1995 and
has undergone minor changes to the system. D25KW FAN PUMP
WITH RELIEF VALVE TEST
AND TEST PORT PORT
DESCRIPTION
The open loop motor and fan system is shown

below is vane pump and vane motor compo-
nents. The system uses a relief valve, thermal
valve with a bypass check valve and oil cooler.
Pressure test ports may vary from model to
Fan pressure is used as a pilot pressure for var- model however one location that is easy to
ious features in the feed system. access on all products is at the feed system
holding valve pilot port connection as shown.
017520-001 ANTI -
CAVITATION CHECK FEED SYSTEM
VALVE NOT SHOWN HOLDING VALVE
TEST PORT
New factory installed systems have a reverse COOLING FAN PRESSURE

flow check valve connected between the high AT THE RATED HIGH
and low pressure ports of the vane motor. IDLE ENGINE SPEED
Available as a field modification the anti-cavita-

tion check valve assists the motor after machine
shutdown.
Cooling Systems - Page 65

A variable speed cooling system designed in ment, working pressure and fan dimension vary
1995 enables two operating speeds. from machine models.
The concept is: When the pump and motors are specified cor-
rect the air flow across the radiator and oil cool-
• Slow fan speed for starting and cool operat- ers range between 1250 to 1400 CFM.
ing conditions.
• Fast fan speed when drilling conditions Aluminum airfoil and steel engine type fan blade
assemblies are in use. Sizes are as noted.
warm fluids and require additional cooling.
One series of the closed loop pump is shown.

STEEL ALUMINUM
NA 36 IN OD 8 BLADE
4 X .4375 X .125 X 24°
SUNDSTRAND 42 IN OD 8 BLADE 42 IN OD 8 BLADE

CLOSED LOOP 4 X .4375 X .125 X 26°
COOLING FAN PUMP
48 IN OD 8 BLADE 48 IN OD 8 BLADE
4 X .4375 X .125 X 24°
54 IN OD 8 BLADE 54 IN OD 8 BLADE
4 X .4375 X .125 X 19°
NOTE:
It should be observed when working with the
aluminum fan that the two center hubs can be
The closed loop motor and fan system is loosened in order to replace or reposition each
shown. fan blade. Field modifications to the fan blade
pitch is not recommended.
SUNDSTRAND CLOSED
LOOP COOLING FAN The balanced design of the aluminum fan
MOTOR MOUNTED TO A
OVERHANG ADAPTER blades to the fan hub is essential to allow
proper air flow through the coolers.
Proper balance can only be achieved with
• The fan assembly removed from the

machine.
• Placed on a flat horizontal surface
• Precision dial indicator used at each of the

fan tip ends.
Overhang adapters are oil filled and require • Improper balance may lead to fan blade fail-
periodic maintenance. ure at it’s rated speed.
• Improper fan speeds and blade pitch will

FAN TYPES redirect unwanted air back into the cooler
enabling fluid overheating.
Fan speed is the primary concern for either of
the cooling systems. Pump and motor displace- • Fan assemblies are mounted to shafts using
taperlock bushings. Spec 008674-000
Page 66
FAN SPEEDS 3. Position a magnetic photo-tachometer or
use a handheld model.
Check fan speed with reflective tape at the fan
hub. Use any brand name photo-tachometer 4. Start machine engine.
capable of measuring 0 to 2000 rpm.
5. Allow adequate air receiver tank pressure
STEEL ALUMINUM for the type of air compressor system.
36 IN (91 CM) OD 36 IN (91 CM) OD
1600 RPM 1800 - 2200 RPM
42 IN (106 CM) OD 42 IN (106 CM) OD 7. Check the fan circuit pressure.

1400 RPM 1600 RPM
48 IN (122 CM) OD 48 IN (122 CM) OD 8. With the photo-tachometer record the fan
1200 RPM 1400 RPM RPM.
54 IN (137 CM) OD 54 IN (137 CM) OD
1100 RPM 1050 - 1100 RPM 9. Adjust the fan relief valve. CCW adjustment
will decrease the pressure and slow the fan
Steel blade fans 42 inches OD and larger have speed. CW adjustment will increase the fan
a maximum fan tip speed. Do not exceed 1400 pressure and increase the fan speed.
rpm with the 48” and 54” steel engine fan.
10. The pump output flow and the motor dis-
Typical open loop fan system schematic: placement sizes determine the rated speed
at a midrange pressure.
The emphasis is on air flow across the radiator

and oil cooler assemblies and this is achieved
by proper fan speed according to fan type and
dimension.
Factors for a good cooling system:
• Pump shaft speed by means of correct gear-

X )
box ratio
• Pump displacement in GPM (LPM)
• Motor displacement receiving the pump out-

put oil
FIXED VANE PUMP AND MOTOR SYSTEM • Fluid condition
Setting Fan Circuit Pressure For Open Loop • Fan size (OD) outside diameter
Vane Pump/Motor System Fan Speed
• Fan style aluminum vs. steel
1. Install adequate pressure gauge, adapters
The formula for circuit system design
and pressure hose (5000 psi 345 bar).
Pump Displacement X pump shaft speed
2. Clean the center hub of the fan assembly
divided by 231 to find pump output flow in
and place reflective tape on the fan center
(GPM) gallons per minute.
hub.

Pump output flow in GPM at estimated 85% effi- Variable Speed Cooling Fan Systems
ciency X 231 divided by motor displacement to
find motor shaft speed. Applicable machines: GATOR, D40KS, D45KS,
D50KS, D55SP, D60KS, D75KS, D90KS,
It is recommended to maintain a midrange D90KSP, 1190D.
hydraulic pressure such as 2000 to 2500 psi
(140 - 170 bar) for best component life. The system consists of a piston pump and pis-
ton motor in a closed loop application.
Driltech part number, motor designation and
displacements for open loop cooling fan sys- Servo pressure from the pump assembly is con-
tems are shown. trolled through a pressure reducing valve and a
engine mounted thermal valve. Reduced servo
DRILTECH P/N CAM DISPLACEMENT pressure enables minimum pump displacement
for slow fan speed.
001011-011 M4C024 1.49
001011-009 M4C043 2.84 Full servo pressure when the thermal valve
closes enable maximum pump displacement for
001011-010 M4C055 3.59
full fan speed.
001011-012 M4C067 4.34
001011-013 M4C075 4.89 PRESSURE

REDUCING
001978-001 M4D088 5.56 VALVE
001978-003 M4D113 7.12
001978-005 M4D128 8.08
001978-007 M4D102 6.44
001978-009 M4D138 8.81

ORIFICE BALL CHECK
017771-001 M4E153 9.67 SHUTTLE
To assist machine start up modes a 24 vdc sole-

noid is added to the cooling system relief valve.
The relief valve spring chamber drain port is This pressure reducing valve is used to tune the
connected to a normal closed solenoid. This machine for a specific ambient related slow fan
application is referred to as fan bypass. speed.
When the operator turns the key switch on and Adjusting the pressure reducing valve ccw out
applies the bypass switch the fan bypass sole- decreases slow fan speed and in cw increases
noid opens to empty the cooling system relief slow fan speed up to pump stroke limit screw
valve spring chamber to low pressure drain. calibration.
During this condition the relief valve is open
enabling pump flow to empty to high pressure A ball check shuttle valve threaded into the
return. The result is low to no fan rpm during pressure reducing valve port 1 separates
critical engine start modes. reduced servo pressure from maximum servo
pressure.
Upon releasing the bypass switch the fan
should make a noticeable speed increase. A .063 (1.6 mm) restrictor is used in the pres-
sure reducing valve port 2 adapter. The orifice
enables a servo pressure drop for slow fan
speed control.
Page 68
A simplified electronic control system replaces
the pilot valving and engine thermal valve. The
application requires two thermal sensors, one
fan control module, wire connections and a new
pump assembly with electronic displacement
control.
The application is used on Gator and D75EX

machines as of January 2002.
COOLING FAN PERFORMANCE CHART

(VARIABLE SPEED APPLICATION)
Engine thermal valves sense engine water tem- Closed loop piston application
perature as hot water above the engine specific
thermostat is returned to the radiator. MODEL MAIN PUMP CHARGE PUMP
The thermal valve is normal open so servo GATOR 0- 283 - 310 PSI
20 - 21.3 BAR
pressure after the orifice may empty to low pres-
sure drain allowing reduced servo pressure to D40KS 0 - 2600 PSI 283 - 310 PSI
control for a specific slow fan speed. 180 BAR 20 - 21.3 BAR
D45KS 0 - 2600 PSI 283 - 310 PSI

180 BAR 20 - 21.3 BAR
D50KS 0 - 2600 PSI 283 - 310 PSI

180 BAR 20 -21.3 BAR
FLOW METER D55SP 0 - 3600 PSI 262 -315 PSI

OUTPUT FLOW 248 BAR 18.1 - 21.7 BAR
3 - 3.5 GPM
11.4 TO 13.3 LPM D60KS 0 - 3600 PSI 262 -315 PSI
SHUTTLE VALVE 248 BAR 18.1 - 21.7 BAR
AND MOTOR DRAIN D75KS 0 - 3600 PSI 262 -315 PSI
248 BAR 18.1 - 21.7 BAR
D90KS 0 - 3600 PSI 262 -315 PSI

LPR 248 BAR 18.1 - 21.7 BAR
* Due to gearbox ratio this application servo

pressure may exceed 315 psi (21.7 bar).
Maintaining adequate servo pressure is the key

to getting the piston pump to stroke to full dis-
placement.
Conditions that may affect the pump stroke

LPD
capability are noted
• Motor hot oil shuttle valve oil flow capacity

out the motor case drain
• Pressure reducing valve for setting the

desired slow fan speed
VARIABLE SPEED COOLING FAN SYSTEM
• Engine thermal valve position in relation to 11. Expected fan speeds are 1050 to 1200
actual engine temperature (fluid valve or dependent on fan dimension. Refer to the
fluid sensor) previous topics for fan type and sizes.
• When applicable: Compressor thermal valve

position in relation to actual compressor oil
temperature (fluid valve or fluid sensor)
• Cold ambient toggle switch position in cold

run mode (thermal module sensor setting)
CHECKING THE VARIABLE SPEED COOL-

ING FAN SYSTEM (WITH PILOT CONTROL)
No Adjustments Required
1. Place reflective tape on fan assembly hub.
2. Start machine engine. System operating pressure will vary according

to fan speed. The load of the motor as it turns
3. Warm hydraulic oil to >100° F (37.7°C). the fan, cutting air, should allow the hydraulic
pressure to operate between 800 and 2800 psi
4. Place the cold ambient toggle switch in the (55 - 193 bar).
above 40° F mode or normal run mode.
PREPARING TO SET THE VARIABLE SPEED
5. Check fan speed with engine at low idle COOLING FAN SYSTEMS
speed (>1200 rpm).
Tools and test equipment:
6. Expected minimum fan speeds of 350 to 500
rpm with the engine at low idle speed. Due • 0 to 15 GPM (0 - 57 LPM) flow meter with #8
to ambient operating conditions it may hydraulic JIC adapters
become necessary to set the slow fan speed • Short length 24 inch (61 cm) #8 medium
as much as 650 rpm. pressure hydraulic hose
7. Set the engine to high idle speed. • Adjustable wrench, 7/8 (22mm) wrench,
9/16 (14mm) wrench, 1/2 (13mm) wrench,
8. Engine temperature has to be > engine reg- flat blade screwdriver
ulator thermostat range allowing hot coolant
return to the radiator. • #4, #8 JIC hydraulic caps and plugs, #4 JIC
swivel tee
9. Warm the engine coolant by momentarily
• Photo-tachometer, reflective tape
covering the radiator with curtain or card-
board material. Do not operate engine
Mount test equipment into determined hydraulic
coolant to shutdown temperature.
system components. Prepare the machine as
follows:
10. Check fan speed with engine at high idle
and the coolant temperature greater than
1. Install the flow meter into the cooling fan
195 to 200° F (90.5 - 93°C).
motor case drain line.
Page 70
5. Check that the applicable pump stroke lim-
HOT OIL SHUTTLE iter is adjusted out (ccw) as viewed on page
ADJUSTMENT 73 of this manual.
6. Adjust the stroke limiter in 3 (cw) turns prior

to pump start-up.
NOTE!
A toggle switch is operator station mounted. A
thermostat module is used in the Gator inside
the cab - lower right side - rear cover panel.
7. Actuate the cold ambient toggle switch to

cold application or dial thermostat to a set-
ting greater than ambient conditions.
8. Machine is configured to run and calibrate

the fan system.
Troubleshooting the cooling fan system may

require removing a single connection #4 hose
2. Place reflective tape on the fan assembly
from the engine thermal valve stamped ‘IN’.
hub.
3. Secure shuttle valve, loosen lock nut, back

out adjustment ccw to stop. Secure lock nut.
4. Adjust the pressure reducing valve (ccw) to

assure a slow fan speed for start-up. Final
adjustments will be made in a later step.
ADJUST OUT
FOR SLOW FAN
SPEED
Use a #4 JIC cap on the thermal valve adapter

and a #4 JIC plug in the hose. Use a 500 psi (35
bar) pressure gauge in the thermal valve hose
to test fan pump charge pressure.

SETTING THE VARIABLE SPEED COOLING become necessary to set the slow fan speed
FAN SYSTEM (WITH PILOT CONTROL) between 450 and 500 rpm.
Adjustments Required
2. Warm hydraulic oil to >100° F (37.7°C). The

fan may not be turning or turning very slow.
Monitor fluid temperatures, make adjust-
ments as fluid temperatures range between
100° - 195° F. Do not operate machine to a
shutdown condition.
3. Check fan speed with engine at low idle FAN PUMP CHARGE
speed (>1200 rpm). PRESSURE RANGE
4. Adjust the pressure reducing valve (cw) to 10. Actuate the cold ambient toggle switch to
the maximum limit. The pressure reducing normal run application or dial thermostat to a
valve is used to adjust a specific slow fan setting lower than ambient conditions or 40°
speed. F (4° C) for final setting.
NOTE!
The fan should make a noticeable speed VSS/CAS
increase with the adjustment of the pressure
reducing valve. GEARBOX
FRAME
5. Make (cw) adjustment to fan motor hot oil
shuttle valve monitoring fan motor case flow
for 3 to 3.5 gpm (11.4 to 13.3 lpm).
6. Check the motor case drain flow to spec

noted and secure shuttle valve lock nut.
7. When applicable: monitor the pump charge

pressure gauge during the motor case drain Troubleshooting the cooling fan system may
adjustments. require electric diagnostic or routing the two
hoses together bypassing this variable speed
NOTE! solenoid/cold ambient solenoid.
Hot oil shuttle valve setting and excess motor
case drain flow can affect the cooling fan pump 11. Set the engine high idle speed.
charge pressure. Charge pressure is used to
stroke the pump for maximum output flow. 12. Check the engine water temperature, the
charge pressure and the fan speed.
8. Adjust the pressure reducing valve (ccw) for
the final minimum fan speed setting. NOTE!
Maximum fan speed is calibrated at the cooling
9. Expected minimum fan speeds of 350 to 500 fan pump stroke limiter adjustment screw.
rpm with the engine at low idle speed. Due
to ambient operating conditions it may
Page 72
13. Adjust the appropriate stroke limit screw out 17. Check that the charge pressure gauge
(ccw) - non working port side of the pump, zero’s, and relieve hydraulic pressure.
and monitor the fan speed. Refer to the fan
speed charts on page 67. 18. When applicable: remove the pressure
gauge from the #4 hose and cap from the
M46 SERIES
engine mounted thermal valve in port.
19. When applicable: connect the #4 hydraulic

hose to the ‘IN’ port of the engine mounted
thermal valve as original configuration.
20. Remove diagnostic test equipment and

reconfigure machine hoses to original spec.
NOTE!
Driltech drawing 019209 hose assembly is
STROKE LIMITER
RIGHT SIDE shown in spare parts manuals.
Machine is ready to operate under normal oper-

ating conditions. It is recommended to:
ADJUST A PORT MULTI B PORT MULTI FUNCTION
FUNCTION VALVE VALVE AT 0 PSI • restart the machine
• set the engine to high idle speed
• confirm a slow fan speed
• cover the engine radiator momentarily

ADJUST STROKE
LIMIT FOR DESIRED • monitor the engine fluid temperature until
FAN SPEED
the fan speed increases
• switch the cold ambient toggle switch to the
M90 SERIES cold operating condition mode
• monitor the fan speed decrease to the slow

NOTE! fan speed setting made to spec
MPV046 series stroke limiter, torque sealing
lock nut to 4 - 7 ft lb (5.4 - 9.5 Nm) • remove the cover from the engine radiator
MPV090 series stroke limiter, torque sealing
lock nut to 18 ft lb (24 Nm) • switch the cold ambient toggle switch to the
normal operating mode
14. Perform a final check of the fan speed and
charge pressure. Make notes. When troubleshooting the cooling fan system
note the engine and compressor fluid tempera-
15. Idle the engine down to the low idle speed, tures.
verify slow fan speed and charge pressure.
Make notes. If the cooling fan system (pump, motor or con-
trol systems) are at fault both fluid temperatures
16. After an adequate cool down period stop the will be high and may enable a shutdown condi-
machine engine. tion.

Check the cold ambient toggle switch position
as this feature enables constant slow fan speed.
Extreme cold ambient conditions and cold oil

will affect the pilot oil circuit. In extreme cold
applications it may be required to increase the
pressure reducing valve slow fan speed setting.
Service motor overhang adapter with gear and

bearing lubricant appropriate for the ambient
conditions.
SETTING THE TWO SPEED COOLING FAN

SYSTEM (WITH ELECTRONIC CONTROL)
Use system set up procedures noted herein at

this time.
Page 74
02-4-98
PUMP DRIVE 9. Fill with MIL-L-2105C or API-GL-5.
(001003-000) 10. Maximum operating oil temperature:

225°F (107° C).
GENERAL
The type of service and operating conditions Table 1: Lubricant recommendations
will determine the maintenance interval.
However, it is recommended that the oil level Lubricant
Temperature
Grade
be checked weekly, at the same time check
for oil leaks. Because the lubricant system is Below -10°F (-23°C) 75W
the heart of the unit, it is especially important Above -10° °
F and up to 100 F 80W-90
that the oil be kept clean. (37.8°C)
Above 100°F (37.8°C) 85W-140
PREVENTIVE MAINTENANCE .
1. Check unit for operational warning tags. POSITION 1
PUMP
! WARNING PADS
Stop the engine before checking or adding

oil.
2. Clean around oil fill before checking or

adding oil. MAGNETIC
DRAIN
OIL LEVEL PLUG
3. It is recommended that lubricating oil be
changed after the first 50 hours of service. The oil capacity in position 1 is approximately
4-1/2 quarts (4.02 liters).
4. Thereafter, and under normal operating

conditions, it is recommended that the oil be POSITION 2
changed after every 500 hours of operation.
The oil in the unit should be changed when-
ever the oil level shows traces of dirt or
effects of high temperature, evident by dis-
coloration or strong odor.
5. Drain oil while the unit is still warm, exam- PUMP

ining for contamination or metal particles. PADS
MAGNETIC
DRAIN OIL LEVEL
6. Clean all magnetic drain plugs before PLUG
replacing. The oil capacity in position 2 is approximately
7. Always use clean oil in clean containers.
8. Do not overfill. This will result in over- REMOVAL AND DISASSEMBLY

heating and possible malfunction of the unit.
1. Drain the oil as described in the “PRE-
001003-000 SHEET 1 OF 3
02-4-98
VENTIVE MAINTENANCE” topic.
2. Remove the hardware securing the

pumps to the drive and pull the pumps FLANGE
straight back from the pump drive. DRIVEN
SEAL GEAR
3. Disconnect the gearbox driveshaft.
4. Using a suitable lifting device, remove the BEARING

gearbox mounting hardware and lift the gear-
box off of the rig.
DRIVE
SNAP GEAR
5. Position the gearbox so that the pump RINGS 1003-c
pads are facing up.
6. Remove the screws securing the pads to

the housing and remove the pads (note the
location of each pad before removing).
7. Note the location of each of the driven O-RING

gears before lifting the gears and bearings ADAPTER
FLANGE
out of the housing. HOUSING
NOTE!
It may be necessary to tip the gears slightly to 14. Clean the inside of the gearbox housing
clear the drive gear bearing pocket with a suitable solvent.
8. If necessary, pull the bearings off all the

gear hubs.
ASSEMBLY AND INSTALLATION
9. Position the gearbox so that the drive
flange is facing up. 1. Press the bearings on the drive and
driven gear hubs.
10. Remove the nuts securing the flange
housing and adapter to the gearbox. Lift the 2. Lubricate the input flange oil seal before
flange housing off of the gearbox. installing it in the flange housing.
11. Separate the adapter from the gearbox 3. Install the input flange bearing into the
housing and discard the O-ring. flange housing and secure it in place with the
outer snap ring.
12. Lift the drive gear and bearings out of the
housing. 4. Lubricate the shaft of the input flange
before installing it in the flange housing and
13. If necessary, remove the inner and outer securing it with the inner snap ring.
snap rings from the flange housing to remove
the input flange bearing, the flange and the 5. With the drive gear and bearings well
seal. lubricated, install this assembly in the gear-
box housing.
001003-000 SHEET 2 OF 3
02-4-98
6. Check the cleanliness of the input adapter 10. Check the cleanliness of the pump pads
and the gearbox surfaces. Apply a silicone and the gearbox surfaces. Apply a silicone
sealant around the adapter and install it over sealant around the pads and install them
the mounting studs and the drive gear bear- over the driven gear bearings. Tighten the
ing. mounting screws to 150 ft-lbs (202 Nm).
7. Lubricate and install a new O-ring in the 11. Using a suitable lifting device, lift the
adapter before installing the assembled input gearbox on to the rig and install the gearbox
flange and housing. Tighten the mounting mounting hardware.
nuts to 150 ft-lbs (202 Nm).
12. Attach the driveshaft and pumps.
8. Position the gearbox so that the pump
cavities are facing up. 13. Refer to the topic “PREVENTIVE MAIN-
TENANCE” and fill the housing with the rec-
9. With the driven gears and bearings well ommended oil.
lubricated, install these assemblies in the
gearbox housing. Be sure that the gear 14. Start the rig and check for oil leaks.
assemblies are placed in the same position if
they were removed and not replaced with
new ones.
001003-000 SHEET 3 OF 3
02-4-98
001003-000 SHEET 4 OF 3
02-11-97
DOUBLE PILOT CHECK

VALVE (001316-000
The double pilot check valve shown above is

used as a cylinder ‘locking device’ to hold
certain drill components in its last controlled
position. Some of the components you will
find this check valve on includes the holding
wrench and the drill pipe loader. As an
example, when the loader swing control lever
is returned to the ‘neutral’ position, the barrel
loader is ‘locked’ and will not vibrate or drift in
either direction until pressure is applied
through the control valve.
CHECK VALVE
If the cylinder does vibrate or drift out of its (USUALLY LOCATED
last controlled position, the check valve IN HYDRAULIC CABINET)
should be removed, thoroughly cleaned and
inspected. As replacement of component
parts are not recommended, the entire
check valve should be replaced if cleaning
the valve does not completely restore
‘locking’ of the component it is used with.
001316-000 SHEET 1 OF 1
02-11-97
001316-000 SHEET 2 OF 1
3-11-98
PUMP & MOTOR

8
SHAFT AND SEAL 6 7
5
REPLACEMENT 1
3
2
(001329-, 001330-, 002746-, &
002764-000)
4
GENERAL
Two types of shaft seals are used on these
pumps and motors; a seal assembly that
CARBON RING - TYPE SEAL
consists of a spring, rubber bellows, and carbon
ring, or a more typical oil seal.
4D
6
CARBON RING - TYPE SEAL 4A
This procedure applies to the following shaft

seals with seal kit part numbers:
001330-052
4B
001330-223
1
001330-416 4C
003785-061 ITEM 4 DETAIL
4F 4E 3
003785-185
Removal
Disassemble and remove the driveshaft as

follows: Cleaning And Inspection
1. Remove the four screws (8) and gaskets (7) All parts must be inspected and be free of
and remove retainer (6) and the stationary sec- material defects, dirt, scratches or any foreign
tion of seal (4). material.
After cleaning, all parts must be covered with a

! CAUTION light film of clean oil.
Do not scratch the seal surfaces on the shaft
when removing seal (4).
Installation
2. Carefully remove the carbon ring and the
remainder of shaft seal (4) from shaft (1). Install the shaft and seal assembly as follows:
3. Remove snap ring (3) and pull out shaft and ! CAUTION
bearing assembly (1). Remove shim (2) where
applicable. Before installing the shaft seal, exercise
care to ensure that all of the parts fit
001329-000 SHEET 1 OF 3
3-11-98
together properly. If the rubber ring (F), K. Place the seal retainer assembly and O-ring
grips the shaft, spring (D) can disengage the (5) over the shaft with the lapped surface
shell of carbon ring (C). Be sure the shell against the carbon face.
and the band of the carbon ring are properly
engaged before reassembling the seal. L. Place the four gaskets (7) on the four screws
(8) and insert seal retainer (6). Depress the
1. Position the pump with the inlet and outlet seal retainer only far enough to start the four
port block facing down. screws and tighten evenly. Torque to 10 ft. lb.
(13.6 Nm).
2. Lubricate the seal and shaft with clean
hydraulic fluid of the same type that will be used
in the system. Install the assembled shaft and
bearing (1) in the mounting flange and cradle. OIL SEAL - TYPE SHAFT SEAL
Be certain that there are no burrs or sharp This procedure applies to the following shaft seal
edges on shaft seal area of the shaft. with seal kit part number:
001329-273
3. For a rigid shaft application use the shim (2)
that results in least clearance around the shaft
bearing. 1
2
4. Install snap ring (3) in the mounting flange to

retain the shaft assembly. Be certain that the
ring is fully seated in the groove. Use the ring
that results in the tightest fit.
5. Seal assembly (4) is available as a complete

unit only. Assemble the seal as follows: 1329-1s
NOTE !
5 4 3
Seal installation must be completed quickly to 6
avoid the rubber friction ring seizing on the
shaft.
OIL SEAL - TYPE SHAFT SEAL
F. Place spring retainer (E) over the shaft and
against the retaining ring on the shaft assembly.
1. Remove the four screws (1) and gaskets (2)
G. Place spring (D) against retainer (E). and remove retainer (3) and O-ring (5).
H. Apply grease to the inner surface of rubber 2. Remove shaft seal (4) from shaft (6).
friction ring (F) and position the shell containing
the rubber friction ring and carbon ring (C) over 3. Remove socket head screw (7) which
the shaft with the carbon ring exposed. secures the cam to the housing.
I. Apply grease to the square section rubber

seal (A) and install on ceramic seat (B). ! CAUTION
Do not scratch the seal surfaces on the shaft
J. Insert the seat and seal in seal retainer (6) when removing it from the cam.
with the lapped side of the seat in position to
contact the carbon ring. 4. Carefully remove shaft and bearing assem-
bly (6) from the cam.
001329-000 SHEET 2 OF 3
3-11-98
3. Install O-ring (5) into the counterbore in the

housing.
Cleaning And Inspection 4. Using a tapered sleeve tool with an inside

diameter of 1.240 inches (31.5 mm) and an out-
All parts must be inspected and be free of side diameter of 1.395 inches (35.5 mm), install
material defects, dirt, scratches or any foreign seal (4) over the splines of the shaft.
material.
5. Slide seal retainer (3) over the shaft and
After cleaning, all parts must be covered with a against seal (4).
light film of clean oil.
6. Place gaskets (2) over capscrews (1) and
install them. Alternately torque the screws to 50
Installation ft-lbs (68 Nm).
Install the shaft and oil seal as follows:
1. Position the cam on the rotating group so

that the thick part of the cam is at the bottom of
the port block.
2. Insert the small end of shaft and bearing

assembly (6) through the bore of the cam and
into the splines of the cylinder barrel.
001329-000 SHEET 3 OF 3
3-11-98
001329-000 SHEET 4 OF 3
3-12-98
HYDRAULIC PUMP DESCRIPTION

This hydraulic pump is an axial piston pump.
(001330-000) Rotation can be either clockwise or
counterclockwise.
GENERAL
TROUBLESHOOTING
This topic contains a description of the pump, a
troubleshooting table, and instructions for
The following table lists some of the difficulties
replacing the shaft seal and shaft assembly.
which may be experienced with this piston
pump. The table indicates the probable cause
and possible remedies for the problem listed.
Problem Cause Remedy

Noisy Pump Air in Fluid a. Leak in suction line
b. Leak at shaft seal
c. Low fluid level
d. Excessive pressure drop in the inlet line from reservoir
e. Suction line strainer acting as an air trap
Cavitation in pump rotating group a. Fluid too cold

b. Fluid too viscous
c. Fluid too heavy
d. Dirty return filters
Misaligned shaft a. Distrotion in mounting

b. Axial interference
Mechanical failure in pump a. Bearing failure

b. Worn parts in displacement control
High Wear in Pump Excessive loads a. Reduce pressure settings

b. Reduce speeds
Contaminent particles in fluid a. Improper filter maintenance

b. Introduction of dirty fluid into system
c. Dirty reservoir breather
d. Improper hose replacement
Improper fluid a. Fluid too thin or thick for operating range

b. Fluid breakdown
c. Incorrect additives in new fluid
d. Weak additives do to chemical aging
Water in fluid a. Condensation

b. Faulty breather
c. Leaking cooler
d. Incorrect flushing practices
Pressure Shocks Worn relief valve a. Repair
Worn compensator a. Repair
Servo pressure too low to maintain control a. Increase pressure & check pressure drop
Pump barrel blow-off a. Check pump hold-down, drain pressure
001330-000 SHEET 1 OF 3
3-12-98

Heating Fluid Excessive leakage a. Rescheck case drain flow
b. Fluid too thin
Hydraulic reservoir a. Fluid level too low

b. Air in fluid
Relief valve a. Set too low (compared to compensator)
Compensator a. Set too high (compared to relief)
Oil cooler a. Clogged or restricted

b. Reduced efficiency due to scale
c. Intermittent fluid flow

001330-052 Cleaning And Inspection
001330-223
001330-416 All parts must be inspected and be free of
003785-061 material defects, dirt, scratches or any foreign
003785-185 material.

Removal light film of clean oil.

follows:
Installation
1. Remove the four screws (8) and gaskets (7) Install the shaft and seal assembly as follows:
and remove retainer (6) and the stationary sec-
tion of seal (4).
! CAUTION
Before installing the shaft seal, exercise
! CAUTION care to ensure that all of the parts fit
together properly. If the rubber ring (F),
Do not scratch the seal surfaces on the shaft grips the shaft, spring (D) can disengage the
when removing seal (4). shell of carbon ring (C). Be sure the shell
2. Carefully remove the carbon ring and the engaged before reassembling the seal.
remainder of shaft seal (4) from shaft (1).
1. Position the pump with the inlet and outlet
3. Remove snap ring (3) and pull out shaft and port block facing down.
applicable. 2. Lubricate the seal and shaft with clean
001330-000 SHEET 2 OF 3
3-12-98
G. Place spring (D) against retainer (E).

8
6 7 H. Apply grease to the inner surface of rubber
5 friction ring (F) and position the shell containing
3
1 the rubber friction ring and carbon ring (C) over
2 the shaft with the carbon ring exposed.

4
seal (A) and install on ceramic seat (B).
J. Insert the seat and seal in seal retainer (6)

contact the carbon ring.
K. Place the seal retainer assembly and O-ring
(5) over the shaft with the lapped surface
against the carbon face.
4D
6
4A L. Place the four gaskets (7) on the four screws
seal retainer only far enough to start the four
screws and tighten evenly. Torque to 10 ft. lb.
4B (13.6 Nm).
1 4C
ITEM 4 DETAIL H FB
4F 4E 3
DG
bearing (1) in the mounting flange and cradle.
Be certain that there are no burrs or sharp B
edges on shaft seal area of the shaft. VB
C
that results in least clearance around the shaft K 3888-s
bearing. REPLENISHMENT
PILOT
4. Install snap ring (3) in the mounting flange to A

D1
that results in the tightest fit. FA
COMPENSATOR VA KG G V

unit only. Assemble the seal as follows:
PORT PORT
A PRESSURE/RETURN H FROM FILTER - SERVO
NOTE ! B PRESSURE/RETURN PRESSURE
C SUCTION K AUXILLIARY REPLENISHING
Seal installation must be completed quickly to D CASE DRAIN KG SERVO STRAINER &
avoid the rubber friction ring seizing on the DG CASE DRAIN GAUGE
FA CONTROL VENT - “A” SIDE
REPLENISHING TEST
V PRESSURE VENT & TEST
shaft. FB CONTROL VENT - “B” SIDE VA “A” SIDE VENT & TEST
G TO FILTER - SERVO PRESSURE VB “B” SIDE VENT & TEST
F. Place spring retainer (E) over the shaft and PORT IDENTIFICATION
001330-000 SHEET 3 OF 3
3-12-98
001330-000 SHEET 4 OF 3
02-11-97
AIR FILTER
(001658-000)
Table 1: PARTS DESCRIPTION
Q
ITEM T DESCRIPTION
Y
1 1 BODY
2 1 O-RING - 75-024
3 1 WASHER - rubber
4 1 LOUVER
5 1 ELEMENT - 5 micron
6 1 STUD
7 1 VALVE
8 1 INSERT
9 1 O-RING - 75-012
10 1 BODY
11 1 NUT
12 1 ELEMENT KIT - includes items 2, 3 and 5
13 1 FILTER KIT - automatic drain, includes
items 7, 8 and 9
During reassembly, make sure valve lip (7) is

turned down. Use a soft, blunt tool such as a
piece of cardboard to turn lip down. Do not
scratch the bowl surface when turning the
lip down.
Table 2: RECOMMENDED TOQUE

ELEMENT INCH POUNDS
Wash all parts using warm water and soap. STUD (ITEM 6)
Dry parts and blow out internal passages in BOWL (ITEM 1) 5 TO 10
body using clean, dry compressed air. Blow NUT (ITEM 11) 5 TO 8
air through filter element from inside to
outside to dislodge surface contaminants.
Replace filter element when plugged or dirty.
001658-000 SHEET 1 OF 1
02-11-97
001658-000 SHEET 2 OF 1
3-12-98
HYDRAULIC PUMP DESCRIPTION

This hydraulic pump is an axial piston pump.
(002764-000) Rotation can be either clockwise or
counterclockwise.
GENERAL
TROUBLESHOOTING
This topic contains a description of the pump, a
pump. The table indicates the probable cause

Noisy Pump Air in Fluid a. Leak in suction line
c. Low fluid level
d. Excessive pressure drop in the inlet line from reservoir
Cavitation in pump rotating group a. Fluid too cold

c. Fluid too heavy

Mechanical failure in pump a. Bearing failure

b. Worn parts in displacement control
High Wear in Pump Excessive loads a. Reduce pressure settings

b. Reduce speeds


b. Fluid breakdown

b. Faulty breather
c. Leaking cooler
Worn compensator a. Repair
Servo pressure too low to maintain control a. Increase pressure & check pressure drop
Pump barrel blow-off a. Check pump hold-down, drain pressure
002764-000 SHEET 1 OF 3
3-12-98

b. Fluid too thin

b. Air in fluid
Relief valve a. Set too low (compared to compensator)
Compensator a. Set too high (compared to relief)
Oil cooler a. Clogged or restricted

b. Reduced efficiency due to scale
c. Intermittent fluid flow

001330-052 Cleaning And Inspection
001330-223
001330-416 All parts must be inspected and be free of
003785-061 material defects, dirt, scratches or any foreign
003785-185 material.

Removal light film of clean oil.

follows:
Installation
1. Remove the four screws (8) and gaskets (7) Install the shaft and seal assembly as follows:
and remove retainer (6) and the stationary sec-
tion of seal (4).
! CAUTION
! CAUTION care to ensure that all of the parts fit
Do not scratch the seal surfaces on the shaft grips the shaft, spring (D) can disengage the
when removing seal (4). shell of carbon ring (C). Be sure the shell
2. Carefully remove the carbon ring and the engaged before reassembling the seal.
1. Position the pump with the inlet and outlet
3. Remove snap ring (3) and pull out shaft and port block facing down.
applicable. 2. Lubricate the seal and shaft with clean
002764-000 SHEET 2 OF 3
3-12-98

8
6 7 H. Apply grease to the inner surface of rubber
5 friction ring (F) and position the shell containing
3
1 the rubber friction ring and carbon ring (C) over
2 the shaft with the carbon ring exposed.

4
seal (A) and install on ceramic seat (B).

contact the carbon ring.
against the carbon face.
4D
6
4A L. Place the four gaskets (7) on the four screws
seal retainer only far enough to start the four
4B (13.6 Nm).
1 4C
ITEM 4 DETAIL H FB
4F 4E 3
DG
Be certain that there are no burrs or sharp B
edges on shaft seal area of the shaft. VB
C
that results in least clearance around the shaft K 3888-s
bearing. REPLENISHMENT
PILOT
4. Install snap ring (3) in the mounting flange to A

D1
that results in the tightest fit. FA
COMPENSATOR VA KG G V

PORT PORT
A PRESSURE/RETURN H FROM FILTER - SERVO
NOTE ! B PRESSURE/RETURN PRESSURE
C SUCTION K AUXILLIARY REPLENISHING
Seal installation must be completed quickly to D CASE DRAIN KG SERVO STRAINER &
avoid the rubber friction ring seizing on the DG CASE DRAIN GAUGE
FA CONTROL VENT - “A” SIDE
REPLENISHING TEST
V PRESSURE VENT & TEST
shaft. FB CONTROL VENT - “B” SIDE VA “A” SIDE VENT & TEST
G TO FILTER - SERVO PRESSURE VB “B” SIDE VENT & TEST
F. Place spring retainer (E) over the shaft and PORT IDENTIFICATION
002764-000 SHEET 3 OF 3
3-12-98
002764-000 SHEET 4 OF 3
06-02-99
PUMP DRIVE 9. Fill with MIL-L-2105C or API-GL-5.
(003837-000) 10. Maximum operating oil temperature:

225°F (107° C).
GENERAL
The type of service and operating conditions Table 4: Lubricant recommendations
will determine the maintenance interval.
However, it is recommended that the oil level Lubricant
Temperature
Grade
be checked weekly, at the same time check
for oil leaks. Because the lubricant system is Below -10°F (-23°C) 75W
the heart of the unit, it is especially important Above -10° °
F and up to 100 F 80W-90
that the oil be kept clean. (37.8°C)
Above 100°F (37.8°C) 85W-140
PREVENTIVE MAINTENANCE
1. Check unit for operational warning tags.
! WARNING
Stop the engine before checking or adding
oil.
2. Clean around oil fill before checking or

adding oil.
3. It is recommended that lubricating oil be

changed after the first 50 hours of service.
4. Thereafter, and under normal operating

OIL LEVEL
conditions, it is recommended that the oil be
changed after every 500 hours of operation. The oil capacity is approximately
The oil in the unit should be changed when-
ever the oil level shows traces of dirt or
effects of high temperature, evident by dis-
coloration or strong odor.
REMOVAL AND DISASSEMBLY
5. Drain oil while the unit is still warm, exam-
ining for contamination or metal particles. 1. Drain the oil as described in the “PRE-
VENTIVE MAINTENANCE” topic.
6. Clean all magnetic drain plugs before
replacing. 2. Remove the hardware securing the
pumps to the drive and pull the pumps
7. Always use clean oil in clean containers. straight back from the pump drive.
8. Do not overfill. This will result in over- 3. Disconnect the gearbox driveshaft.
heating and possible malfunction of the unit.
003837-000 SHEET 1 OF 3
06-02-99
4. Using a suitable lifting device, remove the 2. Lubricate the input flange oil seal before
gearbox mounting hardware and lift the gear- installing it in the flange housing.
box off of the rig.
3. Install the input flange bearing into the
5. Position the gearbox so that the pump flange housing and secure it in place with the
pads are facing up. outer snap ring.
6. Remove the screws securing the pads to 4. Lubricate the shaft of the input flange
the housing and remove the pads (note the before installing it in the flange housing and
location of each pad before removing). securing it with the inner snap ring.
7. Note the location of each of the driven 5. With the drive gear and bearings well
gears before lifting the gears and bearings lubricated, install this assembly in the gear-
out of the housing. box housing.
NOTE! 6. Check the cleanliness of the input adapter

It may be necessary to tip the gears slightly to and the gearbox surfaces. Apply a silicone
clear the drive gear bearing pocket sealant around the adapter and install it over
the mounting studs and the drive gear bear-
8. If necessary, pull the bearings off all the ing.
gear hubs.
7. Lubricate and install a new O-ring in the
9. Position the gearbox so that the drive adapter before installing the assembled input
flange is facing up. flange and housing. Tighten the mounting
nuts to 150 ft-lbs (202 Nm).
10. Remove the nuts securing the flange
housing and adapter to the gearbox. Lift the 8. Position the gearbox so that the pump
flange housing off of the gearbox. cavities are facing up.
11. Separate the adapter from the gearbox 9. With the driven gears and bearings well
housing and discard the O-ring. lubricated, install these assemblies in the
gearbox housing. Be sure that the gear
12. Lift the drive gear and bearings out of the assemblies are placed in the same position if
housing. they were removed and not replaced with
new ones.
13. If necessary, remove the inner and outer .
snap rings from the flange housing to remove
the input flange bearing, the flange and the
seal.
14. Clean the inside of the gearbox housing

with a suitable solvent. 3837sa
ASSEMBLY AND INSTALLATION

INPUT SHAFT
1. Press the bearings on the drive and
driven gear hubs.
003837-000 SHEET 2 OF 3
06-02-99
10. Check the cleanliness of the pump pads

and the gearbox surfaces. Apply a silicone
sealant around the pads and install them
over the driven gear bearings. Tighten the
mounting screws to 150 ft-lbs (202 Nm).
11. Using a suitable lifting device, lift the

gearbox on to the rig and install the gearbox
mounting hardware.
12. Attach the driveshaft and pumps.
13. Refer to the topic “PREVENTIVE MAIN-

TENANCE” and fill the housing with the rec-
ommended oil.
14. Start the rig and check for oil leaks.
003837-000 SHEET 3 OF 3
06-02-99
003837-000 SHEET 4 OF 3
2-18-92
ACCUMULATOR nitrogen cylinder securely.
(004695-000) 7. The bleeder valve can be used to let out any

gas pressure in excess of desired precharge.
RECHARGING 8. Replace dynaseal and valve guard.
The accumulator charges should be pressure

checked at approximately 100 hour intervals. If
! CAUTION the bladder charge cannot be maintained, , the
complete accumulator must be replaced.
Overcharging the accumulator bladder can
damage the accumulator and hydraulic com-
ponents. Extreme temperatures can result in
incorrect pressure readings. Accumulator
charging should only be done when the
ambient temperature is between 70 and
100°F (21 and 38°C).
1. Exhaust all hydraulic pressure from the sys-

tem.
! CAUTION
DO NOT use oxygen as a charge gas. Dry
nitrogen gas should be used.
2. Remove valve guard and dynaseal.
3. Mount hose assembly gland nut to pressure

regulator.
4. Attach a swivel connector to the gas valve.

Hand tighten sufficiently to compress gasket
swivel connector in order to prevent gas leak-
age.
5. Precharge bladder slowly to about 10 PSIG

before completely tightening the valve stem nut.
Use a second wrench on the valve stem flats to
react the torque applied to the stem nut.
6. Proceed to inflate accumulator to 100 psi (7

bars) by slowly opening the pressure regulator
valve on nitrogen cylinder, closing it occasion-
ally to allow needle on pressure gauge to stabi-
lize (thus giving accurate reading of precharge
pressure). When correct precharge has been
reached, close pressure regulator valve on
004695-000 (SHEET 1 OF 1)
2-18-92
004695-000 (SHEET 2 OF 2)
2-14-97
HYDRAULIC TANK
AIR REGULATION SYSTEM
(004756-000)
PLUG TANK AIR

DRAIN VALVE
VALVE
ASSEMBLY
AIR REGULATOR
AIR RELIEF VALVE
1. Machine must be shutdown and all air regulator. Also reinstall the 30 PSI gauge on
pressure released from hydraulic tank the air regulator valve and remove test gauge
through the air drain valve. from air drain valve.
2. Install 100 PSI gauge in street elbow on 6. Restart engine and check air regulator
air drain valve. Rotate street elbow so gauge setting. Pressure reading should be no more
can be easily read. Remove plug from top of than 3-7 PSI.
air regulator and remove spring and valve
assembly. Replace plug. Remove air gauge 7. Air regulators are preset between 3 and
from air regulator and plug opening. 7 PSI. If excessive reading is obtained
regulator must be replaced.
3. Air relief valve adjusting knob must be
turned counterclockwise (CCW) to allow for
maximum relief before starting engine. Do
not unscrew adjusting knob completely.
4. Start engine and allow compressor

pressure to come up to a minimum of 100 PSI
receiver tank pressure. Adjust air relief valve
to 12-15 PSI by turning adjusting knob
clockwise (CW).
5. Release all air from hydraulic tank and

reinstall valve assembly and spring in air
004756-000 SHEET 1 OF 1
2-14-97
004756-000 SHEET 2 OF 1
6-13-97
HYDRAULIC VANE PUMP The inlet flow feeds through ports on both sides
of the cartridges as well as through a large port
through the cam ring at each suction ramp.
(008172-000) The vanes are held outward in a light but steady

contact against the fluid film which separates
them from the cam ring. Their radial position
GENERAL changes to follow the cam and to adjust for fluid
viscosity, contaminants and component wear.
The following pages cover the description, oper-
ation, removal, maintenance overhaul and The rotor is separated from the side plates by
installation instructions for the vane type the fluid film. The sideplates are clamped axi-
hydraulic pump. ally by an overbalance of the internal pressure
forces in the pumping cartridge. They accom-
modate dimensional changes due to tempera-
DESCRIPTION ture and pressure.
The vane pump consists of six basic compo-

nents: the housing or body, two unitized car- MAINTENANCE
tridges consisting of; a rotor, vanes, vane
holdout pins, cam ring, bearing, port plate and The internal parts of this pump are lubricated by
pressure plate, a shaft and bearing, mounting the operating fluid, therefore, preventative main-
cap and end cap. tenance is limited to keeping the fluid in the sys-
tem clean. Dirt should not be allowed to
END CAP BODY MOUNTING CAP
seal. All fittings and bolts should be tight.
NOTE !
It is especially important that the suction or inlet
piping and fittings be tight and in good repair to
prevent air from being drawn into the system.
In the event the pump does not perform prop-

CARTRIDGES SHAFT & BEARING erly or a malfunction occurs, refer to the “Trou-
bleshooting Chart” before proceeding with an
overhaul.
OPERATION
TROUBLESHOOTING
Operation of this hydraulic pump is as follows:
The rotors, driven by the shaft, carry the vanes
in radial slots. The vanes follow the cam ring
which may be experienced with this vane pump.
through their cycle, two cycles per revolution for
The table indicates the probable cause and pos-
each vane; suction-seal-discharge-seal. The
sible remedies for the problem listed.
rotors are loaded by the vanes only when they
are on the major and minor arcs of the cam con-
tour. Diametrical balance of vanes, ports and
pressures causes the rotors to see only pure
torque loads from the pumping action. The shaft
bearings carry the overhung and axial loads
imposed by the pump drive.
008172-000 (SHEET 1 OF 6)
6-13-97

External Leakage a. Seal failure. a. Replace seal.
b. Porosity in casting. b. Replace casting.
c. Damaged or defective seal between c. Replace seal.
housing and mounting cap.
Leakage at Fittings a. Cracked or damaged flange or fittings. a. Replace flange or fittings.

b. Damaged or defective flange threads. b. Replace flange.
c. Damaged or defective O-ring seal. c. Replace O-ring seal.
d. Burr on mating surfaces. d. Remove burr.
Loss in Pump RPM a. Power source too small for pump being a. Provide larger power source. See HP
Under Load used. requirements for pump being used.
Pump Not Delivering a. Pump does not prime. a. Bleed air from system.
Oil b. Wrong direction on shaft rotation. b. Reverse direction of shaft.
Convert pump to reverse direction of rotation.
(Check rotation arrows on ident. plate & cam
ring.)
c. Tank fluid level too low. c. Add fluid and check level to be certain suction
line is submerged.
d. Fluid inlet line or suction strainer d. Clean strainer of all foreign material.
clogged.
e. Air leak in suction line. e. Tighten and seal connections. Replace seals.
f. Fluid viscosity too heavy to pick up f. Use lighter viscosity fluid.
prime.
g. Broken pump shaft or internal parts. g. Replace damaged parts per overhaul instruc-
tions.
Pump Not Develop- a. Relief valve setting too low. a. Reset relief valve.
ing Pressure b. Relief valve sticking open. b. Check for defective or malfunctioning valve.
c. Vane hold out pins not loading vanes. c. Disassemble and check pins & pin bores for
burrs or damage. Check for foreign material.
d. Free recirculation of fluid to tank being d. Check directional control valve for open cen-
allowed. ter or neutral position. Check for open bypass
valve.
Noisy or Erratic a. Air leak at pump inlet or suction lines. a. Check for air leaks by pouring system fluid
Operation around joints and listen for change in sound
level. Tighten as required.
b. Housing and mounting cap separation. b. Check bolts for poor torque.
c. Restricted or clogged inlet line or c. Clean strainer.
strainer.
d. Excessive pump RPM (cavitation). d. Provide power source that does not exceed
maximum pump RPM recommendations.
e. Worn vanes, cam ring or port plates. e. Replace cartridge.
f. Worn vane holdout pins. f. Replace cartridge.
g. Worn bearings. g. Disassemble and replace.
Seal Failure a. Excessive inlet pressure. a. Decrease inlet pressure, inlet pressure must
not exceed 35 PSI.*
* Except for pumps with S-5 seals. These must not exceed 50 PSI inlet pressure.
VANE PUMP TROUBLESHOOTING TABLE
008172-000 (SHEET 2 OF 6)
6-13-97
REMOVAL and INSTALLATION tion for changing cartridges and changing the
shaft and shaft seals.
The following instructions are general and
should only be used as a guide in removing and Drain all fluid from the pump and thoroughly
installing this component. clean the exterior surface. Prepare a clean, lint
free surface on which to place the internal parts
To remove the pump, proceed as follows: for inspection.
9. Stop the engine and allow the hydraulic oil to

cool. Disconnect the battery ground cable and Changing Cartridges
tag the ignition switch to inform others of the
maintenance taking place. When changing cartridges the following instruc-
tions should be observed.
10. Clean the area around the pump drive and
hose connections. 1. Drain all fluid from pump and thoroughly
clean exterior surface.
11. To prevent hydraulic oil from draining out of
the pump supply lines, either drain the hydraulic 2. Match mark the pump end caps and body.
tank or attach a shop vacuum line to the tank’s Secure the pump in a vise with the shaft
breather opening. Build a vacuum and remove extended down. Clamp the vise on mounting
and cap the pump supply line. cap (3), not on body (2).
12. Tag, disconnect and cap the hoses at the 3. Remove the seven screws (20) and lift off
pump. Plug the pump ports to prevent contami- end cap (1) together with the rear cartridge.
nation. Remove seal (16) form the cap.
13. Securely support the pump with a suitable 4. Remove the rear cartridge assembly (P2)
lifting device before removing the pump attach- from end cap. It may be necessary to use a
ing hardware. gear puller with its arms hooked under the rear
port plate (9). Take care not to damage the
14. Before installing the pump be sure the cam ring or port plate.
mounting sufaces of the pump and pump drive
are clean. 20 2 3
15. Once the pump is installed, fill it with clean

hydraulic fluid.
1
16. Start the machine and check the fittings at

the pump for leakage.
16 9 11 21
OVERHAUL
5. Remove the four screws (21) and separate
center housing (2) from mounting cap (3). The
General shaft assembly and shaft seal parts are
removed with the mounting cap. It may be nec-
The instructions contained in this section cover essary to use a gear puller to remove the front
a complete disassembly, inspection and assem- “P1” cartridge by hooking the arms under front
bly of the pump. Also in this section is informa- port plate (11). Take care not to damage the
008172-000 (SHEET 3 OF 6)
6-13-97
ring or mounting cap. 1. Drain the pump of hydraulic fluid. Secure

the pump in a vise. Clamp the vise on end
6. Place pump body (2) on end and install the cap (1), not on body (2).
new front cartridge in the housing. Lubricate the
O-rings before installation. 2. Remove four screws (21) and separate body
(2) from mounting cap (3). The shaft assembly
7. Install mounting cap (3) with the attached and shaft seal assembly will be removed with
shaft assembly by inserting the shaft through the cap. Remove the cartridge assembly from
the cartridge. Rotate the shaft to engage the cap (3). It may be necessary to use a gear
spline in the rotor. puller with its arms hooked under port plate (11)
to remove the cartridge. Take care not to dam-
NOTE ! age the port plate.
Align the match marks by turning the mounting
cap. 30
2 3
18
8. Install four screws (21) and alternately
tighten two to draw down mounting cap. Torque 4
all four to 158 Nm (118 ft. lbs).
9. Install the rear cartridge in opposite end of

housing. Make certain pin in port plate enters 29
drilled hole in housing. 19
11 17 21
3
3. Remove O-ring (17) from cap (3). Remove

1 retaining ring (19) and press or drive shaft
assembly (4) from the cap. Use a soft faced
hammer and gently tap the end of the shaft.
Remove seal (18) only if it is to be changed.
NOTE !
21
Examine ball bearing (30) for wear before
16
removing it from shaft (4). Apply light pressure
to the outer race and rotate to check for wear or
10. Install seal (16) on end cap. Apply hydraulic cracks and excessive looseness. Remove the
fluid to all seals to assist in assembly. Install bearing from the shaft if damaged. Inspect the
end cap (1) over the cartridge and rotate until shaft for damage, especially the seal surface for
the match marks are aligned. the shaft seal. Omit the next procedure if bear-
ing removal is not required.
11. Install the seven screws and alternately
tighten to draw down the end cap. Torque to 45 4. Remove retaining ring (29) and press bear-
ft. lbs. Fill with approved hydraulic fluid. ing (30) off of shaft (4).
Changing Shaft or Shaft Seal

! CAUTION
Retaining ring (31) must be removed by
Change the shaft or shaft seal as follows: passing over the bearing surface of the shaft
and NEVER over the shaft seal surface. A
008172-000 (SHEET 4 OF 6)
6-13-97
damaged seal surface will cause the shaft

seal to leak.
1 20
5. If removed, install retaining ring (31) in the 61 Nm
(45 Ft-lbs)
groove nearest the input end of shaft (4) by
passing the ring over the output end of the 16
shaft. Do not install it over the input end as P2
this may damage the seal surface next to the P2 CARTRIDGE
groove causing seal leakage.
2
29 3 30
18 S
P1 CARTRIDGE
4
19
31 29 30
19
31 18
17 3
6. Install ball bearing (30) by pressing on the
inner race until the bearing is seated against
retaining ring (31). Install retaining ring (29). P1 21
Make sure both rings are fully seated in their 159Nm
(118 Ft-Lbs)
grooves.
4
7. Using a seal driver, press shaft seal (18) into

mounting cap (3). Grease the seal lips.
8. Install a protective sleeve over the splines of
NOTE ! shaft (4) and then press on the outer race of
The open face of seal must be toward installa- ball bearing (30) until it is installed in mounting
tion tool. If a sealant is not furnished on the cap (3).
O.D. of the seal apply a light coat of approved
sealing compound. Use extreme care not to
deposit any of the sealing compound on the
! CAUTION
seal element or on the shaft. Do not press on the end of shaft (4).
9. Install retaining ring (19) to hold shaft (4) in

place. Make sure ring is fully seated in groove.
10. Place the front cartridge in body (2). Install

O-ring (17) on mounting cap (3) and insert shaft
assembly down through the cartridge engaging
the matching serrations.
008172-000 (SHEET 5 OF 6)
6-13-97
! CAUTION
Take special care the splines of the shaft
and rotor engage smoothly. If necessary
rotate the shaft slightly to obtain this.
2 3
18
29
19
11 17 21
11. Align the match marks and secure cap (3) to

body (2) with screws (21). Torque to 159 Nm
(118 ft. lbs).
008172-000 (SHEET 6 OF 6)
6-18-97
of the cartridge as well as through a large port
(008610-000) through the cam ring at each suction ramp.
The vanes are held outward in a light but steady

GENERAL
changes to follow the cam and to adjust for fluid
ation, removal, maintenance overhaul and
installation instructions for this vane type
The rotor is separated from the side plates by
hydraulic pump.
the fluid film. The sideplates are clamped axi-
ally by an overbalance of the internal pressure
DESCRIPTION
ture and pressure.
This vane pump consists of four basic compo-
nents: the housing or body, a unitized cartridge
consisting of; a rotor, vanes, vane holdout pins,
MAINTENANCE
cam ring, bearing, port plate and pressure plate,
a shaft and bearing, mounting cap.
The internal parts of this pump are lubricated by
the operating fluid, therefore, preventative main-
BODY MOUNTING CAP tenance is limited to keeping the fluid in the sys-
NOTE !
CARTRIDGE SHAFT & BEARING
erly or a malfunction occurs, refer to the “Trou-
OPERATION overhaul.

The rotor, driven by the shaft, carries the vanes TROUBLESHOOTING
through their cycle, two cycles per revolution for The following table lists some of the difficulties
each vane; suction-seal-discharge-seal. The which may be experienced with this vane pump.
rotor is loaded by the vanes only when they are The table indicates the probable cause and pos-
on the major and minor arcs of the cam contour. sible remedies for the problem listed.
Diametrical balance of vanes, ports and pres-
sures causes the rotor to see only pure torque
loads from the pumping action. The shaft bear-
ings carry the overhung and axial loads
008610-000 SHEET 1 OF 5
6-18-97


ring.)
line is submerged.
clogged.
prime.
tions.
valve.
strainer.
not exceed 35 PSI.*
* Except for pumps with S-5 seals. These must not exceed 50 PSI inlet pressure.
008610-000 SHEET 2 OF 5
6-18-97

maintenance taking place. When changing the cartridge the following
instructions should be observed.
the pump supply lines, either drain the hydraulic 2. Match mark the pump mounting cap and
tank or attach a shop vacuum line to the tank’s body. Secure the pump in a vise with the shaft
4. Tag, disconnect and cap the hoses at the 3. Remove the four screws (1) and lift off body
pump. Plug the pump ports to prevent contami- (2). Remove seal (3) from cap (11).
nation.
4. Remove cartridge assembly (4) from mount-
5. Securely support the pump with a suitable ing cap (11). It may be necessary to use a gear
lifting device before removing the pump attach- puller with its arms hooked under cam ring (4E).
ing hardware. Take care not to damage the cam ring or
mounting cap.
6. Before installing the pump be sure the
mounting sufaces of the pump and pump drive 4 4E 2 11
are clean. 1

hydraulic fluid.

4B 3
OVERHAUL
5. On a clean workbench install the new car-
tridge in body (2) making sure that drive lock
General pin (4B) is properly seated.
The instructions contained in this section cover 6. Lubricate the O-rings before installation.
a complete disassembly, inspection and assem- Install mounting cap (11) with the attached
bly of the pump. Also in this section is informa- shaft assembly by inserting the shaft through
008610-000 SHEET 3 OF 5
6-18-97
the cartridge. Rotate the shaft to engage the ing it from shaft (9). Apply light pressure to the
spline in the rotor. outer race and rotate to check for wear or
cracks and excessive looseness. Remove the
NOTE ! bearing from the shaft if damaged. Inspect the
Align the match marks by turning the mounting shaft for damage, especially the seal surface for
cap. the shaft seal. Omit the next procedure if bear-
7. Install four screws (1) and alternately tighten
two to draw down mounting cap. Torque all four 4. Remove retaining ring (6) and press bearing
to 155 Nm (115 ft. lbs). (7) off of shaft (9).
! CAUTION
Changing Shaft or Shaft Seal Retaining ring (8) must be removed by pass-
ing over the bearing surface of the shaft and
Change the shaft or shaft seal as follows: NEVER over the shaft seal surface. A dam-
aged seal surface will cause the shaft seal to
1. Drain the pump of hydraulic fluid. Secure leak.
the pump in a vise. Clamp the vise on mount-
ing cap (11), not on body (2). 5
7
2. Remove four screws (1) and separate body
10
(2) from mounting cap (11). Remove the car-
tridge assembly from the cap. It may be neces-
sary to use a gear puller with its arms hooked
under cam ring (4E) to remove the cartridge.
Take care not to damage the cam ring or
mounting cap. 9
4 4E 2 11
1
6
10
8
11
9
3
5. If removed, install retaining ring (8) in the
5 7 groove nearest the input end of shaft (9) by
passing the ring over the output end of the
shaft. Do not install it over the input end as
3. Remove the mounting cap from the vise and this may damage the seal surface next to the
remove O-ring (3) from cap (11). Remove groove causing seal leakage.
retaining ring (5) and using a soft faced hammer
gently tap the end of the shaft. Remove seal 6. Install ball bearing (7) by pressing on the
(18). inner race until the bearing is seated against
retaining ring (8). Install retaining ring (6).
NOTE ! Make sure both rings are fully seated in their
Examine ball bearing (7) for wear before remov- grooves.
008610-000 SHEET 4 OF 5
6-18-97
7. Using a seal driver, press shaft seal (10) into 10. On a clean workbench install the cartridge in
mounting cap (11). Grease the seal lips. body (2) making sure that drive lock pin (4B) is
properly seated.
NOTE !
The open face of seal must be toward installa- 11. Lubricate the O-rings before installation.
tion tool. If a sealant is not furnished on the Install mounting cap (11) with the attached shaft
O.D. of the seal apply a light coat of approved assembly by inserting the shaft through the car-
sealing compound. Use extreme care not to tridge. Rotate the shaft to engage the spline in
deposit any of the sealing compound on the the rotor.
seal element or on the shaft.
NOTE !
8. Install a protective sleeve over the splines of Align the match marks by turning the mounting
shaft (9) and then press on the outer race of cap.
ball bearing (7) until it is installed in mounting
cap (11). 12. Install four screws (1) and alternately tighten
two to draw down mounting cap. Torque all four
! CAUTION to 155 Nm (115 ft. lbs).
Do not press on the end of shaft (9).

place. Make sure the ring is fully seated.
008610-000 SHEET 5 OF 5
6-18-97
008610-000 SHEET 6 OF 5
10-13-98
HYDRAULIC CYLINDER 4. Remove O-ring (6), wear rings (3) and ‘T’
seal (4) from piston (5). Discard these items.
(020050-000)
5. Remove wear ring (7), seal (12) and wiper
ring (13) from inside gland (11).
REMOVAL
6. Remove O-ring (8), back-up ring (9) and dirt
ring (10) from the outside of gland (11).
1. Tag and disconnect the hydraulic hoses at
the cylinder. Cap the lines and plug the cylinder
ports to prevent the entry of dirt.
Cleaning and Inspection
2. Unpin and remove the cylinder.
1. Clean the threads of the gland and cylinder
3. Clean the outside of the cylinder and place
body with solvent to remove any traces of lock-
the cylinder in a clean work area.
ing compound.
2. Check the piston and gland for nicks or

sharp edges. Polish to remove them.
OVERHAUL
3. Check the cylinder wall for signs of scoring.
NOTE!
Replace if needed.
These procedures were written with the
assumption that the cylinder is to be completely
4. Check the piston rod for distortion. Replace
disassembled and a new seal kit installed.
if needed.
Disassembly
Assembly
1. Support cylinder body (1) at both ends and
using a spanner wrench unthread gland (11).
1. Lubricate each part in clean hydraulic oil
before installing it.
NOTE!
Because of the use of thread compound, it may
2. Install wear ring (7), seal (12) and wiper ring
be necessary to heat the gland to 400°F
(13) in gland (11) as shown.
(205°C) and disassemble hot to break the joint.
2. Place a container under the rod end of cylin- 8 9

der body (1) to catch any oil remaining in the 10
cylinder. Pull the cylinder rod assembly straight 13
out of body (1) to prevent the piston assembly
from scoring the cylinder wall. 22237A1
7 12
3. Unthread and remove piston self-locking nut
(2). Carefully slide piston (5) and gland (11) off
of rod (14).
NOTE!
For models -004, -010, -011, -012, -013, and -
015 spacer (15) should also slide off the piston
rod. 11
020050-000 Sheet 1 of 3
10-13-98
3. Install dirt ring (10), back-up ring (9) and O-

ring (8) on the outside of gland (11) as shown.
4. Lubricate rod (14) with clean hydraulic oil INSTALLATION

and slide the assembled gland assembly on the
rod. 1. Pin the cylinder in place.
NOTE! 2. Remove the plugs from the cylinder ports

For models -004, -010, -011, -012, -013, and - and fill the cylinder with oil.
015, lubricate and install the spacer on the pis-
ton rod. 3. Remove the caps from the hydraulic hoses
and connect the hoses.
5. Check the center groove on piston (5) for
sharp edges. The shoulders of the groove 4. Start the machine and cycle the cylinder to
should have a 15-20° bevel. remove air and check for leaks.
6. Using a dull pick, begin walking ‘T’ seal (4) 5. Retract all hydraulic cylinders and check the
into position in the center groove of piston (5). oil level in the hydraulic reservoir. Add oil of the
type specified in Section 2.
NOTE!
It may be necessary to heat the top ring of the
‘T’ seal in oil or water to 210°F (100°C) to aid in
installing the seal.
7. Install wear rings (3) on the outside of piston

(5) and O-ring (6) on the inside.
8. Lubricate the inside of the piston assembly

with clean hydraulic oil before positioning it on
the end of rod (14).
9. Lubricate the threads of a new self-locking

nut (2). Install the nut on the end of rod (14) and
torque to 90 ft-lbs (122 Nm).
NOTE!
If self-locking nut (2) is being reused, apply Loc-
tite #277 to the threads of the nut before install-
ing it. Allow several hours for the locking
compound to cure.
10. Lubricate the gland and piston assemblies

and the walls of cylinder body (1) with clean
hydraulic oil before installing the piston in the
body.
11. Apply Loctite #277 (red) to the threads of

gland (11) before threading the gland into cylin-
der body (1). Using a spanner wrench, torque
the gland to a minimum of 175 ft-lbs (237 Nm).
020050-000 Sheet 2 of 3
10-13-98
2
3
4
3
20050s4.tif
6
15
7
8
10
11
12
13
14
NOTE!
ITEM 15 IS ONLY USED ON
CYLINDERS -004, -010, -011,
-012, -013, & -015.
020050-000 Sheet 3 of 3
10-13-98
020050-000 Sheet 4 of 3
8-98
HYDRAULIC CYLINDER 4. Apply a 1/4 inch (6 mm) bead of Loctite 277

around one half of the threaded inside diameter
PISTON LOCK KIT of the piston.
(020058-055) 5. Using the table below, determine the piston
torque required.
GENERAL NOTE!
The Loctite compound will begin hardening 4-6
The following instructions apply to hydraulic cyl-
minutes after tightening begins.
inders that use one of the following setscrew
and plug piston lock arrangements listed below. PISTON TORQUE TABLE
This arrangement has been upgraded to con-
TORQUE TORQUE
tain; Loctite 277, Loctite 242, a dog-point set- CYLINDER NUMBER
FT-LBS Nm
screw, and a setscrew and steel shear pin.
020058-055 020049-003 & 004 300 407
020059-061 020051-001 300 407
020064-058
020065-059 020056-001 & 003 300 407
020066-059 020058-001, 2, 3 & 4 350 475
020076-059
020077-057 020059-002 350 475
020089-058 020062-002 300 407
020170-061
020064-002 & 003 300 407
020170-071
020199-059 020065-001 & 002 300 407
020066-001 & 002 300 407

Before beginning the piston to rod assembly
check both parts for nicks and burrs. Clean the 020067-002 300 407
parts and their threads thoroughly. 020070-001 & 002 350 475
020071-001 & 002 350 475

ASSEMBLY 020076-001 & 002 350 475
020077-001 300 407

Assemble the piston to the rod as follows:
020078-001 450 610
1. As required, slide the assembled gland and
020089-001 350 475
spacer (4) on piston rod (10).
020170-001 & 002 220 296
2. Apply a thin film of clean hydraulic oil to the 020199-001 & 003 300 407
piston O-ring before installing it in the piston.
022102-001 300 407
3. Begin threading the piston on to the rod 022111-001 350 475
stopping when 1 inch (25 mm) of threads
remain inside of the piston. 6. Using a spanner wrench, tighten the piston
to the value determined.
NOTE!
To decrease the amount of curing time from 6 7. Locate the setscrew hole in the piston on the
hours to 2, it is recommended that Loctite wear ring groove. Use a 5/16” drill bit, drill 1/8 ±
Primer N be applied to the threads. 1/16 inch (3 mm ± 1.5 mm) deep into the
020058-055 SHEET 1 OF 2
threads of the piston rod. 10. If the steel pin and setscrew are used, drop
the steel pin into the hole. Apply Loctite 242 to
8. Clean the drill shavings out of the hole and the last 3/4 threads of the screw before thread-
insert the dog-point setscrew (2). If this set- ing it into the piston. Torque this setscrew to 18
screw cannot be threaded in far enough to ft-lbs (24.5 Nm) of torque.
enable the piston wear ring to be installed cor-
rectly then the steel pin and setscrew must be 11. Lubricate and install the wear rings and
used. seals over the piston.
9. If the dog-point setscrew (2) can be used, 12. Allow the Loctite to cure for 6 hours, 2 hours
remove it and apply Loctite 242 to the last 3/4 if Loctite N primer was used.
threads before threading it into piston (3).
Torque this setscrew to 18 ft-lbs (24.5 Nm) of
torque.
DOG - POINT
SETSCREW
PISTON O-RING
WEAR RING
20170s1
CYLINDER 020170-002 SHOWN
020058-055 SHEET 2 OF 2
8-1-98
of the cartridges as well as through a large port
(021434-000) The vanes are held outward in a light but steady

GENERAL changes to follow the cam and to adjust for fluid
ation, removal, maintenance overhaul and The rotor is separated from the side plates by
installation instructions for the vane type the fluid film. The sideplates are clamped axi-
hydraulic pump. ally by an overbalance of the internal pressure
DESCRIPTION ture and pressure.
The vane pump consists of six basic compo-

nents: the housing or body, two unitized car- MAINTENANCE
tridges consisting of; a rotor, vanes, vane
holdout pins, cam ring, bearing, port plate and The internal parts of this pump are lubricated by
pressure plate, a shaft and bearing, mounting the operating fluid, therefore, preventative main-
cap and end cap. tenance is limited to keeping the fluid in the sys-
END CAP BODY MOUNTING CAP
NOTE !

CARTRIDGES SHAFT & BEARING erly or a malfunction occurs, refer to the “Trou-
overhaul.
OPERATION
TROUBLESHOOTING
The rotors, driven by the shaft, carry the vanes
which may be experienced with this vane pump.
through their cycle, two cycles per revolution for
each vane; suction-seal-discharge-seal. The
rotors are loaded by the vanes only when they
are on the major and minor arcs of the cam con-
tour. Diametrical balance of vanes, ports and
pressures causes the rotors to see only pure
torque loads from the pumping action. The shaft
bearings carry the overhung and axial loads
021434-000 (SHEET 1 OF 6)
8-1-98


ring.)
line is submerged.
clogged.
prime.
tions.
valve.
strainer.
not exceed 35 PSI.*
* Except for pumps with S-5 seals. These must not exceed 100 PSI (7 bar) inlet pressure.
021434-000 (SHEET 2 OF 6)
8-1-98

maintenance taking place. When changing cartridges the following instruc-
tions should be observed.
the pump supply lines, either drain the hydraulic 2. Match mark the pump end caps and body.
tank or attach a shop vacuum line to the tank’s Secure the pump in a vise with the shaft
4. Tag, disconnect and cap the hoses at the 3. Remove the seven screws (20) and lift off
pump. Plug the pump ports to prevent contami- end cap (1) together with the rear cartridge.
nation. Remove seal (16) form the cap.
5. Securely support the pump with a suitable 4. Remove the rear cartridge assembly (P2)
lifting device before removing the pump attach- from end cap. It may be necessary to use a
ing hardware. gear puller with its arms hooked under the rear
port plate (9). Take care not to damage the cam
6. Before installing the pump be sure the ring or port plate.
mounting sufaces of the pump and pump drive
are clean. 20 2 3

hydraulic fluid.
1

16 9 11 21
OVERHAUL
5. Remove the four screws (21) and separate
center housing (2) from mounting cap (3). The
General shaft assembly and shaft seal parts are
removed with the mounting cap. It may be nec-
The instructions contained in this section cover essary to use a gear puller to remove the front
a complete disassembly, inspection and assem- “P1” cartridge by hooking the arms under front
bly of the pump. Also in this section is informa- port plate (11). Take care not to damage the
021434-000 (SHEET 3 OF 6)
8-1-98
ring or mounting cap. 1. Drain the pump of hydraulic fluid. Secure

the pump in a vise. Clamp the vise on end
6. Place pump body (2) on end and install the cap (1), not on body (2).
new front cartridge in the housing. Lubricate the
O-rings before installation. 2. Remove four screws (21) and separate body
(2) from mounting cap (3). The shaft assembly
7. Install mounting cap (3) with the attached and shaft seal assembly will be removed with
shaft assembly by inserting the shaft through the cap. Remove the cartridge assembly from
the cartridge. Rotate the shaft to engage the cap (3). It may be necessary to use a gear
spline in the rotor. puller with its arms hooked under port plate (11)
to remove the cartridge. Take care not to dam-
NOTE ! age the port plate.
Align the match marks by turning the mounting
cap. 2 3 30
18
8. Install four screws (21) and alternately
tighten two to draw down mounting cap. Torque 4
all four to 158 Nm (118 ft. lbs).
9. Install the rear cartridge in opposite end of

housing. Make certain pin in port plate enters 29
drilled hole in housing. 19
11 17 21
3
3. Remove O-ring (17) from cap (3). Remove

retaining ring (19) and press or drive shaft
1
assembly (4) from the cap. Use a soft faced
hammer and gently tap the end of the shaft.
Remove seal (18) only if it is to be changed.
NOTE !
Examine ball bearing (30) for wear before
16 21
removing it from shaft (4). Apply light pressure
to the outer race and rotate to check for wear or
10. Install seal (16) on end cap. Apply hydraulic cracks and excessive looseness. Remove the
fluid to all seals to assist in assembly. Install bearing from the shaft if damaged. Inspect the
end cap (1) over the cartridge and rotate until shaft for damage, especially the seal surface for
the match marks are aligned. the shaft seal. Omit the next procedure if bear-
11. Install the seven screws and alternately
tighten to draw down the end cap. Torque to 45 4. Remove retaining ring (29) and press bear-
ft. lbs. Fill with approved hydraulic fluid. ing (30) off of shaft (4).
Changing Shaft or Shaft Seal

! CAUTION
Retaining ring (31) must be removed by
Change the shaft or shaft seal as follows: passing over the bearing surface of the shaft
and NEVER over the shaft seal surface. A
damaged seal surface will cause the shaft
021434-000 (SHEET 4 OF 6)
8-1-98
seal to leak.
5. If removed, install retaining ring (31) in the 1 20

groove nearest the input end of shaft (4) by 61 Nm
(45 Ft-lbs)
shaft. Do not install it over the input end as 16
this may damage the seal surface next to the P2
groove causing seal leakage. P2 CARTRIDGE
29 3 30 2
18
S
4
P1 CARTRIDGE
19
31
19 29 30
31 18
17
6. Install ball bearing (30) by pressing on the 3
inner race until the bearing is seated against
Make sure both rings are fully seated in their P1 21
grooves. 159Nm
(118 Ft-Lbs)
4
7. Using a seal driver, press shaft seal (18) into
mounting cap (3). Grease the seal lips.
NOTE ! 8. Install a protective sleeve over the splines of

The open face of seal must be toward installa- shaft (4) and then press on the outer race of
tion tool. If a sealant is not furnished on the ball bearing (30) until it is installed in mounting
O.D. of the seal apply a light coat of approved cap (3).
sealing compound. Use extreme care not to
deposit any of the sealing compound on the
! CAUTION

place. Make sure ring is fully seated in groove.
10. Place the front cartridge in body (2). Install

O-ring (17) on mounting cap (3) and insert shaft
assembly down through the cartridge engaging
the matching serrations.
021434-000 (SHEET 5 OF 6)
8-1-98
! CAUTION
Take special care the splines of the shaft
and rotor engage smoothly. If necessary
rotate the shaft slightly to obtain this.
2 3
18
29
19
11 17 21
11. Align the match marks and secure cap (3) to

body (2) with screws (21). Torque to 159 Nm
(118 ft. lbs).
021434-000 (SHEET 6 OF 6)
3-6-98
HYDRAULIC VANE PUMP of the cartridge as well as through a large port

(021435-000)
The vanes are held outward in a light but steady
GENERAL
changes to follow the cam and to adjust for fluid
ation, removal, maintenance overhaul and
The rotor is separated from the side plates by
the fluid film. The sideplates are clamped axi-
hydraulic pump.
ally by an overbalance of the internal pressure
DESCRIPTION
ture and pressure.
This vane pump consists of four basic compo-
nents: the housing or body, a unitized cartridge
MAINTENANCE
consisting of; a rotor, vanes, vane holdout pins,
cam ring, bearing, port plate and pressure plate,
The internal parts of this pump are lubricated by
a shaft and bearing, and the mounting cap.
tenance is limited to keeping the fluid in the sys-
BODY MOUNTING CAP tem clean. Dirt should not be allowed to
NOTE !
CARTRIDGE SHAFT & BEARING In the event the pump does not perform prop-
overhaul.
OPERATION
Operation of this hydraulic pump is as follows: TROUBLESHOOTING

The rotor, driven by the shaft, carries the vanes
in radial slots. The vanes follow the cam ring The following table lists some of the difficulties
through their cycle, two cycles per revolution for which may be experienced with this vane pump.
each vane; suction-seal & discharge-seal. The The table indicates the probable cause and pos-
rotor is loaded by the vanes only when they are sible remedies for the problem listed.
on the major and minor arcs of the cam contour.
Diametrical balance of vanes, ports and pres-
sures causes the rotor pumping action. The
shaft bearings carry the overhung and axial
loads imposed by the pump drive.
The inlet flow feeds through ports on both sides

021435-000 (SHEET 1 OF 5)
3-6-98


ring.)
line is submerged.
clogged.
prime.
tions.
valve.
strainer.
not exceed 15 PSI* (0.7 bar).
* Except for pumps with S-5 or HP seals. These must not exceed 100 PSI (7 bar) inlet pressure.
021435-000 (SHEET 2 OF 5)
3-6-98

maintenance taking place. When changing the cartridge the following
instructions should be observed.
the pump supply lines, either drain the hydraulic 2. Match mark the pump mounting cap and
tank or attach a shop vacuum line to the tank’s body. Secure the pump in a vise with the shaft
16. Tag, disconnect and cap the hoses at the 3. Remove the four screws (1) and lift off body
pump. Plug the pump ports to prevent contami- (2). Remove seal (3) from cap (11).
nation.
4. Remove cartridge assembly (4) from mount-
17. Securely support the pump with a suitable ing cap (11). It may be necessary to use a gear
lifting device before removing the pump attach- puller with its arms hooked under cam ring (4E).
ing hardware. Take care not to damage the cam ring or
mounting cap.
18. Before installing the pump be sure the
mounting sufaces of the pump and pump drive 4 4E 2 11
are clean. 1

hydraulic fluid.

4B 3
OVERHAUL
5. On a clean workbench install the new car-
tridge in body (2) making sure that drive lock
General pin (4B) is properly seated.
The instructions contained in this section cover 6. Lubricate the O-rings before installation.
a complete disassembly, inspection and assem- Install mounting cap (11) with the attached
bly of the pump. Also in this section is informa- shaft assembly by inserting the shaft through
021435-000 (SHEET 3 OF 5)
3-6-98
the cartridge. Rotate the shaft to engage the outer race and rotate to check for wear or
spline in the rotor. cracks and excessive looseness. Remove the
bearing from the shaft if damaged. Inspect the
NOTE ! shaft for damage, especially the seal surface for
Align the match marks by turning the mounting the shaft seal. Omit the next procedure if bear-
cap. ing removal is not required.
7. Install four screws (1) and alternately tighten 4. Remove retaining ring (6) and press bearing
two to draw down mounting cap. Torque all four (7) off of shaft (9).
to 157 Nm (117 ft. lbs).
! CAUTION
Retaining ring (8) must be removed by pass-
Changing Shaft or Shaft Seal ing over the bearing surface of the shaft and
NEVER over the shaft seal surface. A dam-
Change the shaft or shaft seal as follows: aged seal surface will cause the shaft seal to
leak.
1. Drain the pump of hydraulic fluid. Secure
the pump in a vise. Clamp the vise on mount- 5
ing cap (11), not on body (2). 7
10
2. Remove four screws (1) and separate body
(2) from mounting cap (11). Remove cartridge
assembly (4). It may be necessary to use a
gear puller with its arms hooked under cam ring
(4E) to remove the cartridge. Take care not to
damage the cam ring or mounting cap. 9
4 4E 2 11
1
6
10
8
11
9
3
5. If removed, install retaining ring (8) in the
5 7 groove nearest the input end of shaft (9) by
shaft. Do not install it over the input end as
3. Remove the mounting cap from the vise and this may damage the seal surface next to the
remove O-ring (3) from cap (11). Remove groove causing seal leakage.
retaining ring (5) and using a soft faced hammer
gently tap the end of the shaft. Remove seal 6. Install ball bearing (7) by pressing on the
(18). inner race until the bearing is seated against
NOTE ! Make sure both rings are fully seated in their
Examine ball bearing (7) for wear before remov- grooves.
ing it from shaft (9). Apply light pressure to the
021435-000 (SHEET 4 OF 5)
3-6-98
7. Using a seal driver, press shaft seal (10) into 10. On a clean workbench install the cartridge in
mounting cap (11). Grease the seal lips. body (2) making sure that drive lock pin (4B) is
properly seated.
NOTE !
The open face of seal must be toward installa- 11. Lubricate the O-rings before installation.
tion tool. If a sealant is not furnished on the Install mounting cap (11) with the attached shaft
O.D. of the seal apply a light coat of approved assembly by inserting the shaft through the car-
sealing compound. Use extreme care not to tridge. Rotate the shaft to engage the spline in
deposit any of the sealing compound on the the rotor.
NOTE !
8. Install a protective sleeve over the splines of Align the match marks by turning the mounting
shaft (9) and then press on the outer race of cap.
ball bearing (7) until it is installed in mounting
cap (11). 12. Install four screws (1) and alternately tighten
two to draw down mounting cap. Torque all four
! CAUTION to 159 Nm (117 ft. lbs).

place. Make sure the ring is fully seated.
021435-000 (SHEET 5 OF 5)
3-6-98
021435-000 (SHEET 6 OF 5)
3-5-98
FEED & HOIST CHAIN required depending on local conditions. Ideally

we believe chain maintenance should be done
(001085-000) every 100 hours.
INSPECTION
GENERAL
Inspect the chain for cracks, broken, deformed,
This topic applies to roller chains with the fol-
or corroded parts; and for tight joints or turned
lowing Driltech prefixes: 001085, 002556,
pins. If any are found, find and correct the
002579, 002754, 003884, 005543, 009399, and
cause of the damage, and REPLACE THE
016796.
ENTIRE CHAIN. Even though the rest of the
chain appears to be in good condition, it has
New chain is vacuum lubricated during manu-
been damaged and more failures are likely to
facturing. Lubrication increases chain life by
occur.
reducing wear and helping to prevent corrosion
damage, primarily to the pins. Regular applica-
In most roller chain drives, the chain is consid-
tion of a penetrating oil will restore internal lubri-
ered worn out when it has reached 3% wear
cation and drive out moisture. Heavy oil or
elongation. With 3% wear, the chain does not
grease provides a barrier to dirt and moisture.
engage the sprocket properly and can cause
The benefits of lubrication outweigh the wear
sprocket damage or chain breakage. On drives
that may occur from abrasion resulting from
with large sprockets (more than 66 teeth), allow-
drilling dirt picked up by the oil on the chain.
able wear is limited to 200/N (N = no. of teeth on
largest sprocket) and may be substantially less
Most samples of chain examined after failure
than 3%. On fixed-center, nonadjustable
show signs of corrosion on the pins and side
drives, allowable wear elongation is limited to
bars. The pitting that results from corrosion
about one-half of one chain pitch.
establishes points on the pin surface where
cracks and breaks will occur from shock loads
Measure a representative section of chain and if
or high tensile loads. Lubrication will help pre-
wear elongation exceeds 3% or the functional
vent corrosion and premature chain failure.
limit, REPLACE THE ENTIRE CHAIN. Do not
connect a new section of chain to a worn sec-
tion.
SERVICE INTERVALS
A 250 hour interval is the longest recom-

mended. More frequent intervals may be
LENGTH
MEASURED
1085-0s.fmk
N = NUMBER OF TEETH
001085-000 SHEET 1 OF 2
3-5-98
Driltech Ansi Chain

No. of Nominal At 3% Wear
Chain Part Chain Pitch Inches
Pitches Inches (mm) Inches (mm)
Number Number (mm)
002579- 120 1.500 (38.10) 16 24.00 (610) 24.719 (628)
009399- 140 1.750 (44.45) 14 24.50 (622) 25.250 (641)
001085- 160 2.00 (50.80) 12 24.00 (610) 24.719 (628)
002556- 180 2.250 (57.15) 12 27.00 (686) 27.812 (706)
005543- 200 2.500 (63.50) 10 25.00 (635) 25.750 (654)
003884- 200 2.500 (63.50) 10 25.00 (635) 25.750 (654)
002754- 240 3.000 (76.20) 8 24.00 (610) 24.719 (628)
016796- 240 3.000 (76.20) 8 24.00 (610) 24.719 (628)
Do not run new chain on worn out sprockets between the rollers and pins.
because it can cause the chain to wear rapidly.
The pitch of the new chain is much shorter than 3. Brush heavy oil on all surfaces after applying
the effective pitch of the worn sprocket, so the the penetrating oil. A 40 weight oil or heavier is
total chain load is concentrated on the final recommended, grease can also be used.
sprocket tooth before disengagement. Then,
when the chain disengages from the sprocket,
the roller is jerked out of the hooked portion of
the sprocket tooth and that results in a shock
load on the chain as the load is transferred from
one tooth to the next
MAINTENANCE
Driltech recommends the following chain care

procedures:
! CAUTION
When using compressed air to blow chains
clean, reduce pressure to 30 psi (2 bars) and
wear a face shield.
1. Clean the chains at regularly scheduled

intervals. Blow or brush to clean. We do not
recommend direct pressure or steam washing
because this will remove necessary lubrication.
2. Using a light penetrating oil such as WD-40,

brush or spray the cleaned chains. A spray
application will more effectively penetrate
001085-000 SHEET 2 OF 2
5-29-92
FEED & HOIST CHAINS MAINTENANCE
(001085-001) Driltech Mission recommends the following

chain and sprocket care procedures:
GENERAL ! CAUTION
When using compressed air to blow chains
New chain is vacuum lubricated during manu- clean, reduce pressure to 30 psi (2 bars) and
facturing. Lubrication increases chain life by wear a face shield.
reducing wear and helping to prevent corrosion
damage, primarily to the pins. Regular applica- 13. Clean the chains at regularly scheduled
tion of a penetrating oil will restore internal lubri- intervals. Blow or brush to clean. We do not
cation and drive out moisture. Heavy oil or recommend direct pressure or steam washing
grease provides a barrier to dirt and moisture. because this will remove necessary lubrication.
The benefits of lubrication outweigh the wear
that may occur from abrasion resulting from 14. Using a light penetrating oil such as WD-40,
drilling dirt picked up by the oil on the chain. brush or spray the cleaned chains. A spray
application will more effectively penetrate
Most samples of chain examined after failure between the rollers and pins.
show signs of corrosion on the pins and side
bars. The pitting that results from corrosion 15. Brush heavy oil on all surfaces after applying
establishes points on the pin surface where the penetrating oil. A 40 weight oil or heavier is
cracks and breaks will occur from shock loads recommended, grease can also be used.
or high tensile loads. Lubrication will help pre-
vent corrosion and premature chain failure. 16. Inspect sprocket teeth for wear at reqular
intervals. The bottom sprockets are particularly
susceptible to wear because drilling dirt can
SERVICE INTERVALS accumulate around them. When the bottom
radius between the teeth wears and deepens,
A 250 hour interval is the longest recom- the teeth actually form a wedge that can put tre-
mended. More frequent intervals may be mendous force on the pins and rollers as they
required depending on local conditions. Ideally travel over the sprocket under load. Sprockets
we believe chain maintenance should be done should be inspected and if worn, replaced when
every 100 hours. the chain is replaced.
17. Sprocket shafts must be greased regularly.

INSPECTION At regular intervals check to verify that sprock-
ets are receiving proper lubrication and turning
Inspect the chain for cracks, broken, deformed, freely.
or corroded parts; and for tight joints or turned
pins. If any are found, find and correct the
cause of the damage, and REPLACE THE
ENTIRE CHAIN. Even though the rest of the ADJUSTMENT
chain appears to be in good condition, it has
been damaged and more failures are likely to Adjustment of the feed system chains is accom-
occur. plished as follows:
1. Raise the rotary head to the top of the mast.
001085-001 SHEET 1 OF 2
5-29-92
2. Unlock and lower the mast to the horizontal head, and from the bottom edge of the mast
position. chord to the top of the feed chain as shown.
3. Measurements of the feed chain sag must

be made midway between mast table and rotary
MAST ROTARY HEAD AT

CHORD 1/8 INCH TOP OF STROKE
(3mm)
1085S1.TIF
HOIST CHAIN
PEDESTAL FEED CHAIN
MEASURING CHAIN SAG
001085-001 SHEET 2 OF 2
3-5-98
FEED & HOIST

CHAIN SPROCKETS WORN SPROCKET
MATERIAL
(001085-071)
1085-71S.TIF
INSPECTION
Inspect sprockets for chipped, broken, or

deformed teeth. If any are found, find and cor-
rect the cause of the damage and REPLACE
THE SPROCKET. Sprockets normally are
stronger and less sensitive to damage than
chains, but running a worn chain on new
sprockets can ruin the sprockets in a short time.
This is because a worn chain rides very high on Do not run new chain on worn out sprockets
the sprocket teeth and wears the sprocket teeth because it can cause the chain to wear rapidly.
in an abnormal pattern. The pitch of the new chain is much shorter than
the effective pitch of the worn sprocket, so the
A worn sprocket is not nearly as well defined as total chain load is concentrated on the final
a worn chain. However, there are some sprocket tooth before disengagement. Then,
sprocket characteristics that indicate when a when the chain disengages from the sprocket,
sprocket should be replaced. Check for rough- the roller is jerked out of the hooked portion of
ness or binding when a new chain engages or the sprocket tooth and that results in a shock
disengages the sprocket. Inspect for reduced load on the chain as the load is transferred from
tooth thickness and hooked tooth tips. If any of one tooth to the next.
these conditions are present, the sprocket teeth
are excessively worn and the sprocket should
be replaced.
001085-071 SHEET 1 OF 1
3-5-98
001085-071 SHEET 2 OF 1
CHAIN ADJUSTMENT KIT 015847-000
4-25-98
ROTARY HEAD 4. Disassemble planetary carrier (49) if neces-

sary.
PLANETARY DRIVE
NOTE!
(001004-000) The planetary gears are a matched set. Do not
attempt to mix gears in a carrier.
GENERAL
It is recommended that rebuilding of the rotary

head planetary drive assembly be done in a
machine shop rather than in the field. Refer to
the topic “Rotary Head” for instructions on
removing and installing the rotary head and
planetary drive assemblies.
.
ROTARY HEAD
PLANETARY DRIVE 215
.010” to .030”
(2.5 to 7.5 mm)
20915s1a.tif
BULLSHAFT
INSPECTION
All components should be visually checked for

cracks or other major problems that would elim-
DISASSEMBLY inate their usage in the rebuilding of this assem-
bly. All parts should be checked before starting
1. With the rotary head assembly on blocks in the assembly procedure.
the normal operating position. Block the head
securely and proceed with disassembly.
ASSEMBLY
2. Remove splined coupling (3) from the plane-
tary gearbox. 1. Assemble and install the planetary drive on
gearbox as follows:
3. Remove capscrews (5) from top of planetary
drive and remove planetary cover (6), planetary A. Coat the lower surface of planetary adapter
drive ring (10), planetary carrier (49), and plane- (11) with Loctite gasket eliminator #515
tary adapter (11). (001581-005). Position and align the adapter
001004-000 SHEET 1 OF 2
4-25-98
over bolt holes in the top of the gearbox lid. C. Remove capscrews (5). Holding the plane-
tary assembly, remove end cover (6). Do not
B. Grease quad rings (9) and insert in top move planetary adapter (11).
recess of planetary adapter (11) and on top of
planetary ring gear (10). D. Install 1/32” (.8mm) thick gasket (7) or 1/16”
(1.6mm) thick gasket (8) as required to act as a
C. Place planetary sun gear assembly (49) into spacer on top of planetary drive ring.
adapter (11) and install planetary drive ring (10)
on top of the adapter. Make sure quad rings (9) E. Grease and install quad ring (9) and end
are properly seated. cover (6) and retorque capscrews (5) to 100 ft-
lbs (135 Nm).
D. Place splined coupling (3) in the center of
planetary (49) and rotate the bullshaft to center F. Use the feeler gauge to recheck the clear-
the planetary gear assembly around input pin- ance.
ion.
G. After proper clearance is provided, reinstall
E. Coat the threads of capscrews (5) with Loc- splined coupling (3).
tite 242 and place in position. Tighten the cap-
screws alternately and torque to 100 ft-lbs
(135Nm).
2. Check the clearance of the planetary drive

as follows:
A. Remove splined coupling (3).
B. Using a feeler gauge, check the clearance

between top thrust washer (48) and the bottom
surface of the top end cover ((6). Clearance
should be from .010” to .030” (2.5 to 7.5 mm). If
clearance is less than .010” (2.5 mm) then pro-
ceed as follows:
001004-000 SHEET 2 OF 2
2-11-98
ROTARY HEAD AIR SWIVEL E. Carefully place housing (17) over the
bullshaft and push it onto the bullshaft until the
SEAL REPLACEMENT seals are past the O-ring groove. Grease O-
ring (40) and install on bullshaft through top of
(001111-000) the housing. Check alignment of the packing
and press the housing into place.
ASSEMBLY AND INSTALLATION F. Coat the threads of capscrews (18) with

blue Loctite and tighten the housing down
1. Assemble and install upper swivel housing evenly. Torque to 100 ft- lbs (135Nm).
(17) as follows:
G. Coat both sides of wear bushing (15) with
NOTE! Never Seize or GP grease and place on top of
For additional instructions refer to page 002153- packing (16) previously placed in the bullshaft.
0 in this manual. Place remaining packing (14) on top of wear
bushing (15).
A. Pack and thoroughly grease upper seals
(19). H. Install one spacer (13) on top of upper
packing and install air pipe or flanged hose on
B. Insert seals (19) into housing (17) with the top of seal housing. The use of two bolts is suf-
lip of the top seal (19) facing toward the top of ficient as the flange will be removed after the
the housing and lip of bottom seal (19) towards packing and wear bushing are compressed and
the bottom of the housing. seated. Rotate the bullshaft a few turns by
hand to help seat the packing.
C. Place one packing (16) in the recess on top
of the bullshaft. I. Remove the air flange carefully without dis-
turbing spacer (13). Proper compression of
D. Coat the lower surface of housing (17) with packing will allow the spacer to extend above
orange Loctite. housing (17) .156” to .212” (4 to 5.5 mm) after
13 mm
13 1111S2
15 17 1111S1
14 18
17
16 14
19 16
15
49
19
001111-000 SHEET 1 OF 2
2-11-98
the flange is removed. If the spacer extends

more than .212” (5.5 mm) above the housing,
replace spacer (13) with a thinner spacer and
recheck for proper dimension. Use the spacer
which best meets recommended dimensions.
001111-000 SHEET 2 OF 2
11-09-98
HYDRAULIC MOTOR DESCRIPTION

This hydraulic motor can be either a fixed or
(001329-000) variable displacement, axial piston motor.
Rotation is bi-directional.
GENERAL
TROUBLESHOOTING
This topic contains a description of the motor, a
motor. The table indicates the probable cause
motors; a seal assembly that consists of a
spring, rubber bellows, and carbon ring, or a
more typical oil seal.

Noisy Motor Air in Fluid a. Leak in suction line
c. Low fluid level
d. Excessive pressure drop in the inlet line from
reservoir
Cavitation in motor rotating group a. Fluid too cold

c. Fluid too heavy

High Wear in Motor Excessive loads a. Reduce pressure settings

b. Reduce speeds


b. Fluid breakdown

b. Faulty breather
c. Leaking cooler

b. Fluid too thin

b. Air in fluid
001329-1B SHEET 1 OF 4
11-09-98

This procedure applies to the following shaft 8
6 7
seals with seal kit part numbers: 5
001329-151 3
001330-052 1
2
001330-223
001330-416
003785-061
003785-185 4
Removal
Disassemble and remove the driveshaft as CARBON RING - TYPE SEAL

follows:
1. Remove the four screws (8) and gaskets (7) 4D

and remove retainer (6) and the stationary sec- 6
4A
tion of seal (4).
! CAUTION
Do not scratch the seal surfaces on the shaft 4B
when removing seal (4). 1 4C
ITEM 4 DETAIL
2. Carefully remove the carbon ring and the 4F 4E 3
3. Remove snap ring (3) and pull out shaft and Installation
bearing assembly (1). Remove shim (2) where Install the shaft and seal assembly as follows:
applicable.
! CAUTION
Cleaning And Inspection care to ensure that all of the parts fit
All parts must be inspected and be free of grips the shaft, spring (D) can disengage the
material defects, dirt, scratches or any foreign shell of carbon ring (C). Be sure the shell
material. and the band of the carbon ring are properly
engaged before reassembling the seal.
light film of clean oil. 1. Position the pump with the inlet and outlet
port block facing down.

Be certain that there are no burrs or sharp
edges on shaft seal area of the shaft.
001329-1B SHEET 2 OF 4
11-09-98
3. For a rigid shaft application use the shim (2) 001329-273

bearing.
1
2

1329-1s
NOTE ! 5 4 3

shaft.
A. Place spring retainer (E) over the shaft and
against the retaining ring on the shaft assembly. 1. Remove the four screws (1) and gaskets (2)
and remove retainer (3) and O-ring (5).
B. Place spring (D) against retainer (E).
2. Remove shaft seal (4) from shaft (6).
C. Apply grease to the inner surface of rubber
friction ring (F) and position the shell containing 3. Remove socket head screw (7) which
the rubber friction ring and carbon ring (C) over secures the cam to the housing.
the shaft with the carbon ring exposed.
D. Apply grease to the square section rubber ! CAUTION

seal (A) and install on ceramic seat (B). Do not scratch the seal surfaces on the shaft
when removing it from the cam.
E. Insert the seat and seal in seal retainer (6)
with the lapped side of the seat in position to 4. Carefully remove shaft and bearing assem-
contact the carbon ring. bly (6) from the cam.
F. Place the seal retainer assembly and O-ring

against the carbon face. Cleaning And Inspection
G. Place the four gaskets (7) on the four screws All parts must be inspected and be free of
(8) and insert seal retainer (6). Depress the material defects, dirt, scratches or any foreign
seal retainer only far enough to start the four material.
(13.6 Nm). After cleaning, all parts must be covered with a
OIL SEAL - TYPE SHAFT SEAL Installation

This procedure applies to the following shaft seal Install the shaft and oil seal as follows:
with seal kit part number:
001329-1B SHEET 3 OF 4
11-09-98
1. Position the cam on the rotating group so 5. Slide seal retainer (3) over the shaft and
that the thick part of the cam is at the bottom of against seal (4).
the port block.
6. Place gaskets (2) over capscrews (1) and
2. Insert the small end of shaft and bearing install them. Alternately torque the screws to 50
assembly (6) through the bore of the cam and ft-lbs (68 Nm).
into the splines of the cylinder barrel.

housing.
4. Using a tapered sleeve tool with an inside

side diameter of 1.395 inches (35.5 mm), install
seal (4) over the splines of the shaft.
001329-1B SHEET 4 OF 4
10-9-97
ROTARY HEAD PRESSURE ADJUSTMENT
RELIEF VENT NOTE !

001670-002 relief vents are preset at 5 psi
(001670-002) when shipped from the factory.
Adjustment of the vent requires a low pressure

GENERAL output regulator and an air supply. Adjust the
relief vent as follows:
The following procedures describe the opera-
tion and the adjustment of the rotary head pres- 1. Attach the regulator inlet port to the air sup-
sure relief vent. ply and the assembled relief vent to the oulet
side of the regulator.
DESCRIPTION 2. Before suppling air to the regulator, loosen

the jam nut and turn the adjusting capnut ‘IN’ to
This pressure relief vent is mounted directly or increase pressure.
remotely to the rotary head planetary drive
assembly. Its purpose is to relieve internal FROM AIR SUPPLY
gearbox pressures in excess of 5 psi and to pre-
vent oil from draining out of the gearbox when PEEN THREADS
the mast is in the horizontal position. JAM NUT
If not properly maintained, this vent may stick in

the open position causing gearbox oil to
escape. Excessive internal gearbox pressure
will cause the lower bullshaft seal to leak when
the vent is stuck in the closed position.
The vent should be disassembled and cleaned

every 250 hours of service and replaced every REGULATOR ADJUSTING
1000 hours. Disassembly and assembly should ADJUSTMENT CAPNUT
be as shown below.
3. Start the air supply and make slow adjust-
ments to the regulator adjusting screw to
ROTARY
HEAD
001670-002 Sheet 1 of 2
10-9-97
increase output air pressure to 5 psi.
4. Slowly begin to thread the vent capnut ‘OUT’

until air begins to pass out the vent.
5. Turn the jam nut into the adjusting capnut

and tighten it. Peen (stake) the threads behind
the jack nut to prevent the adjustment from
changing due to vibration.
001670-002 Sheet 2 of 2
10-04-06
ROTARY HEAD each side on the bottom of head. It may be nec-

essary to loosen chains to remove connecting
(002153-000) links.
10. Remove the head assembly from the mast

and thoroughly clean before any further disas-
GENERAL
sembly..
It is recommended that rebuilding of rotary head
assembly be done in machine shop rather than INBOARD
GUIDE SHOES
in the field due to the necessity of a large press
and other equipment required. If forced to
repair in the field, the stocking of a bullshaft and
bearing assembly is highly recommended. 20915s1a.tif
REMOVAL
1. With the mast resting in the horizontal posi-

tion slacken the hoist and feed chains.
2. Raise the mast and remove the top sub from

the bottom connection of bullshaft (42). Lower
the head to the bottom stop of the mast. ROTARY HEAD REMOVAL
3. Remove screws (2) and lift and tie-off motor

(1).
DISASSEMBLY
4. Remove the hose retaining block from the
air piping manifold and remove the air hose. 1. Place the assembly on blocks in the normal
operating position. Block the head securely and
5. Using a suitable container, drain the gearbox proceed with disassembly.
oil by removing plug (35).
2. Remove the air piping manifold, front guide
6. Remove the inboard guide shoes assem- shoes and wear plates.
blies from the rotary head to enable the head to
swing out 3. Remove the air breather hose and cap the
ends of the hose.
7. Remove two of the item (20) socket head
screws from the gearbox lid and attach a lifting 4. Remove splined coupling (3) from the plane-
eye or chain. Reinstall the screws securely. tary gearbox.
8. Attach the winch to hold the head assembly 5. Remove capscrews (5) from top of planetary
in place. If using an alternate source for lifting, drive and remove planetary (6), planetary drive
make sure lifting capacity will safely hold 1500 ring (13) and planetary adapter (11).
lbs (675 kg).
6. Remove capscrews (18) from swivel hous-
9. Remove chain connecting links (34) on the ing (17) and lift the housing vertically to remove.
top of each side of the head at the sixth link up
and also the second chain connecting link on
002153-000 SHEET 1 OF 8
10-4-06
7. Remove capscrews (20) from top lid of gear- top of the bullshaft. Do not apply pressure to
box. thin edge on top of bullshaft. Apply pressure
downward forcing bullshaft out of the bearing.
8. Place two of the removed capscrews (20)
into the jack-screw holes located at each end of 15. Thoroughly clean all gearbox parts.
lid. Tighten the capscrews alternately to lift the
lid from the gearbox housing.
9. Gearboxes equipped with a bearing locknut INSPECTION

will require removal of locknut (28), washer (29),
spacer (30), bearing (31) and bullgear spacer All components should be visually checked for
(32). If the gearbox is not equipped with the cracks or other major problems that would elim-
bearing locknut only spacer (32) should be inate their usage in the rebuilding of this assem-
removed. bly. All parts should be checked before starting
the assembly procedure.
10. Remove capscrews (46) and drop seal
housing (45). If the bullshaft dimensions are within tolerance
but seal surfaces are worn, a sleeve replace-
11. Position the gearbox under a press. Support ment kit can be installed to replace the upper or
the circular portion of the lower gearbox on a lower seal area. See instructions on page no.
piece of heavy wall pipe with 10” (25 cm) ID 009532-0 of this manual.
approximately 9”(22.5 cm) long. Center the
pipe to allow the bearing assembly (39 and 42) After all parts and dimensions have been
to lower into pipe. checked the assembly procedure may be
started. Replace all seals, packings and O-
12. To separate bullshaft (42) from bullgear (33) rings.
will require the use of a torch equipped with a
cherry tip. The bullgear should be heated thor-
oughly from the center out for a least 4 inches Dimensions and Tolerances
(10 cm) to 400°F (204°C). Place a heavy wall
1-1/2” (3.75 cm) pipe coupling into the recess in Dimensional tolerances of the bullshaft (42) at
top of bullshaft. Press the bullshaft downward the bullgear seat and bullgear ID (33) are criti-
until the bullgear is freed from bullshaft. Care cal. These parts are shrink fit to ensure that the
must be taken to be sure no pressure is bullgear will remain in position during operation.
applied to thin edge on top of the bullshaft.
If your rotary head uses a bullshaft that does not
13. Lift gearbox (22) over bullshaft (42). use the bearing and locknut arrangement, we
recommend that you replace it at this time.
14. Check main thrust bearings (39). If neces-
sary remove as follows: Bearing and bullshaft assemblies are available
to replace bullshafts that do not include the top
A. Unlock tab lockwasher (37) and remove bearing locknut.
locknut (36), and keyed washer (38). Locknut
may have to be heated to facilitate removal. NOTE!
Use of the bullshaft with the locknut also
B. Set the lower end of bullshaft (42) into heavy requires the replacement of swivel housing (17).
wall pipe 6” (15 cm) ID X 9” (22.5 cm) long, rest-
ing on the cone of bearing (39). Place a heavy
wall 1-1/2” (3.75 mm) coupling in the recess on
002153-000 SHEET 2 OF 8
10-04-06
UPPER BEARING BORE
BEARING BORE DEPTH

ROTARY HEAD
HOUSING
BULLGEAR BORE
2153S1B.TIF
MAIN THRUST BEARING BORE
BULLSHAFT
(BEARING & LOCKNUT STYLE)
UPPER SEAL SURFACE
UPPER BEARING SURFACE
BULLGEAR SURFACE
MAIN THRUST BEARING SURFACE
LOWER SEAL SYRFACE
LOWER SEAL
LOWER SEAL
HOUSING
002153-000 SHEET 3 OF 8
10-4-06
2153s1a.tif
002153-000 SHEET 4 OF 8
10-04-06
ASSEMBLY A. Thoroughly clean and remove nicks and

burrs from seal housing (45).
1. Main thrust bearing (39) should be cleaned
and ready for assembly and at normal room B. Grease and pack lower seals (43) thor-
temperature. oughly with #2 EP grease.
NOTE! C. Assemble both seals with lip up as inserted

Bearing spacers are ground to match the bear- into seal housing.
ing as a set. Do not mix bearings or spacers in
other bearing assemblies. D. Press seals firmly into place using 6-1/2”
(16.25 cm) OD plate.
2. Assemble main thrust bearing (39) to the
bullshaft (42) as follows: E. Grease O-ring (44) and install it in the
groove in lower seal housing (45).
A. Heat bearing assembly (39) in oil or an
oven for one 1-1/2 hours at 300°F (149 C°). F. Grease the lower seal surface of bullshaft
Check with temperature stick. (42).
B. Thoroughly clean bullshaft (42). All nicks 4. Install bullshaft (42) in gearbox housing (22)
and burrs must be removed before assembly. as follows:.
! CAUTION A. Thoroughly clean the upper and lower bear-

ing cavities in the gearbox housing. These
Make sure bearing assembly (39) is installed areas must be absolutely clean and free of any
as shown in the exploded view drawing. nicks or burrs.
C. Install the bearing on the bullshaft. The B. Carefully place bullshaft assembly in the
bearing must seat firmly on the bullshaft shoul- center of lower seal housing (45).
der.
C. Place bearing cup (23) into the lower input
D. Allow bearing and bullshaft to cool to nor- pinion bearing bore and lightly tap or press into
mal room temperature. place firmly.
E. Position the bullshaft with bearing assem- D. Place gearbox (22) over bullshaft (42) and
bled under a press. Place a 5-1/2” (13.75 cm) main thrust bearings (39).
ID pipe X 9” (22.5 cm) long carefully over
bullshaft resting on top of bearing assembly E. Coat threads of capscrews (46) with Loctite
(39). Press with force of 25 to 50 tons (22,500 No. 242 (part no.001581-001).
to 45,000 kg) to ensure the bearing is properly
seated. The bearing should be free to rotate F. Lift lower seal housing (45) up over bullshaft
without axial movement of the bearing cup. (42). Make sure that seals are not folded over
or damaged and that O-ring (44) does not drop
F. Install washer (38), tang washer (37) and out of the housing groove.
locknut (36). Tighten as tight as possible and
lock in place. G. Install capscrews (46) and alternately
torque to 100 ft-lbs (135Nm) for all 1/2”grade 5
3. Install seals (43) in lower seal housing (45) screws, 115 ft- lbs (155 Nm) for all 5/8” grade 8
as follows: screws, and 120 ft-lbs (163 Nm) for all 1/2”
grade 8 screws.
002153-000 SHEET 5 OF 8
10-4-06
NOTE! D. Position bullgear (33) over bullshaft (42). A

A gap of 1/8”(3.1mm) between seal housing press should be available in case the bullgear
(45) and gearbox (22) is normal. does not completely seat to the shoulder on the
bullshaft.
H. If all instructions have been followed the
bullshaft should rotate without any noticeable E. Place lower input pinion bearing cone (24)
end play. into bearing cup (23). Place input pinion (25)
into lower input bearing cone. The gears must
5. Install input pinion bearings (24 & 26) as fol- be meshed properly for proper installation and
lows: the pinion lightly tapped until seated.
A. Heat bearing cones (24) and (26) in oil or F. Place gearbox spacer (32) over bullshaft on
oven for one hour at 300°F (149°C). top of bullgear.
B. Slide bearing cone (26) over the splined G. Place top bullshaft bearing (31) on bullshaft
end of input pinion (25). Make sure the bearing and tap inner race until tight against spacer or
is completely seated on the shoulder. shouldered.
C. Leave the remaining bearing cone (24) in oil H. Gearboxes using bullshafts with bullgear
or oven until after bullgear(33) is installed. locknuts must have lockwasher (29) and locknut
(28) installed and tightened as tight as possible.
6. Assemble and install bullgear (33) as fol-
lows:. 7. Assemble and install gearbox lid (21) as fol-
lows:
! CAUTION A. Thoroughly clean gearbox lid (21). All nicks
Tapped holes (5/8-11 UNC) in top of bullgear and burrs must be removed.
(33) are for lifting eyes only. Do not attempt
to use these for any purpose other than B. Install bearing cup (27) into the upper pinion
lifting the bullgear. opening and tap into place.
A. Bullgear (33) must be heated in oil or an C. Coat the sealing surfaces of gearbox (22)
oven for 5 hours at 425°F (218°C). The use of a with Loctite No. 515 (001581-005).
temperature stick is recommended to assure
the bullgear is completely heated at proper tem- D. Coat threads of capscrews (20) with Loctite
perature No. 242 (001581-001) and install lid (21). Pull
the lid down evenly and torque the capscrews to
B. Place steel key (41) in bullshaft. 200 ft. lbs (272 Nm).
NOTE! E. Gearboxes built with an inspection plug in
Do not substitute any soft steels for key. Key lid can be used to measure from the top of the
material must be AISI 4140 HT. bullgear to the top of the lid to ensure the
bullgear is not moving on the shaft. The mea-
C. Coat the surface of bullgear surface of surement should be same as the measurement
bullshaft (42) must be “X” with Loctite 680 com- stamped near the inspection hole.
pound (001581-006).
8. Assemble and install the planetary drive on
C. Make sure lower input pinion cup (23) has gearbox as follows:
been installed.
002153-000 SHEET 6 OF 8
10-04-06
A. Coat the lower surface of planetary adapter ance.

(11) with Loctite gasket eliminator #515
(001581-005). Position and align the adapter G. After proper clearance is provided, reinstall
over bolt holes in top of gearbox lid (21). splined coupling (3).
B. Grease quad rings (9) and insert in top 10. Assemble and install upper swivel housing
recess of planetary adapter (11) and on top of (17) as follows:
planetary ring gear (10).
NOTE!
C. Place planetary sun gear assembly (49) into For additional instructions refer to page 001111-
adapter (11) and install planetary drive ring (10) 0 in this manual.
on top of the adapter. Make sure quad rings (9)
are properly seated. A. Pack and thoroughly grease upper seals
(19).
D. Place splined coupling (3) in the center of
planetary (49) and rotate the bullshaft to center B. Insert seals (19) into housing (17) with the
the planetary gear assembly around input pin- lip of the top seal (19) facing toward the top of
ion (25). the housing and lip of bottom seal (19) towards
the bottom of the housing.
E. Coat the threads of capscrews (5) with Loc-
tite 242 and place in position. Tighten the cap- C. Place one packing (16) in the recess on top
screws alternately and torque to 100 ft-lbs of bullshaft (42).
(135Nm).
D. Coat the lower surface of housing (17) with
9. Check the clearance of the planetary drive orange Loctite.
as follows:
E. Carefully place housing (17) over bullshaft
A. Remove splined coupling (3). (42) and push it onto the bullshaft until the seals
are past the O-ring groove. Grease O-ring (40)
B. Using a feeler gauge, check the clearance and install on bullshaft through top of the hous-
between top thrust washer (48) and the bottom ing. Check alignment of the packing and press
surface of the top end cover ((6). Clearance the housing into place.
should be from .010” to .030” (2.5 to 7.5 mm). If
clearance is less than .010” (2.5 mm) then pro- F. Coat the threads of capscrews (18) with
ceed as follows: blue Loctite and tighten the housing down
evenly. Torque to 100 ft- lbs (135Nm).
C. Remove capscrews (5). Holding the plane-
tary assembly, remove end cover (6). Do not G. Coat both sides of wear bushing (15) with
move planetary adapter (11). Never Seize or GP grease and place on top of
packing (16) previously placed in bullshaft (42).
D. Install 1/32” (.8mm) thick gasket (7) or 1/16” Place remaining packing (14) on top of wear
(1.6mm) thick gasket (8) as required to act as a bushing (15).
spacer on top of planetary drive ring.
H. Install one spacer (13) on top of upper pack-
E. Grease and install quad ring (9) and end ing and install air pipe or flanged hose on top of
cover (6) and retorque capscrews(5) to 100 ft- seal housing. The use of two bolts is sufficient
lbs (135 Nm). as the flange will be removed after the packing
and wear bushing are compressed and seated.
F. Use the feeler gauge to recheck the clear- Rotate the bullshaft a few turns by hand to help
002153-000 SHEET 7 OF 8
10-4-06
seat the packing. center of the gearbox.
I. Remove the air flange carefully without dis- D. Coat the threads of capscrew (2) with Loc-
turbing spacer (13). Proper compression of tite (001581-001) and tighten evenly to approxi-
packing will allow the spacer to extend above mately 100 ft- lbs (135 Nm) of torque.
housing (17) .156” to .212” (4 to 5.5 mm) after
the flange is removed. If the spacer extends E. Reinstall the air vent hose. (Delay tighten-
more than .212” (5.5 mm) above the housing, ing of one end of hose until gearbox is filled with
replace spacer (13) with a thinner spacer and oil to let trapped air escape.)
recheck for proper dimension. Use the spacer
which best meets recommended dimensions. 4. Remove the planetary case fill plug and fill
gearbox (22) through fill opening with approxi-
mately 22 quarts (20.5 l) of EP 90 gear case oil.
13
5. Refill the planetary assembly until the oil
level is at the top of planetary ring gear (10).
17
14 6. Oil level must be checked a minimum of one
time per week.
15
16
7. Drain, flush and refill gear case every 6
40
months.
19
1111s1.tif 8. Adjust the chain tension as required.
SWIVEL PACKING
INSTALLATION
1. Position the rotary head assembly in the

mast.
2. Reconnect the chains and install the guide

shoes assemblies.
3. Install the rotary head drive motor as follows:
A. Grease and install O-ring (4) (component of

the planetary drive) into the top of planetary
cover (6).
B. Splined adapter (3) must be in the planetary

drive.
C. Position motor (1) on top of planetary drive

with the motor case drain outlet towards the
002153-000 SHEET 8 OF 8
11-09-98
HYDRAULIC MOTOR DESCRIPTION

This hydraulic motor can be either a fixed or
(002746-000) variable displacement, axial piston motor.
Rotation is bi-directional.
GENERAL
TROUBLESHOOTING
This topic contains a description of the motor, a
motor. The table indicates the probable cause
motors; a seal assembly that consists of a
spring, rubber bellows, and carbon ring, or a
more typical oil seal.

Noisy Motor Air in Fluid a. Leak in suction line
c. Low fluid level
d. Excessive pressure drop in the inlet line from
reservoir
Cavitation in motor rotating group a. Fluid too cold

c. Fluid too heavy

High Wear in Motor Excessive loads a. Reduce pressure settings

b. Reduce speeds


b. Fluid breakdown

b. Faulty breather
c. Leaking cooler

b. Fluid too thin

b. Air in fluid
002746-000 SHEET 1 OF 4
11-09-98

This procedure applies to the following shaft 8
6 7
seals with seal kit part numbers: 5
001329-151 3
001330-052 1
2
001330-223
001330-416
003785-061
003785-185 4
Removal
Disassemble and remove the driveshaft as CARBON RING - TYPE SEAL

follows:
1. Remove the four screws (8) and gaskets (7) 4D

and remove retainer (6) and the stationary sec- 6
4A
tion of seal (4).
! CAUTION
Do not scratch the seal surfaces on the shaft 4B
when removing seal (4). 1 4C
ITEM 4 DETAIL
2. Carefully remove the carbon ring and the 4F 4E 3
3. Remove snap ring (3) and pull out shaft and Installation
bearing assembly (1). Remove shim (2) where Install the shaft and seal assembly as follows:
applicable.
! CAUTION
Cleaning And Inspection care to ensure that all of the parts fit
All parts must be inspected and be free of grips the shaft, spring (D) can disengage the
material defects, dirt, scratches or any foreign shell of carbon ring (C). Be sure the shell
material. and the band of the carbon ring are properly
engaged before reassembling the seal.
light film of clean oil. 1. Position the pump with the inlet and outlet
port block facing down.

Be certain that there are no burrs or sharp
edges on shaft seal area of the shaft.
002746-000 SHEET 2 OF 4
11-09-98

bearing. 2
1


unit only. Assemble the seal as follows: 1329-1s
NOTE ! 5 4 3

shaft.
F. Place spring retainer (E) over the shaft and
against the retaining ring on the shaft assembly. 1. Remove the four screws (1) and gaskets (2)
and remove retainer (3) and O-ring (5).
2. Remove shaft seal (4) from shaft (6).
H. Apply grease to the inner surface of rubber
friction ring (F) and position the shell containing 3. Remove socket head screw (7) which
the rubber friction ring and carbon ring (C) over secures the cam to the housing.
the shaft with the carbon ring exposed.
I. Apply grease to the square section rubber ! CAUTION

seal (A) and install on ceramic seat (B). Do not scratch the seal surfaces on the shaft
when removing it from the cam.
with the lapped side of the seat in position to 4. Carefully remove shaft and bearing assem-
contact the carbon ring. bly (6) from the cam.

against the carbon face. Cleaning And Inspection
L. Place the four gaskets (7) on the four screws All parts must be inspected and be free of
(8) and insert seal retainer (6). Depress the material defects, dirt, scratches or any foreign
seal retainer only far enough to start the four material.
(13.6 Nm). After cleaning, all parts must be covered with a
OIL SEAL - TYPE SHAFT SEAL Installation

This procedure applies to the following shaft seal Install the shaft and oil seal as follows:
with seal kit part number:
001329-273 1. Position the cam on the rotating group so
002746-000 SHEET 3 OF 4
11-09-98
that the thick part of the cam is at the bottom of 5. Slide seal retainer (3) over the shaft and
the port block. against seal (4).
2. Insert the small end of shaft and bearing 6. Place gaskets (2) over capscrews (1) and
assembly (6) through the bore of the cam and install them. Alternately torque the screws to 50
into the splines of the cylinder barrel. ft-lbs (68 Nm).

housing.
4. Using a tapered sleeve tool with an inside

side diameter of 1.395 inches (35.5 mm), install
seal (4) over the splines of the shaft.
002746-000 SHEET 4 OF 4
3-87
BULLSHAFT SLEEVE KIT 6. Place installation tool over the sleeve. The
flange end of the sleeve goes on the shaft first.
INSTALLATION
(009532-000)
9532SB
INSTALLATION
1. Clean the surface where the seal contacts

the shaft. File down and polish any burrs or
rough sports.
2. Measure the diameter where the sleeve will

be positioned on an unworn portion of the shaft. 7. Gently pound the center of the tool until the
Measure in three positions and average the sleeve covers the seal worn surface.
reading in case the shaft is out of round. If the
average diameter is within the range for a given
sleeve size, there is sufficient press-fit built into
the sleeve to keep it from sliding or spinning.
No cement is necessary.
9532SC
9532SA
If the installation tool supplied with the sleeve is

too short, a length of pipe or tubing with a
squared-off, burr-free end can be substituted.
8. Leave the sleeve flange intact unless clear-

3. If the shaft is deeply scored, fill the groove
ance is required. Use side cutters to pry the
with epoxy type filler. Install sleeve before the
flange away from the seal surface and twist it
filler hardens.
into a coil. The flange will break loose along the
pre-cut line.
4. If the groove does not require filling, apply a
light layer of nonhardening sealant to the inner
surface of the sleeve.
5. Determine how far back the sleeve must be

positioned to cover the old seal wear tracks.
Measure to the exact point, or mark directly on 9532SD
the surface. The sleeve must be placed over
the worn area, not just bottomed or left flush
with the end of the shaft.
009532-000 SHEET 1 OF 2
3-87
9. After the sleeve is installed, check again for

burrs which could damage the seal.
10. Lubricate the end of the sleeve when install-

ing the seal.
SLEEVE KIT MAXIMUM MINIMUM

PART SHAFT SHAFT
NUMBER DIAMETER DIAMETER
009532-001 5.754” 5.746”
(146.15mm) (145.94mm)
009532-002 3.003” 2.997”
(76.27mm) (76.12mm)
009532-000 SHEET 2 OF 2
9-28-98
TOP SUB LOCK

INSTALLATION
(011201-000) ROTARY HEAD
BULLSHAFT
INSTALLATION
Install the top sub to the rotary head TOP SUB
bullshaft as follows:
11201s1.tif BIT SUB
1. Thoroughly clean the threads in the
bullshaft and the top sub pin. HOLDING WRENCH
2. Apply joint compound to the bullshaft

threads and the top sub pin.
3. Position the bit sub in the table bushing

and extend the holding wrench. TABLE BUSHING
4. Apply joint compound on the pin threads

of the bit sub.
5. Thread the top sub onto the bit sub and

hand tighten only.
6. Position the ENGINE SPEED switch to

the ‘HIGH’ or ‘RUN’ position.
7. Turn the rotary head TORQUE CON-

TROL clockwise to the maximum setting.
8. Slowly lower the rotary head onto the top

sub. Begin threading the two together and
allow the bit sub to slap against the holding
wrench three or four times to ensure maxi-
mum torque.
9. Refer to the welding diagram and install

the bar stock.
10. Loosen the top sub from the bit sub with
the tong wrench.
011201-000 SHEET 1 OF 2
9-28-98
ROTARY GEARBOX
A BULLSHAFT
SPECIAL BAR STOCK

3/8” X 3/8” X 1-1/2” LG
(9.5mm X 9.5mm X 38mm) TOP SUB
PART NO. 011200-001
NOTE! BE SURE TOP SUB THREAD IS GREASED WITH ROD

DOPE AND POWER TIGHTENED BEFORE WELDING
B
BULLSHAFT
TOP SUB
3/4” (19mm) TYP SPECIAL BAR STOCK

120o TYP
1-1/2” (38mm) TYP

3 PLACES TOP SUB
TYP
VIEW A SECTION B
SPECIAL BAR STOCK
011201-000 SHEET 2 OF 2
9-22-97
WINCH (021371-001)
WIRE ROPE INSTALLATION
Since the static brake on this winch is “effective

both directions”, cable can be wound onto the
drum in either direction without any modifica-
tions to the winch. The cable drum has two
anchor pockets to accommodate this. Take the
free end of the wire rope and insert it through
the small opening of the anchor pocket you are
going to use. Loop the wire rope and push the The standard cable anchor wedge supplied with
free end about three-fourths of the way back the winch is intended for 5/16 to 1/2 in. (8 to 13
through the pocket. Install the cable anchor mm) wire rope.
with the small end toward the drum, then pull
the slack out of the wire rope. The cable anchor
will slip into the pocket and secure the wire rope THROUBLESHOOTING
to the drum. A minimum of five (5) wraps of
wire rope should remain on the cable drum at all
The following table lists difficulties which may
times.
be experienced with the winch. The chart also
lists probable causes and remedies.
PROBLEM PROBABLE CAUSE REMEDY
A. 1. Be certain that the hydraulic system tempera-

ture is not more than 180° F (82o C). Excessive
The winch hydraulic oil temperatures may be caused by:
runs hot.
A. Plugged heat exchanger. Thoroughly clean exterior and flush interior.
B. Too low or too high oil level in hydraulic reser- Fill/drain to proper level.
voir.
C. Same as C-1. Same as remedy for C-1.
D. Hydraulic pump not operating efficiently. Remove and inspect pump. Check suction line for damage.
2. Excessively worm or damaged internal winch Disassembly winch to inspect/replace worn parts.
parts.
3. Same as H-5. Same as remedy for H-5.
B. 1. Same as C-1. Same as remedy for C-1.
Winch “chat- 2. Same as D-4. Same as remedy for D-4.

ters” while
raising rated 3. Hydraulic oil flow to motor may be too Increase pump rpm.
load. low.
4. Same as H-4. Same as remedy for H-4.
Troubleshooting Table 1 of 3
021371-001 SHEET 1 OF 10
9-22-97
C. 1. System relief valve may be set too low. Install a pressure gauge in the haul-in port and apply a stall
pull on the winch. If pressure is low, increase relief valve
setting until recommended pressure is obtained.
NOTE: If pressure does not increase in proportion to

adjustment, relief valve may be contaminated or worn out.
Winch will In either case, the relief valve may require disassembly or
not lift maxi- replacement.
mum load.
2. If this trouble occurs suddenly after working at Remove relief valve, disassemble and clean parts thor-
maximum lift, a particle of dirt may be lodged oughly in a suitable solvent. Reassemble and install relief
under the system relief valve, holding it partially valve. Reset pressure according to specifications.
open. If this is the cause, a considerable loss in
line speed may be noticed as the load on the
cable is increased.
3. The oil level in the reservoir may be too low. Check oil level in the reservoir. Check the suction line for
The suction line may be restricted or have an air damage, externally and internally. Replace suction line if
leak causing cavitation at the inlet port. This will necessary.
cause the pump to make a whining noise.
4. Be certain hydraulic system temperature is not If necessary, use steel shim stock to level winch.
more than 180o F (82o C). Excessive hydraulic oil
temperatures increase motor internal leakage and First loosen, then evenly retighten all winch mounting bolts
reduce motor performance. to recommended torque.
5. After all the causes listed above have been Install a pressure gauge in the motor haul-in port and apply
investigated and it is found that the winch will stall a stall pull on the winch. If the pressure is up to maximum
at maximum pressure without developing the max- and the bare drum line pull is less than the specified line
imum pull on the bare drum, the trouble may be in pull, the trouble will be in the winch.
the winch.
Disassemble winch according to disassembly instructions

and check that gear train turns freely. If gear train is found
to be satisfactory, inspect the hydraulic motor, according to
the service instructions for the hydraulic motor.
6. Rigging and sheaves not operating efficiently. Perform rigging and sheave service.
D. 1. Same as C-2. Same as remedy for C-2.
Consider-
able reduc- 2. Same as C-3. Same as remedy for C-3.
tion in line
speed.
3. Same as C-4. Same as remedy for D-4.
4. If this trouble has increased gradually, the Remove and inspect pump. If satisfactory, consult the dis-
hydraulic pump or winch motor may be worn. assembly instructions for the winch and remove and inspect
the motor according to the service instructions for the
hydraulic motor.
021371-001 SHEET 2 OF 10
9-22-97
E. 1. Control valve may be restrIcted in its travel. Check the travel of the control valve spool. The spool travel
should be the same in both directions.
Reverse
speed is 2. Same as C-1. Same as remedy for C-1.
slower than
forward 3. Oil may be too thick causing a high resistance Allow oil to warm.
speed. to rotation at the brake plates and causing the
relief valve to by-pass.
4. Same as H-1 Same as Remedy for H-1.
F. 1. Excessive system back pressure acting on the Install a pressure gauge at the “pay-out” port of the hydrau-
brake release port. lic motor. Operate the pump at full throttle and monitor
Brake will pressure in “neutral” and haul-in positions. If the pressure is
not hold greater than 50 PSI, check for restrictions in the return line
when control from the winch to the control valve and the control valve to
valve is the reservoir.
returned to
neutral after 2. Friction brake will not hold due to worn or dam- Disassemble winch to inspect/replace worn parts.
lifting a load. aged brake disks.
G. 1. Same as F-1 or 2. Same as remedy for F-1 or 2.
Brake will 2. Winch is being overloaded. Install a pressure gauge at the haul-in port and apply a stall
not control pull on the winch. If the pressure is higher than the maxi-
or stop the mum specified PSI, reduce the pressure.
load when
lowering. 3. After the causes listed above have been inves- Disassemble the brake assembly according to the disas-
tigated and found to be satisfactory, the trouble sembly instructions. Inspect the brake springs, and brake
may be in the winch. plates.
H. 1. The friction brake may not be releasing as a Disassemble and inspect the brake cylinder seal.
result of a defective brake cylinder seal.
The winch
will not NOTE ! If the brake cylinder seal is defective you
lower the will usually notice oil leaking form the winch vent
load or not plug.
lower the
load 2. Friction brake will not release as a result of Disassemble brake to inspect brake disks.
smoothly. damaged brake disks.
3. Same as D-4. Same as remedy for D-4.
4. Control valve handle being operated too Operate control valve smoothly when starting and stopping
quickly. a load. Conduct operator training as required.
5. Insufficient gear oil in cable drum. Remove oil level plug and check oil level. Fill to proper
level.
OVERHAUL Work in a clean, dust free area as cleanliness is

Before any part is removed from the winch, all of utmost importance when servicing hydraulic
service instructions should be read and under- equipment.
stood.
Inspect all replacement parts, prior to installa-
021371-001 SHEET 3 OF 10
9-22-97
tion, to detect any damage which might have secure the motor (49) to the motor adapter (38),
occurred in shipment. and lift the motor out of the motor adapter.
Remove and discard the O-ring (37) installed on
Use only genuine replacement parts for opti- the pilot of the motor.
mum results. Never reuse expendable parts
such as oil seals and o-rings.
49
Inspect all machined surfaces for excessive
wear or damage before reassembly operations
are begun.
Lubricate all o-rings and oil seals with gear oil

prior to installation.
Use a sealing compound on the outside surface

of oil seals and a light coat of thread sealing
compound on pipe threads. Avoid getting
thread compound inside parts or passages
which conduct oil. 3. Remove the brake coupling (29) and sun
gear (41) from the winch.
Thoroughly clean all parts in a good grade of
non-flammable safety solvent. Wear protective
clothing as required.
41
Refer to exploded view drawing for item num-
bers used in service procedures.
• Perform all applicable troubleshooting

operations BEFORE disassembling the
winch.
! WARNING 4. Remove the four capscrews (5) and lock-

Do not clean brake friction disks in solvent. washers (6) holding the tieplates (4) to the
Solvent may cause damage to friction mate- brake cylinder endplate. Remove the brake cyl-
rial which may result in brake failure and inder endplate from the drum.
loss of load control.
38
Disassembly
1. Disconnect all hoses and fittings at the

winch.
4
2. Stand the winch on the bearing support
endplate. Remove the brake release tube
assembly (43) between the brake valve block 5
and the brake cylinder endplate. Remove the 6
capscrews (50) and lockwashers (51) which
021371-001 SHEET 4 OF 10
9-22-97
1 7
52
53 3 8
17 9
16
15
13
14
16
41
28
2
27
12
31
11 32
33 4
10
34 45
42 35
33
48 36
47
6
5
29
30 37
45
38
50
43
51
49
44
40 39
WINCH (021371-001)
021371-001 SHEET 5 OF 10
9-22-97
5. Remove the other four capscrews and

lockwashers holding the tieplates to the bearing
support endplate. Remove the planet assembly Planetary Carrier
from the drum and separate the drum from the
bearing support endplate. 1. First drive the rollpins (17) into the center
of the planet pins (14). Now you can remove the
planet shaft (14), two thrust races (16), planet
12 gear (13) and roller bearing (15). Repeat this
procedure for the other two planet gears. Thor-
oughly clean all parts and inspect for damage
3 and wear. The bearing rollers should not exhibit
any irregularities. If the rollers show any sign of
spalling, corrosion, discoloration, material dis-
placement or abnormal wear, the bearing
should be replaced. Likewise, the cage should
be inspected for unusual wear or deformation,
particularly the cage bars. If there is any dam-
age that will impair the cage’s ability to sepa-
rate, retain and guide the rollers properly, the
bearing should be replaced. The thrust washer
Drum contact areas should be free from any surface
irregularities that may cause abrasions or fric-
1. Remove the bearing and seal from each tion. The gears and shaft should be inspected
end of the drum. Thoroughly clean and inspect for abnormal wear or pitting. Replace if neces-
the drum. Check the ring gear teeth (machined sary.
into the inside surface of the drum) for nicks,
spalling or excessive wear. Replace the drum if
wear is greater than 0.015 in. (0.4 mm) when
compared to unworn area of teeth. 14
13
17
12 15
16
2. Insert a bearing into a planet gear and

place a thrust race on each side of the gear.
Position this assembly in the planet carrier and
slide the planet gear shaft through the carrier.
Align the pin hole in the shaft with the hole in the
2. Install new bearings in the drum if replace- carrier and drive a NEW rollpin into place.
ment is necessary. Apply a non-hardening Always use NEW rollpins. When properly
sealant on the outside diameter of each new positioned, the rollpin will be slightly below the
seal and press the seals into the drum, using a surface of the carrier.
flat plate to avoid distortion.
021371-001 SHEET 6 OF 10
9-22-97
3. With a center punch, stake the carrier next

to the pin hole as shown. This will distort the 2. Thoroughly clean and inspect all parts at
hole so the pin will not back out when in service. this time. Check brake piston sealing surfaces
Repeat these steps for each of the three planet on motor adapter and brake cylinder endplate.
gears. Be sure the brake release port in the endpate
(shown above) is free of contamination.
Remove the vent plug (42) from the motor
12 adapter, clean in solvent and reinstall. DO NOT
paint over the vent or replace it with a solid plug.
3. Place each friction disc on a flat surface

and check for distortion with a straight edge.
Friction material should appear even across
entire surface with groove pattern visible.
Replace friction disc if splines are worn to a
point, disc is distorted, friction material is worn
unevenly or groove pattern is worn away. Place
each steel disc on a flat surface and check for
distortion with a straight edge. Check surface
for signs of material transfer or heat. Replace
steel disc if splines are worn to a point, disc is
Brake Cylinder Endplate distorted or heat discolored.
Disassembly and Inspection
1. Note: The capscrews in the motor adapter

should be evenly removed in 1 or 2 turn incre-
ments since the motor adapter is under spring
tension. Remove the capscrews (47) and lock-
washers (48) holding the motor adapter (38) to
the endplate (2). Install 2 capscrews and a
short piece of chain into the motor mounting
38
holes. Using the chain as a handle, lift the
motor adapter out of the endplate. Remove and
discard the O-ring (36) from the motor adapter.
Remove and discard the brake piston seal (32).
Remove brake plate spacers (33), steel discs
! CAUTION
(35), friction discs (34), spring plate (31), Failure to replace brake springs as a set may
springs (27) and spring spacer (28). result in uneven brake application pressure
and repeated brake spring failure.
47 4. Check free length of each brake spring.

48 Minimum free length is 15/16 inch (23.8 mm).
Check springs for any signs of cracking or fail-
ure. If a brake spring must be replaced for any
38
reason, then ALL brake springs must be
replaced.
021371-001 SHEET 7 OF 10
9-22-97
35
38
27
34
ASSEMBLY 3. Install the other brake plate spacer (33)

and the spring plate (31) as shown.
1. Place the motor adapter on workbench
with the motor mounting surface down. Install a
new O-ring (36). Lubricate the brake piston 38
seal with petroleum jelly or hydraulic oil and 31
install on the motor support with the seal lip
down, as shown.
4. Install the spring locator (28) and the eight

(8) springs (27) into the brake cylinder endplate
(2).
36
38 2 27
2. Install a brake spacer (33) into the motor

support. Insert a steel disc (35) against the
spacer, followed by a friction disc (34). Alter-
nately install steel and friction discs until eight
(8) friction discs and nine (9) steel discs have
been installed. Finish with a steel disc on top.
NOTE ! 5. While holding the motor adapter and brake

It is a good practice to lubricate the discs in gear assembly together, turn it over and install into
oil prior to assembly. the brake cylinder endplate. Install the eight (8)
capscrews (47) and lockwashers (48) but do not
tighten them at this time.
021371-001 SHEET 8 OF 10
9-22-97
3
38
2
4
6. Loosely attach the two tieplates (4) to the 8. Install the planet carrier assembly into the
bearing support endplate using capscrews (5) drum while meshing the planet gears with ring
and lockwashers (6). gear and the planet carrier with the bearing sup-
port.
! CAUTION 12
Make certain the snap ring is installed on the

bearing support. This snap ring will keep
the planet carrier correctly positioned in the
winch. Gear train damage may occur if this
snap ring is omitted.
4 1
4
52
9. Lubricate the bearing support and sealing
surface on the brake cylinder endplate and
install the endplate assembly onto the drum.
5
6 41
7. Lubricate the bearing support and sealing

surface with petroleum jelly or gear oil and
place the cable drum (3) on the bearing support
endplate. Check that the drum rotates freely on 5
6
the bearing.
021371-001 SHEET 9 OF 10
9-22-97
and the snap ring in its center must rest on the

sun gear. Evenly tighten the eight (8) cap-
! WARNING screws around the motor adapter one turn at a
time until the motor adapter is firmly seated to
Be certain the snap ring (30) is seated in the the endplate. Torque the capscrews to their
groove in the splined bore of the brake cou- proper value.
pling (29). This snap ring will keep the brake
coupling correctly positioned in the center
12. Install a new O-ring (37) on the motor pilot
of the friction brake pack. Binding of the and lubricate with petroleum jelly or gear oil.
brake or brake failure may occur if this snap Install the motor onto the motor adapter with
ring is omitted. two capscrews (50) and lockwashers (51).
Torque the capscrews to their proper value.
30
29
49
10. Fasten the two tieplates to the endplate

with capscrews (5) and lockwashsers (6), and
toque all eight (8) tieplate capscrews to their
13. Install a hand pump with an accurate 0-
proper valve. Check that the drum turns freely
2,000 psi (0-13,800 kPa) gauge and shut-off
in both directions without binding or any interfer-
valve to the brake release port. Apply 1,000 psi
ence. Install the sun gear (41), meshing with
(6,900 kPa) to the brake and close the shut-off
the teeth on the planet gears in the drum.
valve. Let the brake stand for five (5) minutes.
If there is any loss of pressure, the brake pack
should be disassembled for inspection of the
29 sealing surfaces and the brake piston. Release
the pressure, remove the hand pump and install
the brake release tube (43) between the brake
valve block (39) and the brake release port.
11. Install the brake coupling into the brake

pack with the flat end of the coupling toward the
motor. Turn the coupling back and forth to align
the outer splines with the brake disc splines.
The coupling must engage all the brake discs
021371-001 SHEET 10 OF 10
7-28-97
HYDRAULIC VANE MOTOR force the shaft to rotate in a clockwise direction.
(001011-000) MAINTENANCE
The internal parts of this motor are lubricated by

GENERAL tenance is limited to keeping the fluid in the sys-
The following pages cover the description, oper- accumulate on the motor or around the shaft
ation, removal, maintenance overhaul and seal. All fittings and bolts should be tight.
hydraulic motor. In the event the pump does not perform prop-
overhaul.
DESCRIPTION
This vane motor consists of four basic compo- TROUBLESHOOTING

nents: the housing or body, a shaft and bear-
ing, end cap, and a rotating group consisting of;
a rotor, vanes, vane springs, cam ring, bearing, The following table lists some of the difficulties
port pressure plate,. which may be experienced with this vane motor.
END CAP BODY
REMOVAL and INSTALLATION

should only be used as a guide in removing and
installing this component.
To remove the motor, proceed as follows:

ROTARY GROUP SHAFT & BEARING
1. Stop the engine and allow the hydraulic oil
to cool. Disconnect the battery ground cable
and tag the ignition switch to inform others of
OPERATION the maintenance taking place.
2. Clean the area around the motor and hose

During operation, pressurized oil enters one of connections.
the ports in the end cap and is directed to both
sides of the cam ring assembly through cast 3. Tag, disconnect and cap the hoses at the
ports in the end cap and port plate assemblies. motor. Plug the ports to prevent contamination.
The pressure applied against the vanes forces
the rotor to turn and at the same time rotates
the shaft. As the rotor turns, the oil moves to
the discharge ports in the port plate and end
cap. Oil entering the “A” port of the end cap will
001011-000 (SHEET 1 OF 5)
7-28-97

housing and end cap.

Loss in Speed Under a. Low inlet pressure. a. Check pressure.

Load b. Scored port plate or end cap. b. Relap flat to clean-up.
c. High oil temperature.
Poor Speed Control a. Worn rotating group. a. Replace.
Motor Fails to Start a. Insufficient torque. a. Increase relief valve setting.

Turning b. Excessive motor leakage. b. Check flow from motor outlet. Pressure not
loading plate causing plate to move away from
cam ring.
c. Worn rotating group. c. Replace.
d. Defective O-ring on O.D. of port plate. d. Replace O-ring.
Shaft Play a. Worn bearings. a. Replace.
Excessive Noise a. Worn or damaged rotary group. a. Inspect for excessive wear.
VANE MOTOR TROUBLESHOOTING TABLE

4. Securely support the motor with a suitable Drain all fluid from the motor and thoroughly
lifting device before removing the motor attach- clean the exterior surface. Prepare a clean, lint
ing hardware. free surface on which to place the internal parts
for inspection.
5. Before installing the motor be sure the
mounting sufaces of the motor are clean.
6. Once the motor is installed, fill it with clean Disassembly

hydraulic fluid.
Disassemble the motor as follows:
the motor for leakage.
1. Drain all fluid from motor and thoroughly
OVERHAUL 2. Match mark the motor end cap and body.

Secure the pump in a vise with the shaft
extended down.
General 3. Remove the four screws (1) and lift off end
cap (2).
The instructions contained in this section cover
a complete disassembly, inspection and assem- 4. Remove seal (3) from end cap (2).
bly of the motor. Also in this section is informa-
tion for changing the shaft and shaft seals. 5. If necessary, remove needle bearing (4)
001011-000 (SHEET 2 OF 5)
7-28-97
from end cap (2).

8 9 11
6. Remove the dowel pin (5) that secures end
cap (2).
12
2 6
1
10
NOTE !
Examine ball bearing (12B) for wear before
removing it from shaft (12C). Apply light pres-
4 3 5 sure to the outer race and rotate to check for
wear or cracks and excessive looseness.
Remove the bearing from the shaft if dam-
7. Thread two #10-24 screws into the two aged. Inspect the shaft for damage, especially
tapped holes provided as puller holes in cam the seal surface for the shaft seal. Omit the next
ring (6) and remove the rotating group assem- procedure if bearing removal is not required.
bly.
NOTE !
If resistance is encountered while pulling the
cam ring out, lightly tap the outside of the motor 11
body while lifting. 12B
15
8. Remove dowel (7) from port plate assem-
12
bly (8).
9. Thread two #10-24 screws into the two 12A

tapped holes provided as puller holes in port
plate (8) and remove the port plate assembly.
10. Remove rubber seals (9 and 10). 12C
11. Remove snap ring (11) and remove shaft 14

and bearing assembly (12) from motor body 13
(15).
12. Remove inboard retaining ring (12A) and
001011-000 (SHEET 3 OF 5)
7-28-97
press bearing (12B) off of shaft (12C). Make sure both rings are fully seated in their
grooves.
! CAUTION 3. Install felt wiper (14) in motor body (15).
The remaining retaining ring (12A) must be Using a seal driver, press shaft seal (13) into
removed by passing over the bearing sur- place. Grease the seal lips.
face of the shaft and NEVER over the shaft
seal surface. A damaged seal surface will 4. Press on the outer race of ball bearing
cause the shaft seal to leak. (12B) until the shaft assembly is installed in
body (15).
13. Remove felt wiper (14) and shaft seal (13)
from motor body (15).
! CAUTION
Cleaning and Inspection 5. Install retaining ring (11) to hold the shaft
1. Wash all metal parts in cleaning solvent assembly in place. Make sure the ring is fully
and dry thoroughly. seated.
2. Inspect seals for wear and brittleness. Dis- 6. On a clean workbench install seals (9 and
card and replace if necessary. 10) on the back of port plate (8).
3. Inspect bearings for wear or flat spots. 6 8 9 11 15
4. If the cam ring has excessive wear ripples,

the rotary group should be replaced. 12
5. Inspect the end cap and body castings for

cracks.
6. Replace the shaft if damaged splines are

present.
10
Assembly
Always lubricate all seals and bearings in clean 7
hydraulic oil before installation. Assemble the
motor as follows: 7. Insert dowel pin (7) in the face of port plate
(8).
1. If removed, install retaining ring (12C) in
the groove of shaft (9) by passing the ring over 8. Thread two #10-24 screws into port plate
the output end of the shaft. Just as in disas- (8) to aid in installing it in motor body (15).
sembly, Do not install the ring over the shaft
seal surface this may damage the seal sur- 9. With the port plate installed, remove the
face causing seal leakage. two #10 screws and install them in the cam ring
of the assembled rotating group (6). Install
2. Install ball bearing (12B) by pressing on dowel pin (5) in the cam ring.
the inner race until the bearing is seated against
retaining ring (12C). Install retaining ring (12A). 10. Lower rotating group (6) into motor body
001011-000 (SHEET 4 OF 5)
7-28-97
(15) making sure that dowel pin (7) seats fully in

the cam ring.
2 6
1
4 3 5
11. Lubricate and press needle bearing (4) into

end cap (2).
12. Lubricate seal (3) and install it on end cap

(2).
13. Install the end cap assembly on motor

body (15) and secure it in place with screws (1).
Alternately tighten two to draw down mounting
cap. Torque all four to 102 Nm ( 75 ft. lbs).
001011-000 (SHEET 5 OF 5)
7-28-97
001011-000 (SHEET 6 OF 5)
9-23-97
RELIEF VALVE
(001104-000)
! WARNING
Running the adjustment screw all the way
down will lock the overflow valve closed.
GENERAL 6. Adjust the regulator to the desired operating

pressure by turning adjusting screw assembly
This valve assembly is designed for a capacity (3) clockwise to increase the pressure or coun-
of 2 to 20 gpm (7.5 to 75.5 lpm) and for pres- terclockwise to decrease the pressure. Proper
sures from 200 to 700 PSI (13.8 to 48 bars). settings are 150 PSI (10 bars) on 100 PSI (7
bar) compressors and 300 PSI (20.5 bars) on
The bypass opening in the bottom of the valve 250 PSI (17 bar) compressors.
must be connected to the overflow line. This
line must not have a valve or any other obstruc- 7. To temporarily release the pump operating
tion in it. pressure, flip the handle 180° over the top of
the regulator.
The handle on the top of the valve acts as a
complete pressure release when it is rotated
180° through the vertical position.
PRESSURE RELEASE
The handle is also used as the means of setting
the pressure by turning clockwise to increase
the pressure and counterclockwise to decrease
the pressure.
INITIAL PRESSURE SETTING

1. HANDLE
2. PIN
The initial pressure setting should be made as 3. ADJUSTING
follows: SCREW
4. NYLON ROD
1. Place handle (1) in the pressure release 5. BRASS PIN
6. SPRING SEAT
position. 7. SPRING
8. CYLINDER TUBE
2. Loosen the pressure setting adjustment by 9. CYLINDER
LINER
turning adjusting screw (3) until the threads of 10. CAPSCREW
the screw are showing above the top of cylinder 11. FOLLOWER
tube (8). 12. PLUNGER CUP
13. O-RING
14. VALVE
3. Remove the pressure hose from the relief 15. BODY
valve and attach a pressure gauge. 16. VALVE SEAT
4. Start and run the pump at the desired oper-

ating speed.
5. Close the bypass by rotating the handle

180° over the top of the regulator. Plunger pin
(5) in the center of adjusting screw (3) will not
be completely depressed.
001104-000 Sheet 1 of 3
9-23-97
OVERHAUL Replacing Plunger Cup and/or Valve
1. Grip the plunger assembly in a vise or other

Disassembly suitable holder, being careful not to damage the
valve face area.
1. Be sure that all pumping pressure has been
released by shifting handle (1) to the “pressure 2. Remove capscrew (10).
release” position.
3. Clean plunger follower (11) by removing all
2. Unscrew and remove adjusting assembly old grease and dirt.
(3).
4. Replace plunger cup (12) and/or valve (14)
3. Unscrew and remove cylinder tube (8) with a as needed and reassemble.
pipe wrench.
4. Remove the plunger assembly, spring or

springs (7) and seat (6) from the lower end of Replacing Valve Seat
the cylinder.
Valve seat (16) may be replaced by first knock-
5. Discard O-ring (13). ing out the old seat with a punch inserted
through the bypass opening.
Clean the seat contact area. Then tap the new

Replacing Cylinder Liner seat into place, using a block of wood or brass
to avoid damaging the face of the new seat.
If the stainless steel cylinder liner (9) is worn, it
may be removed with a punch or other suitable
tool as follows: Assembly
1. Clean the surface where cylinder liner (9) 1. Fill the cavity around plunger follower (11)
contacts cylinder tube (8). with lubriplate or grease.
2. Coat the outside of the new cylinder liner (9)

with Permatex or other suitable sealer and
press into cylinder tube (8). ! CAUTION
NOTE !
Do not push plunger assembly into cylinder
Be sure the lower end of the stainless steel liner
so far that cup passes end of stainless steel
is flared to match the end of the cylinder tube.
liner.
Be sure there are no rough edges inside the
2. Insert the plunger assembly into cylinder
installed cylinder liner that would damage the
tube assembly (8) from the cylinder liner end.
plunger cup.
Be sure that the plunger assembly travels freely
in the cylinder.
The cylinder may be purchased complete with
liner installed or the liner may be purchased
3. Put pipe dope on external threads or cylin-
alone for replacement.
der assembly (8) and screw back into cylinder
body (15).
001104-000 Sheet 2 of 3
9-23-97
4. Replace spring/or springs and spring seat 6. When properly reassembled, the adjusting
(6). Be sure the spring/or springs if/are properly handle can be rotated 180° over the top or
seated on plunger. turned in either direction to increase or
decrease the pressure adjustment.
5. Replace adjusting assembly (3) by screwing
it into the end of cylinder (8). Be sure plunger 7. Adjust as outlined in “Initial Pressure Set-
pin (5) is in its proper place in the adjusting ting” instructions.
assembly.
001104-000 Sheet 3 of 3
9-23-97
001104-000 Sheet 4 of 3
2-10-98
FILTER/REGULATOR Clean air flows upward from the element to the

regulator valve (12). The working parts of the
(002428-000) pressure regulator section are diaphragm (7),
regulating spring (5), valve (12), and adjustment
knob (2). One side of diaphragm (7) is refer-
enced to the outlet (secondary) side of the regu-
OPERATION
lator through aspirator tube (A).
This filter/regulator performs two functions in a
With adjustment knob (2) turned counterclock-
compressed air system:
wise until no load is applied to regulating spring
A. It removes most solid and liquid particles
(5), the valve is closed. When adjustment knob
from the compressed air.
(2) is turned clockwise, force is applied to regu-
B. It maintains a nearly constant outlet pres-
lating spring (5) which causes diaphragm (7) to
sure despite changes in the inlet air pressure
move downward and open the valve. The
and changes in downstream flow requirements.
increase in secondary (regulated) pressure act-
ing against the lower (pressure) side of dia-
phragm (7), creates a force tending to move the
diaphragm upward, compressing regulating
spring (5). This upward movement will continue
until the force exerted by the pressure on the
lower side of diaphragm (7) balances the spring
2428S1A.TIF forece exerted on the upper side. If there is no
downstream flow demand, this balance of
forces will occur with the valve open just the
amount necessary to compensate for the
demand, thus maintaining the desired pressure.
The regulator shown is a relieving type and

should a secondary overpressure occur, dia-
phragm will move further upwared and open
relief passage (B) in the diaphragm. This allows
secondary air to esdape into the regulator bon-
net and to vent (C).
However, the flow capacity of the relief passage

is limited, and depending upon the source of the
overpressure condition, the outlet pressure
might increase to a point significantly higher
Air entering the filter/regulator is guided into a than the filter/regulator setting. For this reason,
swirling pattern by the louvers (16). Coarse the relief feature of a filter/regulator must not be
solid particles and liquids are forced to bowl wall relied upon as an overpressure safety device.
(30) by centrifugal force and drop to the bottom.
Baffle (22) creates a quiet zone at the bottom of
the bowl and prevents air turbulence from pick- ADJUSTMENT
ing up liquids and returning them to the air
stream. Air leaving the bowl passes through the 1. Before turning on system air pressure, turn
filter element (18) where most finer solid parti- filter/regulator adjustment counterclockwise
cles are retained. until all load is removed from regulating spring.
002428-000 SHEET 1 OF 4
2-10-98
2. Turn on system air pressure. Clean the bowl using warm water only. Clean
other parts using warm water and soap. Blow
3. Turn filter/regulator adjustment (2) clockwise clean dry air through the filter element from
until the desired outlet pressure is reached. inside to outside to dislodge surface contami-
nants. Dry the parts and blow out internal pas-
4. To avoid minor readjustment after making a sages in the body using clean, dry compressed
change in pressure setting, always approach air. Inspect each part carefully. Replace any
the desired pressure from a lower pressure. parts that are damaged.
When reducing from a higher to a lower setting,
first reduce to some pressure less than that At reassembly, apply a wipe coat of Dow corn-
desired, then bring up to the desired point. ing 44M grease or equivalent to gasket (29).
Tighten baffle (22) 1/4 to 1/2 turn past the point
5. Push the lockring on adjusting knob (2) of initial contact with element (18), DO NOT
downward to lock the pressure setting. To OVER TIGHTEN. When reinstalling the auto-
release, pull the lockring upward. Pressure set- matic drain in bowl, torque retaining nut (25) to
tings can be made tamper resistant by installing 20-25 in-lbs (2.5 Nm). Apply a light coating of
a seal wire in the groove above the lockring. antiseize compound (Armite Laboratories Led-
Plate No. 250 or equivalent) to the full length of
the threads on bowl (32) before assembly to
body. Tighten the bowl by hand.
SERVICING
The lliquid level in bowl (30) should always be Regulator Section

below baffle (22). If the liquid level rises above
the baffle, liquid will be carried downstream. Turn adjusting knob (2) counterclockwise until
Replace filter element (18) when plugged or all load is removed from regulating spring (5).
dirty. Unscrew bonnet assembly (2), spring (5), slip
ring (6), and diaphragm (7) from body (10).
Remove the filter section as described previ-
OVERHAUL ously. Unscrew and remove centerpost (17)
together with gasket (15), louver-deflector (16)
The filter/regulator can be disassembled without and valve spring (14). Pull valve (12) together
removal from the air line. To disassemble, shut with O-rings (11 and 13) out of body.
off inlet air pressure. Reduce air pressure to
zero in lines both upstream and downstream of Clean regulator parts using warm water and
filter/regulator. soap. Do not immerse bonnet assembly (2) for
cleaning as lubricant will be removed. Dry parts
thoroughly. Inspect all parts carefully. Replace
Filter Section any parts that are damaged.
Unscrew and remove bowl (30) and gasket (29). At reassembly, apply a light coat of Dow Corn-
Remove automatic drain items (24, 25, 27, 28) ing 44M grease or equivalent, to O-rings (11and
from the bowl. Unscrew and remove baffle (22) 13), gasket (15), and to the valve stem bore in
and filter element (18). body (10) and valve body bore in centerpost
(17). Insert valve assembly (11, 12, 13) into
body (10). Place louver-deflector (16) and gas-
ket (15) on centerpost (17), drop valve spring
(14) in centerpost, install centerpost in body and
tighten until snug.
002428-000 SHEET 2 OF 4
2-10-98
002428-000 SHEET 3 OF 4
2-10-98
Apply a light coast of Lubriplate 110 or equiva-

lent, to adjusting screw threads inside bonnet
(2). Apply a light coat of antiseize compound to
the lower half of threads on bonnet (2). Stack
diaphragm (7), slipring (6), regulating spring (5)
in upper section of body. Screw bonnet (2) into
body. Turn adjusting knob counterclockwise to
ensure all load is removed from regulating
spring. Tighten the bonnet to 25-30 ft-lbs (34-
41 Nm) of torque.
Reassemble the filter section as described in

this section.
002428-000 SHEET 4 OF 4
2-12-98
DUST COLLECTOR • Ensure that the filter cleaning mechanism is

functioning (listen for air pulsation once
(007702-000) every 3 to 6 seconds). The pressure regula-
tor should be set at 50 PSI (3.4 bars).
• Start the dust collector when air control valve

GENERAL
is placed in OPEN position.
For the dust collector to operate efficiently, the
• Stop dust collector when air control valve is
following steps should be followed:
placed in CLOSED position.
• Do not operate the dust collector if wet drill-

! WARNING ing conditions are encountered. Wet dust
Do not operate blower motor at speeds can clog dust collector air filters.
above 4,000 RPM. The blower may disinte-
grate causing injury to nearby personnel. • When initially setting up blower speed, open
adjustable flow control located adjacent to
! CAUTION blower motor so the blower is operating very
slowly. Gradually increase RPM until dust is
Should visible dust be observed coming no longer coming from the drill table. Check-
from the blower discharge port, immediately ing the RPM with a Frahm Vibratory Reed
turn off blower and check for ruptured fil- tachometer is strongly recommended to
ters. Failure to do this will cause blower ensure that fan speed does not exceed
damage. 4,000 RPM. Blower speeds should be set to
the lowest speed possible that provides
• Ensure dust curtains are forming a seal with dust-free operation.
the ground.
CLEAN AIR
DISCHARGE
WORKING SHORT BURSTS

AIR OF AIR
7702s0
HEAVY CUTTINGS 1. DUST CURTAIN

DUST 2. DUST SHIELD
3. TABLE BUSHING
4. TABLE
5. FILTERS
6. BACKFLUSHING MODULE
7. MOTOR
8. SPEED CONTROL
9. HYDRAULIC PRESSURE SURGE BYPASS
10. BACKFLUSH PRESSURE REGULATOR
11. BLOWER
007702-000 SHEET 1 OF 2
2-12-98
TROUBLESHOOTING
PROBLEM SOLUTION
Dust curtain not confining all dust Dust curtain must touch ground to create seal. Extend dust curtain as
required.
Dust being forced up through table bushing Check for worn table bushing insert or dust shield and/or dust ring.
around drill pipe Replace as required.
Fine dust not being dumped through transition Check for caked cuttings holding rubber belting shut or chute plugged by
chute damp dust. Remove all caked dust from hopper and chute.
Filter severely plugged Remove filters as needed and clean and/or replace. Inspect filter for rup-
ture. If rupture found replace filter.
Check regulator pressure gauge for accuracy. Additional pressure may be

required to clean filter. Do not exceed 50 PSI.
If filters have indication of oil coating check for leakage of blown motor
shaft seal. Replace as required.
Backflushing cycle rate too fast or too slow Timer not adjusted properly. Remove cover of timer for adjustment.
Observe flash of “off cycle” light. Turn adjustment screw to have light flash
at 6 second intervals.
Filters are not being back-flushed properly Blowdown diaphragm valves may be defective. If one particular filter is
not being cleaned check the blowdown valve for ruptured diaphragm or
valve stuck in open or closed position.
Check tubing connecting timer solenoid to blowdown valves for leakage.
Flushing section of dust collector full of dust Check to see that filter is properly tightened against filter retainer.
Retainer must also be secure.
Check filter for ruptures.
Thoroughly clean the flushing section by use of air gun before resuming
operation.
Blower speed too slow Check flow control located adjacent to blower motor for proper setting.
Check for defective hydraulic pump of motor. Replace as required.
007702-000 SHEET 2 OF 2
2-9-98
HYDRAULIC MOTOR
(009999-000) of the difficulties which may be experienced with
this hydraulic motor. The table also lists proba-
ble causes and possible remedies. We recom-
mend that you check this table before
TROUBLESHOOTING
disassembling the motor.
The troubleshooting table that follows lists some

Oil Leakage 1. Hose fittings loose, worn or dam- Check & replace damaged fittings or
aged. “O” Rings. Torque to specifications.
2. Oil seal rings (4) deteriorated by Replace oil seal rings by disassem-
excess heat. bling motor.
3. Loose or its sealing area deterio- (a) Loosen then tighten single bolt
rated by corrosion. to torque specification.
(b) Replace bolt.
4. Internal shaft seal (16) worn or Replace seal. Disassembly of motor

damaged. unit necessary.
5. Worn coupling shaft (12) and Replace coupling shaft and seal by
internal seal (16). disassembling motor.
Significant loss of speed under load 1. Lack of sufficient oil supply. (a) Check for faulty relief valve and
adjust or replace as required.
(b) Check for and repair worn pump.
(c) Check for and use correct oil for

temperature of operation.
2. High internal motor leakage. Replace worn rotor set by disassem-

bling motor.
3. Severely worn or damaged inter- Replace rotor set, drive link and
nal splines. coupling shaft.
4. Excessive heat. Locate excessive heat source (usu-

ally a restriction) in the system and
correct the condition.
Low mechanical efficiency or undue 1. Line blockage. Locate blockage source and repair
high pressure required to operate or replace.
2. Internal interference. Disassemble motor, identify and

remedy cause and repair, replacing
parts as necessary.
3. Lack of pumping pressure. Check for and repair worn pump.
HYDRAULIC MOTOR TROUBLESHOOTING
009999-000 SHEET 1 OF 9
2-9-98
DISASSEMBLY AND INSPECTION .
1. Place the motor in a soft jawed vise, with

6
coupling shaft (12) pointed down and the vise
jaws clamping firmly on the sides of the housing
(18) mounting flange or port bosses.
10
2. Scribe an alignment mark down and across
the motor components from end cover (2) to
housing (18) to facilitate reassembly orientation
where required.
7. Remove commutator (5) and seal ring (3).

Remove seal ring from commutator, using an air
hose to blow air into ring groove until seal ring is
3 lifted out and discard seal ring. Inspect commu-
tator for cracks or burrs, wear, scoring, spalling
or brinelling.
3. Remove the head bolts (1). Inspect the 12

bolts for damaged threads, or sealing rings,
under the bolt head. Replace damaged bolts.
5
4. Remove end cover assembly (2) and seal
ring (4). Discard the seal ring. 8. Remove manifold (7) and inspect for cracks,
surface scoring, brinelling or spalling. A pol-
5. Thoroughly wash end cover (2) in a suitable ished pattern on the ground surface from com-
solvent and blow dry. Inspect the end cover for mutator or rotor rotation is normal. Remove and
cracks and the bolt head recesses for good bolt discard the seal rings (4) that are on both sides
head sealing surfaces. of the manifold.
6. Remove commutator ring (6). Inspect com- NOTE!
mutator ring for cracks, or burrs. The manifold is constructed of plates bonded
together to form an integral component not sub-
NOTE! ject to further disassembly for service. Com-
A polished pattern (not scratches) on the cover pare configuration of both sides of the manifold
from rotation of the commutator (5) is normal. to ensure that same surface is reassembled
Discoloration would indicate excess fluid tem- against the rotor set
perature, thermal shock, or excess speed and
require system investigation for cause and 9. Remove rotor set (8) and wearplate (9)
close inspection of end cover, commutator, together to retain the rotor set in its assem-
manifold, and rotor set bled form, maintaining the same rotor vane
(8C) to stator (8B) contact surfaces.
009999-000 SHEET 2 OF 9
2-9-98
9999s0.tif
9999s2
009999-000 SHEET 3 OF 9
2-9-98
NOTE! (0.13 mm) of clearance, replace the rotor set.

The drive link (10) may come away from the FEELER
coupling shaft (12) with the rotor set, and wear- GAUGE
8C
plate. You may have to shift the rotor set on the 8A
wearplate to work the drive link out of the rotor
(8A) and wearplate.
8B
8A 16
8B
14
9
12. Remove drive link (10) from coupling shaft
(12) if it was not removed with rotor set and
wearplate. Inspect drive link for cracks and
worn or damaged splines. No perceptible lash
(play) should be noted between mating spline
10. Inspect the rotor set in its assembled form parts. Remove and discard seal ring (4) from
for nicks, scoring, or spalling on any surface housing (18).
and for broken or worn splines. If the rotor set
component requires replacement, the complete 13. Check the output end of coupling shaft (12)
rotor set must be replaced as it is a matched to be sure you have removed all signs of rust
set. Inspect the wearplate for cracks, brinelling, and corrosion which might prevent its with-
or scoring. Discard seal ring (4) that is between drawal through the seal and bearing. Crocus
the rotor set and wearplate. cloth or fine emery paper may be used.
NOTE! 14. Remove coupling shaft (12), by pushing on

The rotor set (8) components may become dis- the output end of shaft. Inspect coupling shaft
assembled during service procedures. Marking bearing and seal surfaces for spalling, nicks,
the surface of the rotor and stator that is facing grooves, severe wear or corrosion and discolor-
UP, with etching ink or grease pencil before ation.
removal from the motor will ensure correct reas-
12
sembly of rotor into stator and rotor set into the
motor. Marking all rotor components and mat-
ing spline components for exact repositioning at
assembly will ensure maximum wear life and
20
performance of the rotor set and the motor.
11. Place rotor set (8) and wearplate (9) on a flat

surface and center rotor (8A) in stator (8B) such
that two rotor lobes (180° apart) and a roller
vane (8C) centerline are on the same stator
centerline. Check the rotor lobe to roller vane NOTE!
clearance with a feeler gauge at this common Minor shaft wear in seal area is permissible. If
centerline. If there is more than .005 inches wear exceeds .020 inches (0.51 mm) diametri-
cally, replace coupling shaft.
009999-000 SHEET 4 OF 9
2-9-98
rollers must be firmly retained in the bearing

cages, but must rotate and orbit freely. All roll-
INSPECTION
SURFACES ers and thrust washers must be free of brinelling
and corrosion.
21 NOTE!
The bushing (19) or (13) to coupling shaft diam-
eter clearance must not exceed .010 inch (.025
mm). A bearing, bushing, or thrust washer that
ITEM 12 does not pass inspection must be replaced.
20. If the bearings, bushing or thrust washers

NOTE! must be replaced use a bearing puller to
A slight “polish” is permissible in the shaft bear- remove bearing/bushings (19) and (13) from
ing areas. Anything more would require cou- housing (18) without damaging rhe housing.
pling shaft replacement. Remove thrust washers (14) and thrust bearing
(15) if they were previously retained in the hous-
15. Remove thrust bearing (15) and thrust ing by bearing (13). Discard the bearing/bush-
washer (14). Inspect for wear, brinelling, corro- ing (19) and (13).
sion and a full complement of retained rollers.
16. Remove seal (16) and back up washer (17) NOTE!

from housing (18). Discard both. The depth or location of bearing/bushing (13) in
relation to the housing wearplate surface and
17. Remove housing (18) from vise, invert it and the depth or location of bearing/bushing (19) in
remove and discard seal (20). A blind hole relation to the beginning of bearing/bushing
bearing or seal puller is required. counterbore should be measured and noted
before removing the bearings/bushings. This
20 will facilitate the correct reassembly of new
bearings/bushings.
18
25 18 13
29
18. Inspect housing (18) assembly for cracks,

the machined surfaces for nicks, burrs, brinel-
ling or corrosion. Remove burrs that can be
removed without changing dimensional charac-
teristics. Inspect tapped holes for thread dam- ASSEMBLY
age.
19. If the housing (18) assembly has passed ! CAUTION

inspection to this point, inspect the housing If the bearing mandrel specified is not avail-
bearings/bushings (19) and (13) and if they are able and alternate methods are used to
captured in the housing cavity the thrust wash- press in bearing/bushing (13) and (19) the
ers (14) and thrust bearing (15). The bearing
009999-000 SHEET 5 OF 9
2-9-98
bearing/bushing depths specified must be flush to .03 inch (.76 mm) below the housing
achieved to ensure adequate bearing sup- wearplate contact face. Use the opposite end of
port and correct relationship to adjacent the bearing mandrel that was used to press in
components when assembled. the outer bearing/bushing.
MANDREL
s1 36
3. Press the dirt and water seal (20) into the

[mm]
housing (18) outer bearing counterbore until it is
flush.
BEARING MANDREL
4. Place housing (18) assembly into a soft
1. If housing (18) bearing components were jawed vise with the coupling shaft bore down,
removed for replacement, thoroughly coat and clamping against the mounting flange.
pack the outer bearing/bushing (19) with clean 18
corrosion resistant grease. Press the new bear-
ing/bushing into the counterbore at the mount-
ing flange end of the housing, using the bearing
mandrel which will control the bearing/bushing 42
depth of 0.151/0.161 inches (3.84/4.09 mm)
from the end of the bearing counterbore.
NOTE!
Bearing mandrel must be pressed against the
lettered end of bearing shell. Take care that the
housing bore is square with the press base and 5. Assemble the back up washer (17) and the
the bearing/bushing is not cocked when press- seal (16) with the seal lip facing toward the
ing a bearing/bushing into the housing. inside of the motor into their respective counter-
bores in housing (18).
6. Assemble thrust washer (14) then thrust

MANDREL
bearing (15).
34
NOTE!
The coupling shaft will be seated directly
against the thrust bearing.
7. Apply masking tape around the keyway on

shaft (12) to prevent damage to seal (16).
2. Bearing/bushing (19) and (13) can now be
pressed into its counterbore in housing (18)
009999-000 SHEET 6 OF 9
2-9-98
assemble the drive link splines in their original

! CAUTION position in the mating coupling shaft splines.
The outer bearing (19) is not lubricated by
the system’s hydraulic fluid. Be sure it is
thoroughly packed with the grease (included 10
in each seal kit).
51
8. Be sure that a generous amount of clean
corrosion resistant grease has been applied to
the lower (outer) housing bearing/bushing (19).
Install the coupling shaft (12) into housing (18),
seating it against thrust bearing (15).
11. Assemble wearplate (9) over the drive link
12
(10) and alignment studs onto the housing (18).
TAPE 47 9
52
NOTE!
The coupling shaft (12) will be flush or just
below the housing wearplate surface.
12. Apply a small amount of clean grease to a
9. Apply a small amount of clean grease to a seal ring (4) and assemble it into the seal ring
seal ring (4) and insert it into the housing (18) groove on the wearplate side of the rotor set
seal ring groove. stator (8B).
NOTE! 13. Install the assembled rotor set (8) onto wear-
One or two alignment studs screwed finger tight plate (9) with rotor (8A) counterbore and seal
into housing (18) bolt holes, approximately 180° ring side down and the splines into mesh with
apart, will facilitate the assembly and alignment the drive link splines.
of components as required in the following pro-
cedures. The studs can be made by cutting off NOTE!
the heads of either 3/8-24 UNF 2A or 5/16-24 It may be necessary to turn one alignment stud
UNF 2A bolts as required that are over .5 inch out of the housing (18) temporarily to assemble
(12.7 mm) longer than the bolts (1). rotor set (8) or manifold (7) over the drive link.
10. Install drive link (10) the long splined end If necessary, use the following procedures to
down into the coupling shaft (12) and engage assemble the rotor and vane assembly.
the drive link splines into mesh with the coupling
shaft splines. A. Place stator (8B) onto wearplate (9) with
seal ring (4) side down. Be sure the seal ring is
NOTE! in place.
Use any alignment marks put on the coupling
shaft and drive link before disassembly to
009999-000 SHEET 7 OF 9
2-9-98
8C
8B
70
72
B. Assemble the rotor (8A), counterbore down D. Grasp the output end of coupling shaft (12)
if applicable, into stator (8B), and onto wear- with locking pliers or other appropriate turning
plate (9) with rotor splines into mesh with drive device and rotate coupling shaft, drive link and
link (19) splines. rotor to seat the rotor and the assembled vanes
(8C) into stator (8B), creating the necessary
8A clearance to assemble the seventh or full com-
plement of seven vanes. Assemble the seven
vanes using minimum force.
71 10
73
NOTE!
If the manifold side of the rotor was etched dur-
ing disassembly, this side should be up. If the
rotor is not etched and does not have a counter-
bore, use the drive link spline contact pattern
apparent on the rotor splines to determine the
rotor side that must be against the wearplate.
E. Remove the two assembled bolts (1) if used
! CAUTION to retain stator and wearplate.
Excessive force used to push the rotor 14. Apply clean grease to the seal ring (4) and
vanes into place could shear off the coating assemble it in the seal ring groove in the rotor
applied to the stator vane pockets. set contact side of manifold (7).
C. Assemble six vanes (8C), or as many vanes
that will readily assemble into the stator vane
! CAUTION
pockets. Manifold (7) is made up of several plates
bonded together permanently to form an
integral component. The manifold surface
that must contact the rotor set has it’s series
of irregular shaped cavities on the largest
circumference or circle around the inside
009999-000 SHEET 8 OF 9
2-9-98
diameter. The polished impression left on bolts to pull the end cover and other compo-
the manifold by the rotor set is another indi- nents into place with a final torque of 22-26 ft.
cation of which surface must contact the lbs. (30-35 N m).
rotor set.
15. Assemble the manifold (7) over the align-

ment studs and drive link (10) and onto the rotor
set. Be sure the correct manifold surface is
against the rotor set. 65
10
56
16. Apply grease to the seal ring (4) and insert it

in the seal ring groove exposed on the manifold.
17. Assemble the commutator ring (6) over

alignment studs onto the manifold.
18. Assemble the seal ring (3) flat side up, into
commutator (5) and assemble commutator over
the end of drive link (10) onto manifold (7) with
seal ring side up.
68
5
60 3
19. Assemble the seal ring (4) into end cover (2)
and assemble end cover over the alignment
studs and onto the commutator set.
20. Assemble the bolts (1) and screw in finger

tight. Remove and replace the two alignment
studs with bolts after the other bolts are in
place. Alternately and progressively tighten the
009999-000 SHEET 9 OF 9
2-9-98
009999-000 SHEET 10 OF 9
10-6-97
LUBRICATOR PUMP ing force is relieved from port ‘H’. Residual

pressure at port ‘H’ must fall below 2 PSI to per-
(011353-000) mit full return stroke of the piston.
Air bleed ‘L’ is provided for purging the pumping

chamber. The stainless steel ball used in the air
GENERAL
bleed serves as a spare for the ball used in the
outlet check valve assembly ‘J’.
The following procedures describe the opera-
tion and the overhaul of the air lubricator pump.
OVERHAUL
OPERATION
It is important that the pump be disassembled
and assembled in the order described below to
Lubricant enters through pump port ‘F’, filling
avoid damage to the piston sleeve O-rings.
pumping chamber ‘G’. Pressurized air is
applied at cylinder port ‘H’ moving the piston
assembly forward, blocking the inlet and forcing
Disassembly
the lubricant out through check valve ‘J’.
1. Unthread and remove the power cylinder
assembly.
Piston stop ‘A’ controls the quantity of discharge
by limiting piston stroke. This piston is spring
2. Remove the retainer washer.
returned to the prime position when the motivat-
POWER CYLINDER
ASSEMBLY
RETAINER WASHER
ADJUSTMENT PISTON SLEEVE
GLAND ASSEMBLY
ASSEMBLY
PUMP BODY
(BACK) REAR SEAL
RING
PUMP PISTON
011353-000 Sheet 1 of 2
10-6-97
3. Unthread and remove the adjustment gland Assembly

assembly.
1. Install the adjustment gland assembly. Do
! CAUTION not tighten fully.
Never remove the piston sleeve out of the 2. Install the piston sleeve assembly. Be sure
adjustment gland end of the pump body. rear seal ring is in place before installing
Sleeve o-rings will be sheared by cross retainer washer.
ports in the pump body.
3. Assemble the power cylinder assembly,
4. Push the piston sleeve assembly out the guiding the pump piston carefully into the piston
back of the pump body. sleeve assembly. Engage and fully tighten.
4. Snug up the adjustment gland last until it

bottoms tightly against the piston sleeve
assembly.
011353-000 Sheet 2 of 2
3-1-04
OIL INJECTION purge water from the hammer and cycle new
clean Rock Drill oil into the hammer.
LUBRICATOR (011362-000)
The hammer will not be damaged by too much
oil, but it will be damaged by not enough oil.
GENERAL
DISCHARGE AIR TEMPERATURE F°

AMBIENT AIR TEMPERATURE F°
The following topics aid in determining and
adjusting the flow rate of air lubricating oil.
RECOMMENDED LUBRICATION
Correct lubrication during drilling operation is

extremely important. Inadequate lubrication is a
major cause of hammer wear and failure.
OPERATING PRESSURE (PSIG)
‘Rock drill’ oil is the only lubricant recommended
RECOMMENDED ROCK DRILL OIL
by Driltech for use in the Hammerdril® XL. Use
the grade of rock drill oil that is proper for the cli-
mactic and operating conditions at the drill site.
Use the following chart as a guide for selecting ADJUSTMENT
the proper grade rock drill oil to use.
Air Pressure
When using new drill pipe or pipe that has not
The operating air pressure to the lubricator
previously been coated with oil, pour a quart/
pump should be adjusted to the following:
liter of rock drill oil down the drill pipe each time
Minimum Operating Air Pressure - 60 psi (4
a new joint of drill pipe is added.
bars)
One method to ensure the hammer is getting Maximum Operating Air Pressure - 200 psi
the recommended amount of oil to operate effi- (13.8 bars)
cintly is to calculate ‘.15 -.25 quarts of oil per Standard Air Regulator Setting - 60 psi (4 bars)
hour divided by 100 CFM’.
Example: XL 6/BA with a 3/8" choke uses 1335 AIR

REGULATOR
SCFM.
1335 X .2 = 2.7 qts/hr

100
Check oil levels each shift. Monitor the oil deliv-

ery to the hammer by looking at oil dripping from
the bit after each hole is drilled.
NOTE!
It is recommended that when drilling with water
or foam injection, to use the next higher grade
of Rock Drill oil. An alternative would be to
increase the quantity of oil injected. Always con-
sult the hammer manufacturer’s specifications. cw = increase
ccw = decrease
Upon completing the drilling cycle, always
011362-000 Sheet 1 of 3
3-1-04
Pump Volume and Timer machines.
Adjust pump output volume as follows: 5. On machines with a 2 dial timer mounted on
the lubricator tank, changes in the pump output
1. Add oil to the pump reservoir as required. can be made with the time ‘OFF’ knob but
should not be attempted unless the pump
2. Using a screwdriver, thread the volume stroke adjustment is not set at the desired out-
adjusting screw in (cw) completely and then out put or cycle time is out of adjustment.
(ccw) per the following table.
6.On machines with a 4 dial timer, Driltech part
number 022397-001, adjust the timer to 20
PUMP STROKE SETTING GPH (LPH) cycles per minute as follows:
‘T on’
* 10 Turns CCW 0.62 (2.3)
white dial = 1-10s
16 Turns CCW 1.00 (3.8) blue dial = 1
20 Turns CCW 1.25 (4.7)
‘T off’
* Original factory setting. white dial = 1-10s
Above values with timer set at 2 second intervals. blue dial = 2 to 6 (depending on oil grade)
3. Open the air bleed screw in the pump.
SHOWN WITH
TIMER/RELAY
MOUNTED ON
THE TANK
VOLUME NOTE!
ADJUSTING BLEED SCREW
SCREW The timer/relays (022397-001 and 008765-003)
mounted on the lubricator tank have been
replaced. If ordered, a 025501-052 timer kit will
be supplied.
7.To calibrate a 2 dial timer (025501-001)

4. Start the machine and place the lubricator proced as follows:
switch in the ‘ON’ position.
8.Locate the relay/timer, mounted in the engine
NOTE! control box on model T25KW machines and in
The ‘Working Air’ must be ‘ON’ in Gator model the circuit breaker box in the cab.
011362-000 Sheet 2 of 3
3-1-04
OUTPUT HOSE
TIMER/RELAY LOCATION
(MODEL T25KW)
9.Set the ‘OFF TIME’ to 6 to 8 seconds.
10.Set the ‘ON TIME’ to 1.5 to 2 seconds.
11.Check the lubricator pulse light for the on/off

cycle operation.
12.Tighten the pump bleed screw.
13.Remove the output hose connection at the

air discharge piping to bleed the hose and
ensure oil flow.
011362-000 Sheet 3 of 3
3-1-04
011362-000 Sheet 4 of 3
6-22-98
FIRE SUPPRESSION The basic agent storage system is a tank filled

with Ansul FORAY (monoammonium phos-
SYSTEM phate base) dry chemical which is effective on
Class A, B and C fires. A gas expellant cartridge
(006120-000 & 008836-000) provides pressurization of the dry chemical
upon actuation.
GENERAL The dry chemical extinguishing agent is deliv-

ered from the tank through the hydraulic hose
This topic gives descriptions of the fire suppres- and pre-set nozzles into the fire prone areas or
sion systems, how they operate, it explains onto the fire prone surfaces.
what to do in case of fire, how to recharge the
chemical tank and how to maintain the system.
OPERATION
DESCRIPTION Discharge of the fire suppression system is initi-

ated manually from a remote actuator (1) or
Two types of fire suppression systems are avail- electrically when detection lines signal the sys-
able; Manual and Electric Detection and Actua- tem control module (refer to the figures).
tion.
MANUAL
1
This fire suppression system consists of three
major components: a container to store the dry
chemical extinguishing agent; an actuation
3
device to trigger the system; and a delivery sys-
tem to carry the dry chemical from the storage
container to the fire.
The basic agent storage system is a tank filled 6120-s2 2

with Ansul FORAY (monoammonium phos-
phate base) dry chemical which is effective on 1
Class A, B and C fires. A gas expellant cartridge 4
provides pressurization of the dry chemical
upon actuation. 6
5
The dry chemical extinguishing agent is deliv-
ered from the tank through the hydraulic hose 7
and pre-set nozzles into the fire prone areas or
onto the fire prone surfaces. MANUAL OPERATION
ELECTRIC DETECTION AND ACTUATION

This fire suppression system consists of detec- Depressing the actuator plunger punctures the
tion wire, a manual actuation device, a control seal on the cartridge. The released pressure is
module, a container to store the dry chemical transmitted to the pneumatic actuator/cartridge
extinguishing agent, and a delivery system to receiver (2). A safety relief valve (3) at this point
carry the dry chemical from the storage con- prevents too large an actuation pressure build-
tainer to the fire. up. The pressure causes a seal in the expellant
gas cartridge (4) to be pierced. This releases
006120-000 SHEET 1 OF 5
6-22-98
the expellant gas which is then transmitted to fuel to the fire or restart the fire with sparks.
the dry chemical tank (5) where it fluidizes the
dry chemical before carrying it to the fire haz- React quickly so the fire is caught before it
ard. A bursting disc in the union assembly (6) grows too large.
prevents the flow of dry chemical until sufficient
pressure is built up within the dry chemical tank. By leaving the immediate fire area, you protect
When the proper pressure is reached, the disc yourself from windblown flames, explosions or
breaks allowing the gas/dry chemical mixture to other dangers created by the fire.
flow to the nozzle(s) (7). The pressure at the
nozzle(s) causes the nozzle cap to pop off or Heat remaining from the fire could cause reigni-
the self-closing cap to open and the dry chemi- tion after the fire suppression system has dis-
cal to be discharged. charged. Because of this, it is important that
someone stand by, at a safe distance, with a
hand portable extinguisher. This standby should
be maintained until all possibility of reignition is
IN CASE OF FIRE! past.
When a fire starts, the way you react is very When a fire suppression system discharges,
important. As soon as you become aware of a there is considerable noise accompanied by
fire, do the following four things: clouds of dry chemical. While breathing foreign
particles is not pleasant, the agent FORAY is
1. Turn the machine off. non-toxic and exposure during a fire will not
harm you.
2. Quickly actuate the fire suppression system
by pulling the safety ring pin and pushing down
the plunger on the actuator. After the Fire is Out
Machinery should not be restarted until it has

been serviced and cleaned (water may be used
to remove the dry chemical). Immediately
recharge the fire suppression system. You
needed it once, you may need it again.
6120-s1
RECHARGE
1. Pull the ring on the safety relief valve to

relieve actuation pressure.
3. Get away from your machine. Take a hand
portable extinguisher along if you can. 2. Disconnect the actuation system hose at the
cartridge receiver/actuator assembly.
4. Stand by with the hand portable extin-
guisher. 3. Open the bursting disc union assembly.
4. Remove the dry chemical tank from its

bracket.
Results
5. Replace the ruptured bursting disc with the
If you leave the machine running, it may add new disc. FLAT SIDE OF DISC MUST FACE
006120-000 SHEET 2 OF 5
6-22-98
TANK. Verify that the proper disc is being used 18. Pull up the button on the dashboard actua-
by referring to this machine’s parts manual for tor(s) or the lever on the remote actuator(s) and
the part number. Assemble the bursting disc insert the ring pin.
union, wrench tighten.
19. Remove the spent cartridge.
6. Fill the tank to rated capacity with Ansul
FORAY dry chemical as specified on the name- 20. Obtain a new actuation gas cartridge and
plate. verify the proper part number by referring to this
machine’s parts manual. Weigh the new car-
7. Clean the fill opening threads and gasket, tridge. The weight must be within 1/4 ounce of
and the fill cap threads. Coat the gasket lightly the weight stamped on the cartridge.
with a good grade of high heat resistant grease.
21. Connect the actuation system hose at the
8. Secure the fill cap, hand tighten. cartridge receiver/actuator assembly, wrench
tighten.
9. Loosen the bolts(s) on the expellant gas car-
tridge bracket or remove the cartridge guard. 22. Attach a lead and wire seal to the ring pin
and actuation button or lever.
10. Unscrew and remove the empty expellant
gas cartridge. 23. Install new detection wire (Electric Systems).
11. Make certain that the puncture pin on the 24. Notify operating personnel suppression sys-
pneumatic actuator/cartridge receiver is fully tem is back in service and record date of
retracted. recharge.
12. Obtain a new expellant gas cartridge and

verify the proper part number by referring to this
machine’s parts manual. Weigh the new car- MAINTENANCE
tridge. The weight must be within 1/2 ounce of
the weight stamped on the cartridge. Daily Checks (Electric systems only)
13. Screw the fully charged expellant gas car- 1. Visually verify that the GREEN battery LED
tridge into the pneumatic actuator/cartridge is flashing once every three seconds (replace
receiver, hand tighten. the battery as required) and that no other LED
is flashing on the control module.
14. Secure the expellant gas cartridge assembly
in its proper position in the bracket with the car- 2. Check that the detection lines are secure
tridge retaining bolt(s) or return the cartridge and not damaged.
guard.
15. Return the tank to its bracket and secure it.

Monthly Checks (Electric and Manual sys-
16. Check all hose and fittings for mechanical tems)
damage. Replace any hose that has been
exposed to fire. To provide reasonable assurance that your fire
suppression system is charged and operable:
17. Check the nozzles for mechanical damage.
Clean them and install blow-off caps or silicone The following figures are keyed to the mainte-
grease. nance steps.
006120-000 SHEET 3 OF 5
6-22-98
1. Note the general appearance of the system 9. Check the nozzle openings -- slot on F-1/2
components for mechanical damage or corro- nozzle should be closed (capped) with silicone
sion. grease or covered with plastic blow-off cap
(4120).
2. Check the nameplate(s) for readability.
10. Remove the cartridge from the manual actu-
3. Remove the fill cap. ator(s), and examine the disc -- the seal should
be unruptured.
4. Make certain the tank is filled with free-flow-
ing Ansul FORAY dry chemical to a level of not 11. Return the cartridge to the manual actua-
more than 3 inches from the bottom of the fill tor(s) assembly, hand tighten.
opening.
12. Replace any broken or missing lead and
5. Secure the fill cap, hand tighten. wire seals and record date of inspection.
MONTHLY MAINTENANCE CHECKS Semi-Annual Checks (Electric and Manual

systems)
6120-s2 To provide maximum assurance that your fire

suppression system will operate effectively and
10 3 safely:
11 4
12 5
1. Perform the monthly maintenance proce-
dures.
2. Examine the fill cap gaskets for elasticity --

2 clean and coat lightly with a good grade of high
6 heat resistant grease.
7
3. Inspect the threads on the fill cap and in the

fill opening for nicks, burrs, cross-threading,
rough or feathered edges.
1 9
4. Check the pressure relief vent in the fill
8 opening threads for obstruction.
5. Engage the bursting disc union (wrench

6. Remove the expellant gas cartridge and tighten).
examine the disc -- the seal should be unrup-
tured. ! CAUTION
7. Return the cartridge to the pneumatic actua- Overtightening can damage the bursting
tor/cartridge receiver, hand tighten and secure disc.
in the bracket.
6. Loosen the bolt(s) which restrain the car-
8. Check the hose, fittings and nozzles for tridge or remove the extinguisher cartridge
mechanical damage and cuts. guard assembly.
006120-000 SHEET 4 OF 5
6-22-98
7. Inspect the expellant gas cartridge assembly 13. Check the nozzle openings -- the slot should
for evidence of mechanical damage or corro- be closed (capped) with silicone grease or cov-
sion. ered with plastic blow-off cap.
8. Unscrew the cartridge from the pneumatic 14. Check the remote actuator -- remove the
actuator/cartridge receiver and weigh it. cartridge and weigh (replace if weight is 1/4
Replace if its weight is not within 1/2 ounce of ounce less than stamped on the cartridge).
the weight stamped on the cartridge. Inspect the threads on the cartridge and in the
actuator for nicks, burrs, cross-threading, rough
9. Inspect the threads on the cartridge and in or feathered edges. Check pressure safety vent
the pneumatic actuator/cartridge receiver for in actuator body for obstruction. Examine the
nicks, burrs, cross-threading, rough or feath- actuator cartridge gasket for elasticity -- clean
ered edges. and coat lightly with a good grade of high heat
resistant grease. Pull the ring pin and operate
the actuator button several times to check for
free movement.
SEMI-ANNUAL MAINTENANCE CHECKS
13 26
14
6120-s2
15
16
26
19
20
21
22
23
18
24 17
25
10. Check the pressure vent in the pneumatic

actuator/cartridge receiver for obstruction.
11. Examine the cartridge receiver gasket for

elasticity. Clean and coat lightly with a good
grade of high heat resistant grease. Return the
cartridge pneumatic actuator/cartridge receiver,
hand tighten.
12. Be sure the dry chemical tank is firmly

mounted in its bracket.
006120-000 SHEET 5 OF 5
6-22-98
006120-000 SHEET 6 OF 5
01-15-01
THREAD GREASE B. Replace the cover nut on the pump stud to

hold the airmotor cover securely in place.
LUBRICATOR
C. Assemble the nipple and adapter through
(015587-001) the hole in side of airmotor cover and into air-
motor. This connection must be leakproof.
ASSEMBLY
7. Connect the air coupler to an air hose of suf-
1. Assemble the drum cover to the pump as ficient length so the lubrigun can be used to
follows: cover the entire lubrication area.
A. Remove the cover nut from the top of the

pump. Lift the air motor cover from the pump.
B. Remove the four screws holding cover bot-

tom to the pump outlet body.
C. Hold pump with pump outlet body resting

securely on the inner surface of the cover-bot-
tom. Insert end of pump tube through hole in
drum cover. Line up holes in the drum cover, 15587-1e
cover-bottom and pump outlet body.
2. Push the insert through follower with the

small cone of the wiper body facing up. Place
the insert retainer over the insert and align the
holes on the insert and insert retainer. Secure
the assembly with four self tapping screws.
3. Remove the drum top and insert the follower

into the drum against the surface of the lubri-
cant.
4. Insert the pump into the lubricant drum.
A. Guide end of pump tube into the follower

insert.
B. Lower the pump tube into the lubricant drum

until the drum cover rests on the top bead of the
drum.
5.Assemble the lubricant hose to the pump out-

let body. Connections must be leakproof.
6. Replace air motor cover.
A. Place the cover over the airmotor and posi-

tion it over cover-bottom.
015587-001 SHEET 1 OF 1
3-6-98
DRILL MONITOR SYSTEM NOTE!

The click of the shutdown relay (SDR) contacts
(DMS) and the fuel system should be audible both ON
and OFF (DMS pins 20 and 21).
(015702-000)
Periodically a more comprehensive test should
The Drill Monitor System provides warning sig- be made to verify that the sensors actuate at the
nals to the operator or automatically shuts down proper settings and that disconnecting or
the machine (for critical out-of-limit conditions) grounding (depending on whether the sensor is
in the event that the monitored conditions are normally open or normally closed) a sensor will
not within safe limits. The system is provided indicate a fault.
with a thirty second delay for start up, a system
test push button, audible alarm, and a “first out” NOTE!
indication for shut downs. Engine oil pressure and coolant temperatures
are monitored by the engine electronic control
There are three different levels of fault sensing: module (ECM).
Level 1. Flashing amber light.

SYSTEM TEST
Level 2. Flashing amber light and audible
alarm. 1. Before applying power to the monitor sys-
tem, verify that all sensors are properly installed
Level 3. Flashing red light, audible alarm, and and that the wiring is correct.
machine shutdown.
2. On the back of the monitor panel, ensure
The audible alarm can be silenced at any time that switches 1, 2, 5 and 8 are in the ‘ON’ posi-
by means of a silence push button. The light will tion. For machines equipped with a low pres-
continue to flash until the fault condition is sure compressor (100 psi - 6.9 bar), switch 12
cleared. Only one level three fault will be indi- should also be ‘ON’.
cated at any one time (first out). This will allow
the cause of the shutdown to be easily deter- NOTE!
mined. Level three faults can be converted to The switch numbers correspond to the sensor
alarm only, if desired, by an external wiring connected to the terminal labeled two digits
change. higher than the switch number. (The sensors
connected to terminals 3, 4, 7 and 10 are
‘OPEN’ under normal conditions and terminal
SYSTEM OPERATION 14 is ‘OPEN’ on machines with low pressure
In the event of a machine shutdown, after the compressors.)
problem is rectified, it is necessary to turn off
the key switch at the start panel momentarily to 3. Turn the ignition key switch to ‘ON’ and ver-
reset the system and restart the 30 second time ify that terminals 1 20 and 21 are +24 volts and
delay to start the engine. the engine fuel solenoid has energized. After 30
seconds in the ‘ON’ position; the ALTERNA-
The system operation should be checked once TOR light should illuminate, the alarm should
per shift by turning on the key switch and wait- sound, the fuel solenoid should de-energize
ing 30 seconds to verify that a shutdown fault is and the following lights should illuminate:
indicated and that the fuel system is de-ener- • COMPRESSOR OIL PRESSURE
gized. • ENGINE OIL PRESSURE
• ENGINE COOLANT FLOW
015702-000 Sheet 1 of 5
3-6-98
Push the ALARM SILENCE button. C. Reconnect wire -- light off.
4. Turn the ignition key switch to ‘OFF’ - then

back to ‘ON’, and push the LAMP TEST button.
All lights should illuminate. Release the button.
Repeat step 2 after 30 seconds. L
Compressor
E Air Filter Alternator
V
5. Turn the ignition key switch to ‘OFF’. Con- E Engine
Air Filter
Engine
Coolant Level
nect jumper wires from terminals 13, 15 and 17 L
to ground to prevent the timed shutdown from 1 Fuel Level Compressor
Separator
activating. Check the operation of each moni-
tored point as follows: LAMP ALARM Hydraulic
Oil Level
L
E Hydraulic
COMPRESSOR AIR FILTER V TEST SILENCE Oil Temp.
A. Connect a jumper wire from M3 to ground-- E

Hydraulic
COMPRESSOR AIR FILTER light illuminates. L Oil Filter
2
B. Disconnect jumper wire -- light off.
ALARM
Power On Engine Oil
ENGINE AIR FILTER Temperature
A. Connect a jumper wire from M4 to ground -- L Compressor Engine

Air Temp. Oil Pressure
ENGINE AIR FILTER light illuminates. E
B. Disconnect jumper wire -- light off. V Compressor Coolant
Oil Pressure Temperature
E
L
FUEL LEVEL Compressor
inter-stage F°
Engine
Coolant Flow
A. Disconnect wire M5 from terminal 5 -- FUEL 3
LEVEL light illuminates.
B. Reconnect wire -- light off.
ENGINE COOLANT LEVEL

A. Disconnect wire M6 from terminal 6 -- HYDRAULIC OIL FILTER PRESSURE
ENGINE COOLANT LEVEL light illuminates. A. Connect a jumper wire from M10 to ground --
B. Reconnect wire -- light off. HYDRAULIC OIL FILTER PRESSURE light illu-
minates and alarm sounds.
COMPRESSOR SEPARATOR B. Push ALARM SILENCE button -- alarm off.
A. Connect a jumper wire from M7 to ground -- C. Reconnect wire -- light off.
COMPRESSOR SEPARATOR light illuminates.
B. Disconnect jumper wire -- light off. ENGINE OIL TEMPERATURE
A. Disconnect wire M11 -- ENGINE OIL TEM-
HYDRAULIC OIL LEVEL PERATURE light illuminates and alarm sounds.
A. Disconnect wire M8 from terminal 8 -- B. Push ALARM SILENCE button -- alarm off.
HYDRAULIC OIL LEVEL light illuminates and C. Reconnect wire -- light off.
alarm sounds.
B. Push ALARM SILENCE button -- alarm off. NOTE!
C. Reconnect wire -- light off. The following tests will de-energize the engine
fuel solenoid. Reconnecting the wire should not
HYDRAULIC OIL TEMPERATURE cause the light to illuminate. It will be necessary
A. Disconnect wire M9 from terminal 9 -- to turn the ignition key to ‘OFF, then ‘ON’ and
HYDRAULIC OIL TEMPERATURE light illumi- wait 30 seconds between the testing of each
nates and alarm sounds. point.
B. Push ALARM SILENCE button -- alarm off.
015702-000 Sheet 2 of 5
3-6-98
COMPRESSOR AIR TEMPERATURE D. Turn ignition key to ‘OFF’ then ‘ON’ -- light
A. Disconnect wire M12 from terminal 12 -- off.
COMPRESSOR AIR TEMPERATURE light illu- E. Reconnect the temporary ground wire.
minates, and alarm sounds and fuel solenoid
off. ALTERNATOR
B. Push ALARM SILENCE button -- alarm off. Verify the ALTERNATOR indicator light with the
C. Reconnect wire -- light still illuminated. engine off by connecting a 12 volt supply to ter-
D. Turn ignition key to ‘OFF’ then ‘ON’ -- light minal 18 -- the ALTERNATOR light should go
off. off. To check the alternator light with the engine
E. Reconnect wire 12. running, disconnect wire M18 from terminal 18 -
- the light should illuminate.
COMPRESSOR OIL PRESSURE If all the above conditions are met and all the
A. Disconnect the temporary ground wire from sensors are operational, remove the ground
terminal 13 -- COMPRESSOR OIL PRESSURE jumpers from terminals 13, 15 and 17.
light illuminates, and alarm sounds and fuel The engine can now be started. After starting
solenoid off. the engine and the 30 second delay has
B. Push ALARM SILENCE button -- alarm off. elapsed, make one final check by disconnecting
C. Reconnect wire -- light still illuminated. one of the level three sensors and verify the
D. Turn ignition key to ‘OFF’ then ‘ON’ -- light engine shutdown system and proper indication.
off. (Wire M12, M13, M14, M15, M16 or M17.)
E. Replace temporary ground wire.
ENGINE OIL PRESSURE

A. Disconnect the temporary ground wire from
terminal 15 -- ENGINE OIL PRESSURE light
illuminates, and alarm sounds and fuel solenoid
off.
C. Reconnect wire -- light still illuminated.
D. Turn ignition key to ‘OFF’ then ‘ON’ -- light
off.
E. Replace temporary ground wire.
ENGINE COOLANT TEMPERATURE

A. Disconnect wire M16 from terminal 16 --
ENGINE COOLANT TEMPERATURE light illu-
minates, and alarm sounds and fuel solenoid
off.
D. Turn ignition key to ‘OFF’ then ‘ON’ -- light
off.
ENGINE COOLANT FLOW

A. Disconnect the temporary ground wire from
terminal 17 -- ENGINE COOLANT FLOW light
illuminates, and alarm sounds and fuel solenoid
off.
015702-000 Sheet 3 of 5
3-6-98
015702-000 Sheet 4 of 5
3-6-98
015702-000 Sheet 5 of 5
3-6-98
015702-000 Sheet 6 of 5
07-22-98
REMOTE PROPEL wise and counter-clockwise.
CALIBRATION ‘OPERATE’ PUSH-BUTTON - prevents

inadvertent machine movement if only the
(019907-000) joystick handle is moved.
VALVE OUTPUTS - provide a typical cur-

GENERAL DESCRIPTION rent range of 180 to 380 milliamps to two
separate single coil valves, via 200 Hz pro-
This system implements the drive and steer- portional PWM signals. Current flow is
ing control for a dual track driven machine. reversible, and the threshold and maximum
output currents are independently adjust-
able in both directions, for each valve.
GENERAL
AUX. OUTPUT - provides a +12 volt signal
The controller is a dual axis joystick with an (3 amps maximum) whenever any of the
‘Operate’ (deadman) push-button in its RG valve outputs are active. This will drive an
handle. The joystick’s handle position is external customer supplied horn.
measured by two ‘Digisensors’.
The ‘Superflex’, located in the cab, is a WIRING

device that converts signals from the joy-
stick controller’s Digisensors to proportional Refer to the wiring schematic.
PWM signals to drive two single coil valves
and a horn. The Superflex also monitors the • Power - Nominal + 12 volts DC is con-
Operate button on top of the joystick to pro- nected to the Dual relay and DJS6 devices.
vide the proper machine operation.
• Valves - Relay terminals 9 and 12 con-
The dual relay assembly contains two DPDT nect to the valve (relay K1 is for the Left
relays that reverse the current flow to the 2 valve and K2 for the Right valve). The
valves. It also contains DIN tie points for relays are de-energized for forward move-
connecting power and ground to the system. ment: current flows from terminal 9, through
the valve to terminal 12. (Refer to the valve
The Optimizer OPT-3 is a hand held user instructions for additional hookup informa-
interface with a keyboard and an alphanu- tion.)
meric display. It is used as a calibration and
diagnostic tool, to display various system • DJS6 Joystick - three wires connect to
values, and to make adjustments. the Superflex, and one wire to +12 volt
power.
FUNCTIONS • The Optimizer is connected to the right

side of the 8 pin Superflex connector with
TRACK DRIVE (SKID STEER) - The Super- the provided 4 conductor cable assembly.
flex converts forward/reverse and left/right
movement of the joystick handle into suit- • Aux. Output is wired to the customer’s
able commands for driving the two machine horn.
tracks. This allows precise steering and
speed control with a single lever, and also
provides the ability to “turn in place” clock-
019907-000 SHEET 1 OF 6
07-22-98
OPTIMIZER’S MAIN DISPLAY plus and <-> minus keys are then used to
increase or decrease the values. The Super-
When the Optimizer is first connected to the flex has built in limits to certain adjustments.
Superflex, the display will be similar to this: For example, the Threshold cannot be set
greater than 80%, but the Max Out can be
LEFT TRACK RIGHT set to 100%.
45 %F 52 %F
The Calibration Diagram shows all of the
possible data items, functions and how to
The main display shows the actual Superflex
access them by stepping or scrolling. Sev-
outputs to the machine’s valves. As the joy-
eral of these items are not applicable to this
stick lever is moved, this display changes to
application (SF1-1-159). Whenever a data
show the instantaneous outputs. In this
variable is flashing, it may be adjusted (incre-
example, the Superflex is outputting 45 per-
mented or decremented). To permanently
cent of the maximum current in the forward
(F) direction to the left track, and 52% to the save the new data, press the <ENTER> key
until the display stops flashing.
right track. The F will change to an R when
the output current is in the reverse direction.
If the Optimizer is disconnected and then re-
connected, the system will return to the first
CALIBRATION (USING THE OPTIMIZER) display screen. If any adjustments were
being made when the Optimizer is unplugged
(the display was flashing), these changes will
For ease of use, only three of the Optimizer’s
keys are used to make adjustments and be lost.
access all of the data. The <+> plus and <->
Threshold
minus keys are used to step or scroll through
the various data items. Pressing the
<ENTER> key while displaying Threshold, L THRESHOLD
R
Maximum Out, or Ramp Up will allow these
F: 40% F: 40%
parameters to be adjusted.
Threshold sets the minimum amount of out-

put that is applied to the machine’s electro-
hydraulic valve when the joystick is just
moved into the start of its active region. The
Threshold should be set so the machine just
starts to move when the joystick lever is in
this position.
19907sc
For convenience, both the Left and Right
Thresholds can be adjusted up and down
together (both will flash). Then each individ-
ual Threshold can be adjusted for fine turning
or balancing.
Threshold may be adjusted between 0 and

80%. There are four separate adjustments:
for the Forward and The Reverse directions
When any adjustment is allowed, the data on
of each valve.
the display’s bottom line will flash. The <+>
019907-000 SHEET 2 OF 6
07-22-98
19907sb
CALIBRATION DIAGRAM
019907-000 SHEET 3 OF 6
07-22-98
Maximum Output flex cover can be used for diagnosing certain

problems such as short circuited or discon-
L MAX OUT R nected wires.
F: 85% F: 85%
Joystick Position - Optimizer Display
‘Max Out’ sets the maximum amount of out-
DS1 (X) DS2 (Y)
put that is applied to the machine’s electro-
128 131
hydraulic valve when the joystick is moved
fully into its active region. The ‘Max Out’ is
adjusted with the joystick fully on. Set the The Optimizer may be used to check for cor-
‘Max Out’ so that the machine is just at its rect operation of the joystick controller.
maximum speed. Be sure to adjust the
Threshold before adjusting the ‘Max Out’. DS1, the ‘X’ axis Digisensor will vary as the
joystick handle is moved left to right. In the
For convenience, both the Left and Right center, the value should be approximately
maximum outputs can be adjusted up and 128 (between 125 and 131). When the han-
down together (both will flash). Then each dle is moved toward the left, this number
individual ‘Max Out’ can be adjusted for fine should decrease to < 10. When the handle is
tuning or balancing. moved to the right, this number should
increase to > 245.
‘Max Out’ may be set between 20 and 100%.
There are four separate adjustments for the DS2, the ‘Y’ axis Digisensor will vary as the
forward and the reverse directions of each joystick handle is moved forward and
valve. reverse. In the center, the value should be
approximately 128 (between 125 and 131).
Ramp Up Time When the handle is moved in reverse (toward
the operator), this number should decrease
This sets the amount of time it takes for the to < 10. When the handle is moved forward
Superflex outputs to increase or “ramp up” (away from the operator), this number should
whenever the joystick is rapidly moved. The increase to > 245.
initial setting is 0.1 seconds, which is effec-
tively “no” ramp. The Ramp Up may be Joystick ‘Operate’ Pushbutton - Optimizer
adjusted between 0.1 and 5 seconds. There Display
are separate adjustments for the Forward
and Reverse directions. DUAL ACTV LT RT
0 1 0 0
TROUBLESHOOTING The ‘Operate’ button, on the joystick handle,

may be tested on this display. The number
Superflex LEDS under ACTV (activate) should be a 1 when
the Operate button is pressed, and 0 when
There are three red LEDs on the Superflex, the button is released. If it is always 0, check
labeled “Inputs”, “SFLEX” and “Outputs”. for a broken or disconnected wire. If it is
Normally, when the power is on, the Input always 1, check for a wire shorted to +12
and the SFLEX LEDs will be flashing. When
the machine is being driven, all 3 LEDs will
be flashing.
A troubleshooting chart printed on the Super-

019907-000 SHEET 4 OF 6
07-22-98
volts.
19907SA
019907-000 SHEET 5 OF 6
07-22-98
Part Number and Serial Number
OEM PART NUMBER

SF1-1-159.000
SERIAL NUMBER
D246
The Superflex’s part number and serial num-

ber may be displayed on the Optimizer. The
part number includes the software version
number.
019907-000 SHEET 6 OF 6
THE HUMAN BODY AND
ELECTRICAL SHOCK
GENERAL
Personnel safety should be the main concern

when working with any AC or DC electrical sys-
tem or circuit.
DESCRIPTION
Most circuits in any surface mine are of suffi-

cient voltage to overcome your body’s resis-
tance. Therefore the miner must be able to
recognize and avoid coming into contact with an
One milliampere (ma) is 1/1000 of an amp.
electrical source.
If a fellow worker becomes part of an electrical
When a person is electrocuted, he/she
circuit and cannot let go of the source, DO NOT
becomes the path of least resistance for the
rush over and grab him/her. You can become
electrical source to ground and in effect
part of the electrical shock as well. Instead, dis-
becomes a part of the circuit.
connect the power to the circuit. If this is not
possible, remove the person from contact by
Properly grounded equipment is the best way to
using something insulated to PUSH or PULL the
prevent electrical shock. Another effective
person away while protecting yourself.
means is insulation by means of rubber gloves
and boots, rubber mats, insulated platforms and
guards around cables.
! DANGER
Handling electrical equipment with wet
hands or while standing in water will cause
electrocution. Handle all electrical equip-
ment in a dry environment.
The killing factor in electrical shock is current.

Current is measured in amps and is determined
by voltage. Ordinary household appliances
require currents high enough to kill a person.
Current necessary to operate a 100 watt light
bulb is (eight 8) to (ten 10) times the fatal
amount. In the event of accidental electrical contact call
• 5 milliamp (safe) for help and apply the appropriate first aid mea-
• 8 milliamp (slight shock) sures.
• 20 milliamp painful shock
Federal law requires that any repair, installation,
• 50 milliamp (very painful shock) or testing of electrical equipment be done by or
• 100 milliamp (possible fatal shock) under the supervision of a qualified electrician.
Electrical Safety Page 3
All disconnecting devices must be tagged out of Appropriate ground fault management systems
service prior to work being performed. should be employed at the mine and made
available to the specific machine.
Follow any lock out and tag out procedures rec-
ommended by the mine site. Do not attempt to Sandvik Mining and Construction mandates that
operate the equipment until all lockout devices each miner responsible to perform maintenance
are cleared by a shift supervisor(s). or operating duties on a drill machine utilize the
appropriate PPE personnel protective equip-
All persons performing maintenance work shall ment deemed necessary to perform the duties
have a separate lock and signed tag connected of the job or task assigned.
to the multi lock.
HIGH VOLTAGE AC or DC powered equipment

should be de-energized prior to and during
maintenance work performed on the electrical
system(s).
Only electricians specifically trained to work

with high voltage circuits should be permitted to
perform electrical maintenance.
Page 4
OHM’S LAW and ELECTRICAL CIRCUITS
Ohms Law
Ohms law expresses the relationship between the current (I), the voltage (E), and the resistance (R)
in a circuit. Ohms law can be expressed in three different ways and can be applied to the entire cir-
cuit or to any part of a circuit. When any two factors are known the third unknown factor can be cal-
culated from Ohms law.
I= E AMPERES = VOLTS
OHMS
R
E = IR VOLTS = AMPERES X OHMS
R= E OHMS = VOLTS
AMPERES
I
Ohms law is factored into the design of electrical and electronic systems. Specific components are
selected to meet the design essentials to make the components last for hours of maintenance free
operation.
Ohm’s Law Page 5

ELECTRICAL CIRCUITS
SERIES
PARALLEL
+ -
+ -
SERIES PARALLEL
G R
+ -
Page 6
FUNDAMENTALS OF CURRENT
Electrical current is the flow, or movement of
ELECTRICITY electrons. This movement can be compared to
the flow of water through a pipe. Without pres-
sure (voltage) the current will not flow. Electrical
GENERAL current is measured in amperes or “amps”.
Electrical terms mentioned in the Sandvik Min-

ing and Construction training module are com-
mon to the electronic industry.
DESCRIPTION
The following terms apply to basic electric sys-

tems.
• VOLTAGE
• ELECTRONS CURRENT = ELECTRON FLOW
• RESISTANCE
• OHMS RESISTANCE
• CURRENT Resistance is simply a restriction of current flow.
Increasing resistance reduces current flow
• AMPERES which can be detected by voltage decreases or
loss in the electrical circuit. Electrical resistance
The following terms are common electrical sys- is measured in “ohms”.
tem tools used to diagnose electrical compo-
nents and the overall system performance:
• VOLTMETER RESISTANCE CURRENT
“OHMS” “AMPS”
• AMMETER
• OHMMETER
In basic terms:
VOLTAGE
Voltage provides the electrical pressure, or
force that causes the current or electrons to
flow. The voltage is the difference in electrical
pressure between two points in a circuit. Electri-
cal voltage is measured in “volts”.
VOLTAGE = ELECTRICAL PRESSURE
Fundamentals of Electricity Page 7

MAGNETIC FIELD DIGITAL MULTIMETER
A magnetic field is produced when current is The Fluke 83V meter shown is a multimeter. It
forced through a conductor. The magnetic field has capability to measure AC and DC volts, mil-
and direction of flow are factors to consider livolts, amps, milliamps, ohms, diodes. Other
when using test equipment such as ammeters. features are frequency, capacitance, duty
cycles and temperature.
VOLTMETER
The voltmeter is used to measure the electrical
- pressure in the circuit. Analog and digital mod-
els are available. It is suggested to use the digi-
tal type.
+ In a DC circuit voltmeters are always connected

across (in parallel with) a part of the circuit.
TEST EQUIPMENT
The use of test meters is an invaluable and
essential aid in diagnosing troubles in an electri- VM
cal circuit. If values of voltage, current and
resistance are not measured with suitable test
meters, only a guess can be made as to what
type of defect exist in the circuit.
VOLTMETER
Voltmeters measure the difference in electrical

potential or pressure between the points where
the voltmeter leads are attached. Typical leads
are red for positive (+) and black for negative (-)
polarity.
Common 24 volt systems may read (0 - 32)

volts.
Common 12 volt systems may read (0 - 16)

volts.
AMMETER
The ammeter is used to measure the amount of
current flow. It is suggested to use a digital type
ammeter.
Ammeters generally require opening the circuit

so the ammeter can be connected in series to
measure the current flow.
Page 8
AM
AMMETER
In a DC circuit amps and milliampere are two

common circuit flows.
OHMMETER
The ohmmeter is used to measure resistance in
the circuit. Make certain that the socket connector is
sealed from contaminants and the contact ter-
Ohmmeters are connected across the unit or minals are clean and tight. Dirt, rust and loose
portion of the circuit of which the resistance is to connections lead to interruptions in the electric
be measured. flow to the device resulting in erratic or intermit-
tent control.
The ohmmeter has it’s own power source, usu-
ally a small battery or fuse which forces current Battery Specific Gravity Test
through the circuit to be measured.
This test is performed with a hydrometer, which
Never connect a ohmmeter to an external is the most accurate hand held tool for deter-
source of voltage. Battery, fuse or meter move- mining the state of charge of a lead acid battery.
ment damage may occur.
Coil Testing
When testing the coil resistance take note of the

meter reading. In Ohm mode a good coil will
register some reading such as 40 ohm as
shown by this meter. If the meter reading indi-
cates OL or some number less than the coil
spec a new coil is in order.
1. Draw electrolyte into the hydrometer a few

times so that the float reaches the same
temperature as the electrolyte. This will
increase the accuracy of your readings.
2. Hold the hydrometer vertically so that the

float is free and does not touch the inner
walls of the barrel.
Fundamentals of Electricity Page 9

3. Hold the hydrometer so that the liquid is
level in the barrel and at eye level.
4. When you draw the electrolyte, make sure

that the hydrometer is full.
5. Check each individual battery cell. If the spe-

cific gravity varies more than .050 or "50
points" among the cells while the battery is
at a 75% state of charge or above, then the
battery is bad and should be replaced. The
cells that have a specific gravity of 50 points
less than the highest cell are bad cells. A
hydrometer reading of 1.265 or greater at
80°F indicates a full charge for Interstate
batteries. To determine the battery's state of
charge, compare the hydrometer reading to
the Specific Gravity Chart.
6. To get the most accurate hydrometer read-

ing, you should adjust your hydrometer
reading according to the temperature. If the
electrolyte temperature is ABOVE 80°F ,
ADD .004 (called "four points") to the
hydrometer reading for each 10 degrees
above 80°F. If the electrolyte temperature is
BELOW 80°F, SUBTRACT four points from
the hydrometer reading for each 10 degrees
below 80°F.
Specific Gravity Specification
1.265 100%
1.225 75%
1.190 50%
1.155 25%
1.120 00%
Page 10
COMPONENT LOCATION
D45KS GENERAL OVERVIEW

PVS*
APS LBS* BAT
(DCTJB) RBS* ECF BDS
LRP CLO
FL2
FL1 ESS CHI CFP*
(MJB) CSP
ECL
DHP
HWP
FRP
VSS
PLP
FL3
(DCJB) CAC ACC
(CJB 3) LT*
EOT CIT
EFL LS*
(EJB 2) CAT EFP*
FL4-6 COP
ESPB* RRP - FFV - HFP LPS
CFP
(CJB 1) FOS - FVS - HOL
(TIJB) HVS --------- HOT
FRS
FPS * - ALTERNATE LOCATIONS
CIS (.JUNCTION BOXES)
Crawler mounted machines use common elec- • replace corroded wire terminals
trical component locations. Asterisk * in the gen-
eral location drawing indicate alternate location. • replace corrosion inhibitors 015411-001
annually
Maintenance for electrical systems include: • maintain a good seal for the wire bundle
• learn the equipment electrical system prior entering the cab through the fire wall
to performing any electrical service • eliminate any wire harness contact points
• follow electrical safety guidelines respective that rub against hard surfaces
to company policy • maintain cab and engine control module
• keeping the junction box doors closed and braided ground strap
sealed from moisture • when applicable locate wire harnesses away
• periodic checks inside the junction box for from contaminating fluids, (oils and fuels)
terminal wire connections, tighten compo- • test each battery, battery cables and the
nents as needed charging system annually using approved
• clean inside junction box with low pressure test equipment and skilled personnel
dry compressed air
Component Location Page 11
OPERATOR CONSOLE OVERVIEW
PITH BUZ
EDC
PLS RSM FLG
VSS LSW PL1-2 MLE MLD
CSW CFL LRL FRL RRL
CKE DIA
ESPB1 ESM
WTG ATG
OPG VM
ESM
FFS
BMS
DMS KS BPS
POS SPB FPL
EPB IRS
MLS
Open the center console cover to expose com-
LTC VC* mon cab ground buss bars with green wires.
RTC
(TIJB) (CJB 1) Open the right console cover to expose wire ter-
TIBP
TFS
CB1-10 minals and cab monitoring components.
TPL MR VC HIR
CR1-4 TAR FSP
Gauges are polarity sensitive. Note gauge have
CRAWLER EQUIPMENT OPERATOR CONSOLE three terminals I for power in, S from a sender
and G for ground.
Loosen the two lock screws at the top of the Refer to service literature 006269 for Cat and
panel to open the operator station monitor panel 007672 for Cummins engine speed meter ESM
and access the electrical component wires. calibration.
RSM FG Refer to service literature 015702 for DMS drill

monitor system troubleshooting.
ESM
OPERATOR CAB JUNCTION BOXES
Lower right side cab junction box.

ATG
TB WTG
VC
VM CB 8 - 1
OPG
MLS
IRS
EPB
LTR
SPB
BPS CB 10 - 9
HIR TAR
DMS* KS
INSIDE D45KS CAB MR
OPERATOR STATION MONITORING JUNCTION BOX 1
Page 12
Circuit breaker 1 through 10 are common. Addi- Verify wire and application with machine spe-
tional options may require extra circuit breakers. cific electrical group and schematics.
Confirm wire numbers with machine specific Electric schematics are used in conjunction with
electrical group and schematics. this manual for training purposes. Electric sche-
matics show all options available for the specific
Circuit breakers 015178-0 - - have a 0 to 30 blasthole drill.
VDC rating. Current capacity are 10, 15, 20, 25,
30, 35, 40, and 50 amp breakers. They are nor- Since each machine is customer specific the full
mal closed and will open under high electric list of options may not be used. When diagnos-
loads as well as electrical short circuits. ing the machine using electrical schematics it
will be necessary to understand the machine
Each circuit breaker has a manual reset func- model and specifications.
tion. Inspect each circuit breaker individually as
they are dedicated to specific circuits. This is achieved by the machine serial number
and checking the machine specific parts man-
Typical wire and applications: ual.
WIRE/SIZE APPLICATION
B 2/4/6/10 STARTING/SUPPLY
L 10/14 NIGHT LIGHTING

A1
A2
K 10/14 AIR CONDITIONING VC*
D1
E1
A 14/16 OPERATOR MONITORING
H 14 CAB ACCESSORIES
E 14/16 12 VDC CONTROLS (EDC D90KS)
B 3/0 BATTERY POWER

TB
S 14/16 CAB STARTING ENGINE RUN LTR*
CIRCUIT PROTECTION L3
M 14/16 (16) DRILL MONITOR SYSTEM (DMS)
R 14/16 MACHINE TRAM/DRILL FEATURES

R3
J 14 OPERATOR FEATURES AND S1
OPERATING OPTIONS MR
F 14/16 (16) MACHINE LEVELING DRILLING G HIR TAR

FEATURES/OPTIONS
D 14 COLD WEATHER OPTIONS
C 14 DRILL/PROPEL FEATURE* LOWER RIGHT SIDE DRILL CONSOLE PANEL
C 14 DRILL AUTOMATION*
Machine options such as tram interloc, jack
N 14/16 24/12 ACCESSORIES*
brake tram interloc and rotary head - jack brake
P 14/16 24/12 ACCESSORIES* interloc requires a junction box positioned in the
T 14/16 (16) DEPTH COUNTER OPTIONS operator cab lower left side under the operator
console.
G 3/0 2/4/6 BATTERY/ALTERNATOR GROUND
G 10/14/16 GROUND Proximity switches, relays and a floor mounted

foot pedal enable the tram feature. The tram

interoc components have a power indicator and Maintenance is limited to inspecting the box for
a bypass feature for diagnostic purpose. loose wires, component condition and terminal
subplate mounting.
POWER
BYPASS LIGHT
SWITCH
SMS
EMB
CONTROL SDR
RELAYS 1 - 4
ER
OPTIONAL TRAM INTERLOCK

SMS are magnetic solenoids that energize from
JUNCTION BOX the starter push button and key switch power.
One magnetic solenoid per engine starter. The
contacts allow battery current from B6 wire to
ENGINE JUNCTION BOX B3 and B4 wires to the engine starter solenoid.
ESPB ACB is a circuit breaker from the engine sup-

plied alternator. They are 105 amp or 80 amp
MCB rated and special application 175 amp.
ACB
SMS1/SMS2 ESPB MCB is the main circuit breaker for the entire
machine supply current. If the main circuit
breaker opens all machine power is lost.
ESPB is a manual controlled safety shutdown

switch. It is a push lock type button that is nor-
mal closed contact until the button is engaged
at which point the contacts open and stop power
ER/SDR to the shutdown relay.
MCB
ACB
The machine frame is the ground. All DC power
happens due to selected components having a
constant ground to the machine frame.
TB
INSIDE ENGINE JUNCTION BOX 2
The engine junction box will support the engine

starting, engine run and circuit protection com-
ponents.
Page 14
COMPRESSOR JUNCTION BOX MAST AND COMPONENTS
ENC
RHU/EDC
FCS/HLI
INSIDE COMPRESSOR
JUNCTION BOX RHU/TI
The compressor junction box is a terminal point CIP

FL2
for electrical component wires from the front of
the machine. No electrical components are sup-
ported in the compressor junction box.
(MJB)
PLP
Maintenance is limited to inspecting the box for
loose wires or terminal subplate mounting. LOP
LIP
ROP
HWP RIP
MLP
Wires from switches positioned inside the mast

should have power and ground contacts
brought back to the mast junction box or opera-
tor cab junction box for proper frame grounding

DATA COLLECTION JUNCTION BOX The Sandvik data collection system consists of
multiple components.
The data collection is a new concept on D45KS
machines. This feature was added to the option • transducer feed
list as of June 2006.
• transducer rotation
• transducer air
• rotation speed sensor
• canbus data collection module 1
• run and error LEDs
• external mount sealed junction box
• Sandvik DMS
• Engine ECM
• Sandvik EDC
Data received at the sensors and tranducers will

be available to record or transmit when modular
mining system is connected to the Sandvik data
collection system
The Sandvik drill rig data collection system is a

terminal junction port to be used with a after-
market field installation of Modular Mining Sys-
tem.
Page 16
ELECTRONIC ENGINES
CATERPILLAR APPLICATION
GENERAL
Sandvik Mining and Construction uses two

quality engine manufacturers to power our
blasthole drill machines:
• Caterpillar
• Cummins
Both suppliers provide service through compe-

tent world-wide distributor networks.
DESCRIPTION
Our blasthole drills require engine horsepowers

that both Caterpillar and Cummins are capable
of delivering.
Engines manufactured from 1993 to 1995 may

have been served with either the Woodward or CUMMINS APPLICATION
Barber Coleman type speed controls.
In 1995 and early 1996 to present the engine

manufacturers converted to electronically con-
trolled engines with high pressure fuel systems
At present all blasthole drill equipment utilize

the electronic fuel injection.
Light indicators at the operator station allow the

operator a means to monitor the engine ECM
electronic control module. A data link connec-
tion enables diagnostic test equipment installa-
tion.
In the event that the check engine light is on

and the diagnostic indicator light is flashing the
operator should take appropriate measures.
Refer to engine data section of this manual or

the engine specific diagnostic code retrieval
specs.
Crawler mounted operator controls are a desk

type panel with hydraulic and electrical systems.
Electronic Engines Page 17

Page 18
CATERPILLAR TIER II AND FUEL PRESSURE SENSOR
The fuel pressure sensor monitors filtered fuel
TIER III ENGINE DATA pressure.
INTAKE MANIFOLD AIR TEMPERATURE

GENERAL SENSOR
The inlet air temperature sensor detects the
The electronic system consists of the following temperature of the air that is passing through
components, electronic control module ECM, the inlet manifold. The ECM uses the data from
mechanically actuated electronically controlled the inlet air temperature sensor in order to accu-
unit injectors MEUI, wiring harness, switches rately control the emission level of the engine.
and sensors. As the inlet air temperature changes the fuel
injection timing is advanced.
DESCRIPTIONS OIL PRESSURE SENSOR

The engine oil pressure sensor provides an oil
The following sensors are components of Cater- pressure signal to the ECM for the purpose of
pillar engines. engine monitoring. The signal is compared to
the oil pressure map that is stored in the ECM.
ATMOSPHERIC PRESSURE SENSOR The oil pressure map is derived from a direct
Measures crankcase pressure. Atmospheric relationship between engine speed and the oil
pressure sensing is used to reduce smoke pressure that is expected at that speed. Low oil
emissions at high altitudes. pressure is recorded in the ECM.
BOOST PRESSURE SENSOR SPEED/TIMING SENSOR

Measures intake manifold pressure. Boost pres- Determines both engine speed and fuel injec-
sure is used to reduce smoke emissions during tion timing by magnetic sensor to camshaft con-
acceleration. nection. Primary and secondary units apply
(12vdc). If one sensor fails replace both units.
COOLANT LEVEL SENSOR
This sensor monitors the engine coolant level in DIAGNOSTIC LAMP
the cooling system expansion tank. The coolant Communicates engine status or operational
level sensor signal is sent to the ECM for the problems. Two digit diagnostic codes are given
purpose of engine monitoring. with one-second pauses between code digits. A
three-second pause occurs between codes.
COOLANT TEMPERATURE SENSOR Additional diagnostic codes may follow after the
The engine coolant temperature sensor moni- 3-second pause.
tors the temperature of the engine coolant. The
coolant temperature is sent to the ECM for the ETHER INJECTION SYSTEM
purpose of engine monitoring and for improved The engine ECM controls the ether system to
engine control. improve the cold starting capability. The ECM
uses the Coolant Temperature Sensor to control
FUEL TEMPERATURE SENSOR ether injection. The ECM uses actual engine
The fuel temperature sensor monitors the inlet rpm to determine if ether should be injected.
fuel temperature. Changes in the temperature The ether control logic assumes a “continuous”
of the fuel affects power output of the engine. ether system is being utilized and the duration
The ECM adjusts the engine fuel rate according of injection is a linear function of coolant tem-
to the temperature of the fuel. Fuel temps perature. The automatic ether injection circuit
exceeding 194° F (90° C) for ten minutes log a turns ON the relay driver when the following
diagnostic code. conditions are met. The engine speed must be
Caterpillar Engine Data Page 19
between 30 rpm and 1500 rpm and the coolant ECM DIAGNOSTIC CODES
temperature is between –40° to +50° F (-40° to
+10° C). The ether injection time is selected Diagnostic codes are used by the electronic
from a linear relationship between these tem- system in order to alert the operator that a prob-
peratures. The end points of this function are – lem exists.
40° F (-40° C) for 130 seconds, 50° F (+10° C)
for 15 seconds. A two digit diagnostic code also indicates the
nature of the problem to the service technician.
Manual ether injection can occur between 30
and 1500 rpm if the coolant temperature is
below 150° F (+60°C) for maximum time dura- FLASH
DESCRIPTION
SHUT
SER
SCH
CODE DOWN SER
tion of 2 minutes. This function is a customer
supplied override switch. 72 CYLINDER 1 FAULT X
72 CYLINDER 2 FAULT X
Troubleshooting the engine requires a skilled 73 CYLINDER 3 FAULT X
engine technician familiar electronic fuel sys-
tems and the computer program Caterpillar
electronic technician or (Cat ET). 74 CYLINDER 5 FAULT X
21 5 VOLT SHORT TO +BAT- X

TERY
21 5 VOLT SHORT TO X
GROUND
24 OIL PRESSURE SENSOR X

SHORT TO +BATTERY
24 OIL PRESSURE SENSOR X

SHORT TO GROUND
46 LOW OIL PRESSURE X X

WARNING
46 LOW OIL PRESSURE X X

SHUTDOWN
25 TURBO OUTLET PRES- X

SURE ABOVE NORMAL
25 BOOST PRESSURE SEN- X

SOR OPEN/SHORT TO
+BATTERY
25 TURBO OUTLET PRES- X

A check engine and diagnostic light installed on SURE SENSOR SHORT TO
GROUND
the machine operator panel will enable active
38 INTAKE MANIFOLD TEMP X
fault codes to be seen when they occur. The SENSOR OPEN CIRCUIT
sequence of flashes represents the system
38 INTAKE MANIFOLD TEMP X
diagnostic message. SENSOR SHORT CIRCUIT
64 HIGH INTAKE MANIFOLD X

The first sequence of flashes represents the first TEMP WARNING
digit of the diagnostic code. A one second 64 VERY HIGH INTAKE MANI- X
FOLD TEMPERATURE
pause then a second sequence of flashes will
occur which represent the second digit of the 26 ATMOSPHERIC PRESS X
SENSOR OPEN/SHORT TO
diagnostic code. +BATTERY
26 ATMOSPHERIC PRESS X
Active diagnostic flash codes may be displayed SENSOR SHORT TO
GROUND
with the engine running or with the ignition key
in the on position, engine off.
Page 20
FLASH SHUT SCH
C15, C16 and C18 model engines have
DESCRIPTION SER
CODE DOWN SER replaced 3406E models on blasthole drill
27 COOLANT TEMP SENSOR X
machines.
OPEN/SHORT TO +BAT-
TERY
27 COOLANT TEMP SENSOR X

SHORT TO GROUND C15 C16 C18 CATERPILLAR ENGINE SENSORS
61 HIGH COOLANT TEMPER- X
ATURE WARNING
61 HIGH COOLANT TEMPER- X

C D E F
ATURE SHUTDOWN B G
51 SYSTEM VOLTAGE INTER- X
MITTENT/ERRATIC
65 HIGH FUEL TEMPERA- X

TURE WARNING
A
13 FUEL TEMPERATURE X
SENSOR OPEN/SHORT TO
+BATTERY
13 FUEL TEMPERATURE X
H
SENSOR SHORT TO
GROUND
63 FUEL FILTER RESTRIC- X J1/P1

TION WARNING
J2/P2
63 HIGH FUEL PRESSURE

I
J
35 ENGINE OVERSPEED L K
WARNING
34 LOSS OF SPEED TIMING X1 X

SENSOR/ENGINE RPM
SIGNAL
A SECONDARY SPEED TIMING SENSOR
62 LOW COOLANT LEVEL X
WARNING B INLET MANIFOLD AIR PRESSURE SENSOR
C CUSTOMER CONNECTOR J61
53 ECM ERROR/FAULT X D ELECTRONIC GROUND STUD
E FUEL PRESSURE SENSOR
Engines are factory programed to shutdown F FUEL TEMPERATURE SENSOR
under common Caterpillar switch parameters. G INLET MANIFOLD AIR TEMPERATURE SENSOR
H TC PROBE CONNECTOR
I ELECTRONIC CONTROL MODULE
Active diagnostic code represents a problem J ENGINE OIL PRESSURE SENSOR
with the electronic control system. K ATMOSPHERIC PRESSURE SENSOR
L PRIMARY SPEED TIMING SENSOR
When the ECM generates a diagnostic code the
ECM will log the code in the permanent memory
Tier II and Tier III C15, C16 and C18 engines
of the ECM.
monitor fuel pressure and coolant level.
Additional reference materials: Event Codes
Caterpillar Electronic Troubleshooting Guide Events refer to engine operating conditions
SENR 9576-04 and System operation, testing such as low oil pressure or high coolant temper-
and adjusting manual RENR 2347-02 for C15 ature.
and C16 industrial engines.
Logged events usually indicate a mechanical
Caterpillar 3406E Industrial engine, Systems problem instead of electronic system problem.
Operation Testing and Adjusting manual SENR
1067 has necessary information for trouble-
shooting and maintaining the engine systems.
Caterpillar Engine Data Page 21
FLASH DESCRIPTION OF CODE
CODE
35 ENGINE OVERSPEED WARNING
46 LOW OIL PRESSURE WARNING
46 LOW OIL PRESSURE DERATE
46 LOW OIL PRESSURE SHUTDOWN
61 HIGH ENGINE COOLANT

TEMPERATURE WARNING
3. Disconnect the J1/P1 and J2/P2 connectors
61 HIGH ENGINE COOLANT of the ECM. Move the harness to a position
TEMPERATURE DERATE that will not allow the harness to accidentally
61 HIGH ENGINE COOLANT move back and make contact with any of the
TEMPERATURE SHUTDOWN ECM pins.
62 LOW ENGINE COOLANT LEVEL
WARNING
63 FUEL FILTER RESTRICTION DERATE
63 FUEL FILTER RESTRICTION WARNING
63 HIGH FUEL PRESSURE
64 HIGH INLET TEMPERATURE DERATE
64 HIGH INLET TEMPERATURE WARNING
65 HIGH FUEL TEMPERATURE DERATE
65 HIGH FUEL TEMPERATURE WARNING
Welding On A Machine That Is Equipped

With Electronic Engines. 4. Connect the welding ground as close as
possible to the area that will be welded.
Proper welding procedures are necessary in
order to avoid damage to the engines ECM,
sensors and associated components. ! CAUTION
If possible remove the component that requires Improper grounding can cause damage to
welding. bearings, hydraulic components, electrical
and electronic components
When component removal is not applicable use Do not ground the welder to electrical com-
the following procedure. ponents such as the ECM or sensors.
1. Stop the engine, turn the key switch to the 5. Use standard welding methods to weld the
off position materials.
2. Disconnect the negative battery cable from Clamp the ground cable from the welder to the
the battery or open the battery disconnect component that will be welded. Place the clamp
switch. as close as possible to the weld.
Page 22
CUMMINS QSK19 SERIES • High coolant temperature
CELECT ELECTRONIC • Low coolant level (optional)

CONTROLS • Low coolant pressure
DESCRIPTION • High fuel temperature

Cummins engines detect two types of fault
codes; electronic fuel system fault codes and • High intake manifold temperature
engine protection system fault codes.
• Low/very low oil pressure
All fault codes are recorded will either be:
• High blow by pressure
• active
SENSORS POSITIONED ON THE ENGINE
• inactive QSK CUMMINS ENGINE SENSORS (LEFT)
C D
Active fault codes may be read using the check B
engine (amber) and diagnostic light (red) on the
drill console. Inactive fault codes may be read A
with a laptop only.
To check for active fault codes: E
• Turn the key switch to the off position.
• Move the diagnostic switch to the on posi-

tion.
• Turn the key switch to the on position.

G
F
• If active fault codes are available the check
engine light will begin flashing a three digit
A COOLANT TEMPERATURE SENSOR
code with one second pauses between dig- B OIL PRESSURE SENSOR
its. C INTAKE MANIFOLD TEMPERATURE SENSOR
D INTAKE MANIFOLD PRESSURE SENSOR
The lights will remain off during normal engine E ENGINE SPEED SENSOR
operation. F AMBIENT AIR PRESSURE SENSOR
G ENGINE CONTROL MODULE
• Red light on while engine is running, stop
the engine in a safe manner as soon as pos-
sible. This fault may be engine disabling. Some external components will be at different
locations for different engine models.
• Amber light on the engine can still be run but
may loose some system features which may
result in a power loss condition. The failure
must be repaired as soon as convenient.
Cummins engine protection system monitors

the QSK series engines for:
Cummins Engine Data Page 23
QSK CUMMINS ENGINE SENSOR (RIGHT)
I H
H COOLANT PRESSURE SENSOR

I STARTER MOTOR
Troubleshooting the engine requires a skilled

engine technician familiar with electronic fuel
systems.
Three lights positioned on the machine operator

panel will enable active fault codes to be seen
when they occur. The sequence of flashes rep-
resents the system diagnostic message.
The first sequence of flashes represents the first

digit of the diagnostic code. There will be a 1
second pause between flashes. Codes are in a
three digit numeric sequence.
Diagnostic retrieving may be performed using

the toggle switch labeled increment/decrement.
Page 24
FAULT CODES FAULT
DESCRIPTION EFFECT
CODE
FAULT 452 FUEL PRESSURE SENSOR - COMPONENT RED LIGHT

DESCRIPTION EFFECT
CODE SHORT LOW (< 0.15 VDC)
111 ELECTRONIC CONTROL MODULE - MEM- RED LIGHT 554 FUEL PRESSURE SENSOR - IN RANGE AMBER LIGHT
ORY FAILED FAILURE (< 0.50 / > 1.83 VDC)
115 ENGINE SPEED SENSOR - BOTH SIGNALS RED LIGHT 555 HIGH BLOW BY PRESSURE ENGINE PRO-
LOST SHUTDOWN ( > 14.5 IN H2O) TECTION
122 BOOST PRESSURE SENSOR - COMPO- AMBER LIGHT 719 BLOW BY PRESSURE SENSOR - COMPO- AMBER LIGHT
NENT SHORT HIGH (> 4.72 VDC) NENT SHORT HIGH ( > 4.94 VDC)
123 BOOST PRESSURE SENSOR - COMPO- AMBER LIGHT 729 BLOW BY PRESSURE SENSOR - COMPO- AMBER LIGHT
NENT SHORT LOW ( < 0.33 VDC) NENT SHORT LOW ( < 0.29 VDC)
135 OIL PRESSURE SENSOR - COMPONENT AMBER LIGHT

SHORT HIGH ( > 4.88 VDC) Reference material Quantum wiring diagram
141 OIL PRESSURE SENSOR - COMPONENT AMBER LIGHT bulletin no. 3666133-02, Operator and mainte-
SHORT LOW (< 0.31 VDC) nance manual QSK19 series engine bulletin no.
143 OIL PRESSURE SENSOR - DATA BELOW ENGINE PRO- 3666120-02 (publication 020235-000)
NORMAL RANGE TECTION
144 ENGINE COOLANT TEMP SENSOR - COM- AMBER LIGHT

PONENT SHORT HIGH ( . 4.95 VDC)
145 ENGINE COOLANT TEMP SENSOR - COM- AMBER LIGHT

PONENT SHORT LOW ( < 0.21 VDC)
151 ENGINE COOLANT TEMP SENSOR - DATA ENGINE PRO-

ABOVE NORMAL ( 212° f 100° c) TECTION
153 iNTAKE MANIFOLD TEMP SENSOR - COM- AMBER LIGHT

PONENT SHORT HIGH ( > 4.88 VDC)
154 INTAKE MANIFOLD TEMP SENSOR - COM- AMBER LIGHT

155 INTAKE MANIFOLD TEMP SENSOR - DATA ENGINE PRO-

ABOVE NORMAL (220° f 104° c) TECTION
221 AMBIENT AIR PRESSURE SENSOR - COM- AMBER LIGHT

PONENT SHORT HIGH (> 4.78 VDC)
222 AMBIENT AIR PRESSURE SENSOR - COM- AMBER LIGHT

234 ENGINE SPEED - DATA ABOVE NORMAL RED LIGHT
254 FUEL SHUT OFF VALVE - COMPONENT RED LIGHT

SHORT LOW ( < 17 VDC)
261 FUEL TEMPERATURE SENSOR - DATA ENGINE PRO-

ABOVE NORMAL ( > 160° f 71° c) TECTION
263 FUEL TEMPERATURE SENSOR COMPO- AMBER LIGHT

NENT SHORT HIGH ( > 4.94 VDC)
265 FUEL TEMPERATURE SENSOR COMPO- AMBER LIGHT

NENT SHORT LOW ( < 0.21 VDC)
343 ELECTRONIC CONTROL MODULE - INTER- AMBER LIGHT

NAL COMMUNICATOR ERROR
346 ELECTRONIC CONTROL MODULE - AMBER LIGHT

POWER ERROR
415 OIL PRESSURE SENSOR - DATA INDI- ENGINE PRO-

CATES VERY LOW OIL PRESSURE TECTION
441 BATTERY VOLTAGE UNSWITCHED - DATA AMBER LIGHT

BELOW NORMAL (12VDC)
442 BATTERY VOLTAGE UNSWITCHED - DATA AMBER LIGHT

ABOVE NORMAL (38 VDC)
451 FUEL PRESSURE SENSOR - COMPONENT RED LIGHT

SHORT HIGH ( > 4.78 VDC)
Cummins Engine Data Page 25

Page 26
ELECTRIC SCHEMATIC SYMBOLS
(TYPICAL SYMBOLS USED ON BLASTHOLE DRAWINGS)
THERMAL OVERLOAD
FUSE (BREAKER) CIRCUIT BREAKER
PUSH BUTTON (N.O.) PUSH BUTTON (N.C.) SWITCH (N.O.)
PRESSURE SWITCH (N.O.) TEMPERATURE SWITCH (N.C.) LEVEL SWITCH (N.C.)
FLOW
FLOW SWITCH (N.O.) DIODE RHEOSTAT
ALTERNATOR/
BATTERY (MOTOR/ GENERATOR)
GAUGE
VARIABLE
LIMIT SWITCH (N.O.) LIMIT SWITCH (N.C.) RESISTOR
Electrical ISO Symbols Page 27

COIL SOLENOID LIGHT
CONTACT (N.O.) CONTACT (N.C.) GROUND
PLUG & SOCKET COIL (INDUCTOR) CAPACITOR
E E
I= E = IR R=
R I
I = AMPERES E = VOLTS R = OHMS
SOLID WIRE
STRANDED WIRE
Page 28
CIRCUIT SCHEMATICS • Starter solenoids, one for each starter motor
(STS).
• 50MT starter motor one or two depending on

GENERAL operating condition. (STR) Pre-lube type
starter motors are available for special oper-
Sandvik blasthole rigs use common electrical ating conditions.
components and similar design circuits.
B1 BAT
DESCRIPTION
BDS
This section will show specific systems that are B1
currently used across the product line.
CC B2
ACB ALT
When ever possible the wire number will be STR
B1
shown in this section training schematics. If the
wire number is not shown refer to the machine
MCB
SMS B3 STS
application electrical schematic.
C C
Starting And Charging
B6
The machine engine must start before other CC A1

systems can function. Starting and charging cir- CB KS MR
cuits consist of the following components:
MR
• 2 - 12 volt batteries in series to enable a 24 LTC RTC TAR

volt circuit. (BAT, BDS, RS) B7 CC S1 S3
(
CB
• Alternators are 100 and 175 amp capacity,
with circuit protection. (ALT, ACB)
• Main circuit breaker enables 105 or 175 amp

overload protection. (MCB)
BPS SPB SMS
• Key switch that enables operator monitoring B7 R1 R3
and main relay power for the machine run
CC
mode. (KS) CB TAR TA
G
• Neutral safety switches interrupt the start
mode if propel levers are off neutral. (LTC,
RTC) CHARGING AND STARTING CIRCUIT
• Bypass and start push buttons allow the

machine operator starting control. (BPS, The components in this charging and start cir-
SPB) cuit are positioned on the engine, in the engine
junction box (EJB2), in the operator cab (CJB1)
• Manual ether injection for cold weather start- and operator panel (OPJB).
ing. Engine parameters enable or interrupt
this feature. (EPB) Maintain the battery and charging system and
related cables per 250 hour service instructions.
• Starter magnetic switches, one for each
starter motor circuit. (SMS)
Circuit Schematics Page 29

The specific gravity of the batteries should be Neutral Safety And Tram Alarms
checked between seasons. Ambient conditions
will effect battery capacity when a load is Neutral safety start systems are mandatory for
induced. crawler mounted drill machines.
Battery life may be affected by: Due to the cable or electronic controls that com-
• dirt mand pump displacement a safety interlock is
placed on the left and right tram controls that
• corrosion will interrupt the machine starting system.
• frayed cables
• overfilling NEUTRAL SAFETY AND TRAM ALARM
• loose hold down LTC RTC TAR
CB
• cell connector corrosion C
C
• sealing compound defect BPS

• cracked cell cover
• cracked case
• low electrolyte SPB SMS
CB
Battery test equipment includes a hydrometer. C
C
When possible maintain battery electrolyte in a TAR ALM

1.270 specific gravity range.
This may be achieved with 64% H2O and 36%

Neutral safety switches are a supplemental
acid H SO. Use distilled water as the filling solu-
component of all tram control levers.
tion.
Cable operated tram levers have the neutral
When replacing a battery cable, cut the cable
switches positioned on the center cam frame
length as short as possible and route as direct
and a square pin is positioned on the rotating
as allowable. Avoid sharp turns and bending.
cam of the same lever.
Pre-lube starter may be fitted to the engine for
A secondary function of the neutral safety
cold weather operating conditions. The starter
switch is to activate a TAR tram alarm relay that
solenoid operates a gear pump. Engine oil will
enables a alarm to give a audible signal during
circulate through the engine block to a normal
the tram mode of operation.
closed 7 psi (0.5 bar) oil pressure switch.
When the start button is actuated prelube will

occur until engine oil pressure opens the 7 psi
switch or the preset timer times out. Continue to
hold the start button. There will be a two second
pause between the prelube pump stop and the
engine start cycle.
Refer to the DMS section of this manual for

details on prelube timer and DMS run systems.
Page 30
• Production data collection (EDC, ENC,
HWP, RHU, CR, PITH, PS)
• Production data collection I (DCM1)
Options listed are customer specific. These

LTC AND RTC options may be fitted to machines in the field by
PROPEL NEUTRAL competent mechanical persons. Installations
SWITCHES may require minor welding, common hand tools,
basic hydraulic and electrical system experi-
ence.
Feed override
The feed override operating principal is to

enable maximum feed pump pressure when
Failure of the square pin or misalignment of the retracting drill pipe from a drilled blasthole.
switch can hinder engine starting and audible
alarm during tram modes. The feed pump can be controlled from 0 flow
through it’s specific output flow rate when maxi-
Features and Options
mum pressure is achieved.
Features and options are a mixture of toggle
switches, proximity switches, magnetic CB POS FRS FOS
switches, control relays, and electric/hydraulic CC
solenoid valves.
The following will be the most common features

fitted to machine applications.
• Feed override (POS, FRS, FOS) FEED OVERRIDE SYSTEM G
• Fast feed (FFS, FFI, FFV)

Operators select the feed override mode. The
• Air conditioning/heating (AC, ACC, BM, sequence shall start with the feed pump in neu-
BMS) tral
The following will be the most common options • apply the pressure override toggle switch
fitted to machine applications.
• move the feed control valve to the hoist posi-
• Dust control (DCT, FS) tion
• Tram interlock (TFS, PVS, LBS, RBS) • select the appropriate feed pump speed with
the feed pump control
• Head/jack/brake interlock (LRP, RRP, FRP,
RHU, CR1-4, PVS, LBS, RBS) Note!
• Head loader interlock (FCS, PLP, HIR, FVS) When stopping the feed system the feed speed
must be slowed prior to centering the feed con-
• Angle drill interlock (FCS, PGP) trol valve or switching the pressure override
switch.
• Monitoring (DMS, SDR, SR)

D45KS HIGH PRESSURE APPLICATION
POS
POS
D45KS LOW PRESSURE APPLICATION
The hydraulic valves are situated inside the The hydraulic valves are situated inside the
hydraulic cabinet lower left side corner. hydraulic cabinet lower left side corner.
FRS
FRS
FOS
In the high pressure application the FOS feed

override solenoid is above the manifold shown
D45KS LOW PRESSURE APPLICATION
in this view.
In the low pressure application the FOS feed OPEN LOOP FEED SYSTEM
override solenoid is lower left corner mounted
on the angle support.
A benefit of the feed override circuit is that it

increases the feed cycle time when retracting
the feed cylinder(s) and raising the rotary head
FOS
for multipass drilling applications.
The feed override solenoid coil requires 45 to

33 ohm to properly shift the hydraulic spool. The
Page 32
hydraulic spool section uses 2 each oring and
back up rings to separate ports P, A and T.
FFS FFI
CB FFV
Loss of resistance on the coil or broken orings
w
C
C
can lead to a pressure related problem on the
feed pump circuit.
Fast feed
FAST FEED SYSTEM
Fast feed is a systems designed to increase the
feed cycle time when extending the feed cylin-
der(s) and lowering the empty rotary head for The sequence for fast feed operation shall be
multipass drilling applications.
• select the feed control handle to the down
Operators select this feature with a thumb con- position
trolled switch attached to top of the feed control • set the feed pump control to the desired
handle. speed value from zero through full control
forward
FFS • actuate the thumb control for fast feed
• release the thumb control to resume normal

feed speed
• center the feed pump control to slow the

feed system when preparing to stop or
change directions
D45KS LOW PRESSURE APPLICATION • place the feed control handle in the center
position
In the high pressure application the fast feed Do not use fast feed with drill pipe connected to
control is in the same feed control handle. the rotary head.
SINGLE OR DUAL
CYLINDERS
FFS
FFV
FAST FEED
REGEN
NOTE!
The application shall be used to lower the rotary COOLING
FAN SYSTEM
head from the top to the bottom of the mast PILOT
without drill pipe attached.
Air conditioning and heating The units pressurization motor keeps the cabin
pressurized between a range of 2 to 4” Hg as
Sandvik blasthole drills utilize a roof mounted long as doors and window are closed and the
Sigma vehicular air conditioning unit. seals are intact.
Roof mounted air conditioning systems are

most common in earth drilling equipment due to
harsh environmental operating conditions.
The 019148 series Sigma units are used on all

blasthole machines.
Maintenance to air conditioning units is required

on a as needed basis and noted in lubrication
and maintenance manuals.
All units contain approximate capacity 3.5 LB of

134A refrigerant and shall be maintained per Cab climate control
local state and federal regulations.
Roof mounted air conditioner/heater elements
Sigma roof mounted units are constructed of circulate engine coolant through a heater core
stainless steel housings with removable panels enabling climate control for the cab.
to access the condenser, evaporator and fan
motors. Operators may modulate the heat control ball
valve to mix heat with fan speed for cabin com-
Cab pressurization is essential during equip- fort. To modulate temperature mix air condition-
ment operation to minimize dust entry into the ing and heat accordingly.
cabin.
Power supply and schematic
This control panel allows equipment operators
to place the fan switch on during machine oper- A thermal circuit breaker of 20 or 35 amp rating
ation. Heat and cooling may be regulated by is the main supply to the machine specific elec-
low, medium and high fan speed selection. trical system through wires designated with K or
N that operate within the 24 vdc system.
Remove the cabin filter to access a bank of 6

individual switch circuit breakers applicable for
pressurization, fan, and condenser circuits.
Page 34
Dust collector timer
This dust collector timer junction box is gener-

ally mounted on the dust collector housing. The
timer box consists of a epoxy sealed circuit
board with input and output wires attached.
Open the sealed door to access the circuit

board with time adjustment screws.
The timer calibrations enable a off time and on

time sequence to one filter cleaning cycle at a
time.
• Adjust on time to enable a quick burst of air

to the dust filter. The on time shall be
approximately 300 ms.
• Adjust the off time according to material col-

lected. Typical setting is 6 seconds off time.
The circuit board powers one solenoid and LED

per flushing valve. The LED illuminates to indi-
cate when the corresponding solenoid receives
a on cycle.
Close and tighten the door retainer latches.

Maintain the door seals to minimize dust and
019148 AIR CONDITIONING ELECTRICAL
water entry.
1R = 1 OHM
2R = 1 OHM
1CB - 6CB = 8 AMP Regulated air pressure is directed to four or five
flushing valves and electric solenoids inside the
dust collector cabinet.
Refer to the machine specific electrical sche-
matic for supply wires to the air conditioning Plastic tubes connect the flushing valve vent
system. port and electric solenoid valves. With trapped
air pressure the flushing valve is closed.

Tram interlock(s)
x Crawler mounted equipment that are subjected

DCT to varying ground terrains may require a sec-
ondary operator control as a safety feature.
50 A
PSI
In the drill machine applications the terms dead-
man and tram interlocks refer to the secondary
F operator control system.
A
90 Most often the tram interlock is a combination of
PSI F electrical and hydraulic valves that enable the
A propel pump and final drive brake systems to
operate when conditions are correct.
F
Components of the tram interlock consist of
F
• pump vent solenoid (PVS)
A • left brake solenoid (LBS)
F
)( • right brake solenoid (RBS)
CONDENSATION DRAIN A • tram foot switch (TFS)
• tram interlock junction box (TIJB)

DUST CONTROL SYSTEM
• control relays (CR 1 - 4)
When the timed cycle energizes a solenoid the • proximity switches (RHU)
flushing valve vents air to atmosphere at which
time the flushing valve opens and regulated air • limit switch (RHU)
pressure is directed to clean the specific filter.
Tram interlock may be a basic system or addi-
tional relays and switches may be attached for
added machine component safety
PVS
TFS
RELIEF SOLENOID LBS
FLUSHING
VALVE VALVES
VALVES
RBS
Flushing valve repair kits are available.

BASIC DEADMAN/TRAM INTERLOCK
Maintain good door seals. Tighten each door to
maintain adequate vacuum inside the dust col- The sequence of operating the basic tram inter-
lector. lock system
Page 36
• step on the tram foot switch (TFS) Applications used with leveling jacks may be
jack/brake interloc.
• operate the tram control levers (LTC/RTC)
forward or reverse as needed Applications used to protect drill pipe and level-
ing jacks may be head/jack/brake interloc.
• center the tram control levers to neutral posi-
tion to stop the machine travel
A tram interlock junction box supports 4 control
• step off the tram foot switch relays, terminal strips a power light and bypass
switch.
When stepping on the tram foot switch 24 VDC
power will energize the pump vent solenoid and The four control relays are connected in series
the left and right brake solenoids. with leveling jack proximity switches and a
rotary head proximity or limit type switch.
As the solenoid coils energize the hydraulic
spools move, propel pump main pressure is In the event that one of the electrical compo-
blocked and the servo pressure can release the nents become inoperable the bypass feature
track brake enabling the tram mode. may be used during system diagnostic or trou-
bleshooting.
The LBS and RBS coils require 45 to 33 ohm to
properly shift the hydraulic spool. The hydraulic
spool section uses oring and back up rings to PVS
separate ports P, A and T.
Loss of resistance on the coil or broken orings

can lead to a loss of propel pump servo pres-
sure or inadequate brake release pressure and
brake failure.
Tram foot switches and terminal contact pins

are subject to corrosion from work shoes and LBS
RBS
environmental conditions. Clean or replace ter-
minal contacts and wire ends as needed.
LTC RTC All leveling jacks shall be in the retracted posi-

tion and the rotary head shall be up or near the
crown of the mast to enable tram interlock.
With head/jack/brake interlock the sequence of

operating remains the same as long as the
rotary head and leveling jacks are up.
TFS

Head loader interlock
CR4 A feature to protect the rotary head from con-

tacting drill pipe loaders is referred to as head
loader interloc.
PVS
TFS
FCS RHU
LBS
RBS
G
TIBP
TPL
JACK/BRAKE INTERLOC
HEAD/JACK/BRAKE INTERLOCK
Sensing distance is 3/8 inch (10mm). Wire
length may be cut to fit the application. Deutch
connectors are used to connect switches into
the wire harness.
Hydraulic systems that use independent propel
pumps need to supply servo oil to the track
Proximity switches have three 18 gage wires;
brake and deadhead system pressure to enable
brown - power in, black - output to relay or con-
the machine tram mode.
trol, and blue - ground.
The proximity switch black output wire actuates

a control relay circuit that enables or disables
LBS the hydraulic system feed pump pressure.
T T
PROPEL Z P A
PUMP
T
w
V
W
TRACK
BRAKE PLP
PVS P T
T T
w
T T HIR
A B FCS
TFS
24 VDC POWER IN
FVS
If electrical systems cannot apply the hydraulic
components the hydraulic system may be termi-
nated momentarily for diagnostic purpose.
*HVS
Pressure type #4 series 1/4 hydraulic caps,
plugs and unions are required. HEAD/LOADER INTERLOCK
Page 38
The loader bottom section seat plate will make Angle Drill Vee Block Or Pipe Guide
contact with the proximity switch. Proximity
switches are magnetic sensing and offer a LED Machines with extended masts and angle drill
light to check sensitivity. options use drill pipe guides. Operators must
use the pipe guide in full extend or retract posi-
The loader switch is normal closed until it tions only.
senses metal. Upon sensing metal the loader
proximity switch goes open. The FCS feed car- Vee block and pipe guides are angle drill acces-
rier switch and HIR head interloc relay are not sories. The intended use is to stabilize drill pipe
energized. during the threading procedure.
When the operators use these items for their

intended principal drill pipe alignment will be
proper for connecting and loosening of drill pipe
threads.
PLP
ANGLE DRILL PIPE GUIDE
When the feed vent solenoid becomes ener-

gized via loader proximity switch and head inter-
loc relay, hydraulic pressure through the feed
vent solenoid vents feed pump pressure to Failure to position the pipe guide in the full out
drain. position can lead to damaged structure.
Caution:
FVS The rotary head may come in contact with the
vee block or pipe guide if not the component is
T T
not full retracted.

V
w
A combination of proximity switches, control

PRESSURE
CONTROL relays and solenoid valves may be used as a
w
safety to protect these items. This circuit will

give notice to the operator that the guide are in
position.
w
T T
FOS X OPEN LOOP FEED PUMP

FVS
T T
FCS
V
w
HIR
PGP
PRESSURE
CONTROL
w
w
T T
FVS FOS X OPEN LOOP FEED PUMP
Note!:
*HVS When the feed pump pressure is near zero the
*PGL feed down, feed up or hoist and the lower
ANGLE DRILL INTERLOCK
stacker circuits are affected.
The safety circuit will vent the feed pump to zero

pressure and stop feed system operation.
When the pipe guide is full retracted the PGP

proximity switch is open. When the pipe guide is
moved in to the mast the PGP proximity switch
closes making continuity to the HIR coil.
When the feed system carrier sprocket moves

into the FCS proximity switch range the FCS
proximity switch contacts close and 24 vdc
power enables through the FCS, PGP to the
HIR coil. When the HIR coil is energized the
FVS feed vent solenoid vents the feed pump V
port to low pressure drain.
In some applications a pipe guide light will illu-

minate telling the operator the pipe guide is in
the way of rotary head travel.
Page 40
Drill Monitor System.
CIRCUIT BOARD CONNECTIONS
EOP AND ECT

1991 - 1996 SDR
EOP AND ECT HAVE BEEN REMOVED

FROM THE DMS WITH 1996 MODEL
ENGINES AS THESE ARE MONITORED
BY ENGINE MANUFACTURERS
DIP Switch positions Engine coolant flow ECF and compressor oil
pressure COP are normal open sensors how-
ever in a dynamic run mode they are closed.
ON *
The ECF and COP, DIP switch positions must
be in the down (open position) as a closed
OPEN switch for normal run conditions.
INPUT SENSOR SELECTOR SWITCH
ON FOR NORMAL OPEN SENSORS Compressor interstage temperature CIT, DIP
OPEN FOR NORMAL CLOSED SENSORS
switch position 12 * is used on high pressure
two stage air compressors only.
DIP switch positions have to correspond with
physical switch rating. Make the DIP switch position down or open for
high pressure compressor applications.
When DIP switches differ from the physical
switch rating, alarms or shutdown conditions Make the DIP switch position up or on for low
can occur. pressure compressor applications.

Power to the DMS is initiated from the key • Level two is referencing immediate mainte-
switch KS and the main relay MR as standard to nance indicating amber light and alarm
DMS terminals 1, 20 and 21. A green power
light indicates 24 vdc power to the monitor cir- • Level three is referencing shutdown condi-
cuit board. tion indicating red light, alarm and engine
shutdown
The DMS circuit board retains memory as long

LEVEL 1 as the green power light is illuminated. When
the key is turned off the DMS green power light
is off and the DMS memory resets.
Prelube starter - DMS
When customer options include a prelube

starter system power to the DMS is initiated
LEVEL 2
after the prelube cycle occurs. A self latching
relay (SR) enables power to the DMS after the
lube cycle is finished.
The DMS power light will illuminate after the

prelube time cycle completes. Continue to hold
LEVEL 3 the bypass switch after the start cycle until
engine runs smooth at low idle.
Applied power through the DMS maintains for

30 seconds or until monitored pressures close
the normal open pressure switches. SR SR
If the machine is not started with pressures met

the DMS will time out after 30 seconds. Power
through terminal 20 and 21 will open, the engine BPS SPB PTR SMS
will stop and/or will not start.
DMS terminal 21 engages a shutdown relay

+ -
SDR that communicates to the engine control
module ECM. The SDR coil must be energized SR
to run. The SDR contacts enable a ground con-
tact to the ECM through the relay terminals. DMS
If the SDR is not energized fuel cannot get to

the injectors, the engine starter will turn the
engine flywheel but no fuel will be available.
The monitor offers three levels of monitored

protection.
• Level one is referencing maintenance indi-

cating amber light
Page 42
EDC Electronic Depth Counter
POWER IN
The electronic depth counter is a monitoring 24VDC GROUND
device that enables a drill operator the capabil-
ity to preset drilling parameters, change pro-
grams and select drilling modes during the drill VC
cycle
HWP
ENC
00.00
PHL
RHU
TEST PS CR
BUZ
EDC CR PITH
Before servicing, turn off all power. The key Depth counter nomenclature and descriptions
switch power off will suffice and remove the key
from the switch to prevent accidental power on. VC voltage converter
Access to the EDC monitor terminal strip is on Voltage as low as 18 and high as 50 VDC.
the rear panel. Power in, ground, and signal Orange wire input is @ 24 - 27.5 VDC with 15
wires are secured to specific pins that enable amp automotive fuse. Key switch input power is
the counter to function properly. connected on the EDC at terminals 25 and 28.
New and replacement EDC monitors require Regulated voltage output is @13.8 VDC output.
specific programing parameters to suit the Red wire is 13.4 VDC no fuse. Input regulated
model of Driltech machine. power is connected on EDC terminal 15.
Program parameters are priority to Driltech Both black wires are common ground (1 input)
engineering and specific machine models. (1 output) and must be connected to ground
due to high currents developed in this unit. Con-
When the EDC monitor is removed from the verters are mounted inside the cab under the
mounting cover the terminal strip is exposed. operator console with the heat sink fins vertical
for maximum heat dissipation.
Input and output connections are marked on the

converter side plate.
ENC encoder

The encoder signals range between 0 to 5 VDC Cut excess wire to an appropriate length and
variable due to shaft speed. Maximum input to secure wire ends with sealed Deutch electrical
the encoder should not exceed 135 ma. A oscil- connectors.
loscope is required to see the square wave sig-
nals 0 - 5 volt range. Electric connector kit number 019244-112.
RHU rotary head up proximity switch

CIRCUIT BOARD
The rotary head up proximity switch is mounted
SHAFT onto a fixed plate that supports the specific
metal sensing switch.
Metal sensing occurs when the rotary head is

up near the switch with the starter drill pipe con-
D D - RED WIRE 12 VDC POWER IN nected to the rotary head indicating that drill
F F - BLACK WIRE GROUND
A A - WHITE WIRE 0 - 5 VDC pipe is out of the blasthole.
B B - GREEN WIRE 0 - 5 VDC
There are four variations of this switch.
Encoder signals are transmitted through a 4 • proximity switch center mast @ carrier
wire shielded cable assembly. Testing the signal sprocket position.
inputs may be performed on the EDC terminals
11 white wire, or 12 green wire. • proximity switch top center of feed rail
• micro switch top left side mast chord posi-

The gear ratio, sprocket sizes are factory set. tion.
Encoder sprocket mounting requires free move-
ment of the taperloc bushing onto the encoder • magnetic switch top left side mast chord
shaft. Sprocket alignment and chain tension position.
held @ 3/8 (9.5 mm) are the only maintenance.
PHL preset hole depth light

RHU MICRO SWITCH
A typical 24 volt light senses input power only
when the EDC preset hole depth counter mea-
surement is reached. The counter may be man-
ually programed for various hole depths.
HWP holding wrench proximity switch
A shock mounted proximity switch positioned on

the side of the holding wrench (deck wrench) is
used to stop the counter is used with multipass
drilling applications. This proximity switch may Proximity switches use Brown (I) power in,
be omitted with single pass drill applications. Black (S) output signal and Blue (G) common
ground wires for the switch will work as a nor-
Brown (I) power in, Black (S) output signal and mal closed contact - opening contacts when
Blue (G) common ground wires for the switch sensing metal. The proximity switch has a red
will work as a normal open contact - closing LED that should illuminate when the brown and
contacts when sensing metal. The proximity black wires become common.
switch has a red LED that should illuminate
when the brown and black wires become com-
mon.
Page 44
Cut excess wire to an appropriate length and
secure wire ends with sealed Deutch electrical
connectors. (I)
Position insolated wire with at least 4 inches (10 CR

cm) and tie strap the wire to the proximity switch 7 2
body. This action removes stress from the wire
and housing bore. PS (I)
B
1 3
R
8 6
(H)
BR PIPE IN THE HOLE WARNING
BLK
The normal open switch continues a circuit to a
control relay typically positioned under the EDC
display panel. (I) equals input voltage measured
at 24 - 27.5 VDC.
BL
The PITH control relay enables audible and
visual warning only when the leveling jack or
BR
mast raise cylinders are used.
BLK A diode connects pin 2 to pin 7 so magnetic

field can dissipate to earth when the coil deen-
ergizes. Failure of the 013613-002 diode may
lead to memory failures and erratic depth count.
GENERAL PURPOSE
BL
PROXIMITY SWITCHES
DIODE
PS pressure switch and CR control relay 2 1 8 7
As part of the pipe in the hole warning system

one pressure switch (013051-007) is ported into
the machine leveling - hydraulic system.
The switch is in the hydraulic cabinet with a

pressure hose from the lower stacker inlet sec- 3 4 5 6
tion. A preset pressure value of (H) equals 900
psi (60 bar) and is adjustable on a as needed CONTROL RELAY SOCKET
basis. (002099-001)
Operation And Maintenance
Maintain a dust and water free environment for

the EDC major electronic components. Compo-
nents inside the cab are protected as best as
possible with a cover.

4. This display reading is required for the pipe
in the hole warning indication. A calibrated
display reading of -.030 will be the point at
which the pipe in the hole warning disables
the buzzer and warning light during leveling
50.00
jack and mast raise operations.
NOTE!
• The preset warning depth calibration should
not have to be reset during daily drilling
activity.
• The preset warning depth calibration may
need to be reset when a new length of drill
Calibrating preset hole depth string is added to the machine. Top sub, bit
sub and drill pipe length and rotary head
1. Press program button the red LED will blink proximity switch location affect the preset
on/off for 10 seconds in this mode. If no pro- warning depth feature.
gram change occurs the preset hole depth
program will remain unchanged. Bit position
2. Press the preset hole depth button then 1. Lower the feed and place the drill bit on the
press the corresponding number sequence ground to be drilled.
required for the drilling application. A display
reading of 50.00 will be the depth that the 2. Press reset button, the press bit position but-
preset hole depth light illuminates. ton.
3. Press the enter button when the correct hole 3. The bit position reading will be 00.00
depth factors are on the EDC display.
4. Commence drilling to the required depth or
4. The new preset hole depth calibration will until the calibrated preset hole depth light
illuminate the preset hole depth light during illuminates.
the drilling application. The drilling cycle will
not be stopped. The bit position feature is to assist the drill oper-
ator for accurate hole depths according to the
Calibrating The Preset Warning Depth specific drill bench.
1. Press program button the red LED will blink Accumulated depth
on/off for 10 seconds in this mode. If no pro-
gram change occurs the preset warning 1. Press the reset button, then press the accu-
depth will remain unchanged mulated depth button at the beginning of
each shift or at drill bit change intervals etc.
2. Press the preset warning depth button, then The display will read a 00.00 value.
press the corresponding number sequence
followed by the setup button. A negative The accumulated depth feature is to record drill
number should be displayed. related activities as needed.
3. Press the enter button when the correct neg- Programming A New Counter
ative factor are on the EDC display.
The EDC has to be programed for a specific
machine for either metric or english display
Page 46
readings. The unit has to be run through 19 set
up modes to be calibrated for a specific model
of machine.
01
DIP
4. Continue to press enter, through the number

SET UP MODE ONLY 19, noting or changing the parameters as
ADD MOMENTARY JUMP WIRE needed.
ON (PIN 1 ENB) AND (PIN 16 GND)
NOTE!
Prior to mounting the EDC into the cover frame When changing a parameter in a specific set up
perform the following procedure. mode select the appropriate number then push
the enter key. The new number will be saved
Position the 6 DIP switches as shown and the next program set up mode will appear
on the display.
1. = off, down
2. = on, up 5. Remove the momentary jump wire from pin
3. = off, down 1 and 16 at the completion of set up. This
prevents accidental set up mode changes
4. = on, up during machine operation.
5. = off, down
6. = off, down NOTE!
The 19 machine specific codes are engineering
Set up parameters protected.
1. Add a momentary jump wire to pin 1 and pin Sandvik service may render machine specific
16 in order to enter the set up mode to cali- codes on a as needed basis according to the
brate the unit. machine serial number, when requested by an
authorized Sandvik servicing dealer.
2. Press the set up button, then press enter
button. The number 01 will appear on the Use the following table with pencil to note the
display. set up parameters for a specific model and
serial number machine.
3. Press enter again, this is the first program
able set up mode. Machine model: ________________________
Machine serial number: ___________________
EDC CODES:
01- 02- 03-

Maintenance to the data collection system is
04- 05- 06-
limited.
07- 08- 09-
Components consist of
10- 11- 12-
• sealed junction box on cab wall
13- 14- 15-
16- 17- 18- • data module inside junction box
19- X X • led indicator lights
• transducers in the cab

Troubleshooting the EDC system requires a
basic knowledge of electronics, component • sensors from DMS
locations as described, test equipment such as
a digital meter and possible spare parts. • sensors on compressor and rotary head
Aftermarket Data Collection • encoder on the mast timing shaft
Customer request for remote data collection This option as it is does not enable downloads.
and management requires aftermarket compo- Once the aftermarket vender configures their
nent installation. data retrieval system the data can then be sent
by radio transmission or downloaded into a lap-
To simplify the aftermarket component installa- top.
tion Sandvik offers a terminal collection port for
the out sourced vender to connect to the Sand- Data collection junction box
vik blasthole drill machine electrical system.
Open the sealed junction box to see the data
The electrical option is called Sandvik data col- module and XM terminal points.
lection system.
DATA COLLECTION
MODULE (DCM 1)
Refer to schematic 025430-002 for wire config-

The sealed junction box supports electrical urations.
components, wires in and out.
Page 48
Electric connector kit 019244-112 is required for If the green LED were to blink or if the red LED
making or opening connections of the data col- were to blink or stay on steady the technician
lection system. should disconnect connector XM4 at the data
collection module 1 for 30 seconds then recon-
The data collection junction box door offers two nect XM4 to the data collection module 1.
CAN1 LED lights, one green and one red.
CAN2 is not used. Disconnecting and reconnecting the battery
should enable the green LED.
• CANopen run green LED
Data control module 1
• CANopen error red LED
The module collects input data from switches
The CANopen run LED shall indicate the status
and sensors. The basic system does not store
of the CANopen network state machine. While
data. It requires a 3rd party hardware for user or
the device is executing a reset the CANopen
remote interfaces.
run LED will be off.
Programming the PLC is currently limited to fac-
The green CANopen run LED is connected to
tory installation. At the present time the data col-
digital output XM1-2 of the data collection mod-
lection module DCM 1 cannot be field loaded
ule.
and will not require down loading.
RUN LED STATE DESCRIPTION
SINGLE STOPPED THE DEVICE IS IN STATE

FLASH 1 STOPPED
BLINKING PREOPERATIONAL THE DEVICE IS IN STATE

2 PREOPERATIONAL
ON OPERATIONAL THE DEVICE IS IN STATE

OPERATIONAL
The CANopen error LED shall indicate the sta-

tus of the CAN physical layer and errors due to
missing CAN messages.
The red CANopen error LED is connected to

digital output XM1-3 of the data collection mod-
ule.
RUN LED STATE DESCRIPTION
OFF NO ERROR THE DEVICE IS IN

WORKING CONDITION
SINGLE WARNING LIMIT AT LEAST 1 OF THE

FLASH 1 REACHED ERROR COUNTERS OF
THE CNA CONTROLLER
HAS REACHED OR
EXCEEDED THE WARN-
ING LEVEL (TOO MANY
ERROR FRAMES)
ON BUS OFF THE CAN CONTROLLER

IS BUS OFF

PAGE 3 OF 025430-002 DATA COLLECTION SYSTEM
Page 50
Input from switches and sensors Engine
The following components are sending a input The following components are sending a input
to the data control module 1. to the data control module.
• battery voltage
Digital
• engine boost pressure
• compressore air filter
• engine inlet manifold temperature
• compressor inter stage temperature
• engine oil pressure
• compressor oil filter
• engine fuel injection rate estimate
• compressor oil pressure
• engine fuel temperature
• compressor oil temperature
• engine speed
• engine air filter
• engine coolant temperature
• engine coolant flow
• engine coolant level
• fuel level
• engine percent load
• hydraulic oil filter
• engine percent torque
• hydraulic oil temperature
• engine hours
• hydraulic oil level
• engine fuel consumption
• lubrication oil level
• receiver separator filter The engine active warnings will be published in
the data collection module.
• fire suppression
• pipe in hole Active warnings
• zero bit position • low engine oil pressure shutdown
• high engine coolant temperature shutdown
Analogue
• low engine coolant level shutdown
• mast angle
• high fuel temperature shutdown
• rotary head position
• engine overspeed shutdown
• rotary head speed
• injector cylinder #1 open circuit
• fuel level
• injector cylinder #1 fault
• compressor oil temperature
• high inlet air temperature shutdown
• feed hydraulic pressure
• high auxilliary pressure shutdown
• rotation hydraulic pressure
• high auxilliary temperature shutdown
• receiver ari pressure
• throttle osition signal abnormal
• working air pressure
• throttle position calibration required
• drill bit position
• high fuel pressure warning
• drill penetration rate
• engine oil pressure open/short to + battery
• engine oil pressure abnormal rate of change

Transducers ENC 1 encoder for aftermarket
Transducers are input signals to the data mod- The encoder signals range between 0 to 5 VDC
ule. variable due to shaft speed. Maximum input to
the encoder should not exceed 135 ma. A oscil-
There are 4 transducers inside the cab. loscope is required to see the square wave sig-
nals 0 - 5 volt range.
• monitoring feed hydraulic pressure
• monitoring rotation hydraulic pressure CIRCUIT BOARD
• monitoring working air pressure SHAFT
• monitoring receiver air pressure
D D - RED WIRE 12 VDC POWER IN

F F - BLACK WIRE GROUND
A A - WHITE WIRE 0 - 5 VDC
B B - GREEN WIRE 0 - 5 VDC
Encoder signals are transmitted through a 4

wire shielded cable assembly. Testing the signal
inputs may be performed on the EDC terminals
11 white wire, or 12 green wire.
TRANSDUCERS
The gear ratio, sprocket sizes are factory set.
Encoder sprocket mounting requires free move-
ment of the taperloc bushing onto the encoder
Troubleshooting the transducers will require a shaft. Sprocket alignment and chain tension
digital electric meter placed in the mA range. held @ 3/8 (9.5 mm) are the only maintenance.
Expected power will be 4 to 20 mA. Operator controls
A bit zero switch BZS is on the operator station

for the purpose of communicating bit position
zero to the data collection module.
APPLY BIT ZERO

FOR EACH NEW
BLASTHOLE
Page 52
The bit zero switch must be applied secondary The frequency control selector dial must be
to the electronic depth counter EDC bit position pointing to the zero mark for run modes.
button 6 after the drill bit is placed on the ground
and prior to starting the drilling cycle. Drill Monitor System
The drill monitor system DMS and the three lev-

els of monitoring remains the same. There are
additional wires on the monitor terminals giving
00.00 inputs to the data collection module DCM 1.
When a fault occurs from a monitored compo-

nent switch the DMS gives the maintenance or
shutdown condition as standard operational
procedure. That fault is registered in the data
control module DCM 1 also.
Failure to the engage the bit zero switch BZS at The drill monitor circuit board has no service-
the start of each hole will not affect the elec- able or maintenance parts.
tronic depth counter bit position.
Maintenance is limited to cleaning the unit with
Frequency control a static free cloth, tight terminal connections,
proper DIP switch positions and proper switch
The data collection junction box supports one inputs.
programable frequency controller. It is responsi-
ble for converting a digital signal from the rotary
head mounted rotary speed sensor 2 with a 4 to
20 mA output to analog signal for the data con-
trol module 1.
DIP switch position shall be in the off position

for normal run mode. The DIP switches are for
program modes and rotary speed calibrations
only.
Reference program instructions 033418-001.

The following descriptions are exclusive to the
Sandvik data collection center.
ABREVIATION/DESCRIPTION ABREVIATION/DESCRIPTION ABREVIATION/DESCRIPTION
B E M
BZS BIT ZERO SWITCH ECM ENGINE CONTROL MODULE MAS MAST ANGLE SENSOR
EDC ELECTRONIC DEPTH COUNTER MP MONITOR PANEL
C EL 1 ENGINE LINK 1
CFP2 COMPRESSOR FILTER PRESSURE 2 EL 2 ENGINE LINK 2 R
COT COMPRESSOR OIL TEMPERATURE ENC 1 ENCODER 1 RAP RECEIVER AIR PRESSURE
CR CONTROL RELAY RHP ROTATION HYDRAULIC PRESSURE
F RHU ROTARY HEAD UP
D FC FREQUENCY CONTROLLER RSS 2 ROTATION SPEED SENSOR 2
DCI 1 DATA COLLECTION INTERFACE 1 FHP FEED HYDRAULIC PRESSURE
DCI 2 DATA COLLECTION INTERFACE 2 FLS 2 FUEL LEVEL SENSOR 2 S
DCM 1 DATA COLLECTION MODULE 1 FSP FIRE SUPPRESSION PRESSURE SDR SHUT DOWN RELAY
DL +
DL - L W
DLS DIAGNOSTIC LIGHT SWITCH LED 1 WAP WORKING AIR PRESSURE
LED 2
Page 54
ELECTRICAL COMPONENT ABREVIATION AC/DC VOLTAGE RESISTANCE
SPECIFICATIONS LRP 12/48 - 24VDC 200MA/200Hz
MR 12/36 - 24VDC 53OHM/25°C
OPS 0 - 30VDC
GENERAL RHU 12/48 - 24VDC 200MA/200Hz
FRS 0 - 30VDC 5AMP CONT

Electrical components are purchased parts from 3AMP INT@28VDC
various suppliers. Engineers determine ratings FL 0 - 24VDC 70 WATT
and capacities required for the dedicated cir-
SMS 0 - 36VDC 65AMP CON
cuits. 120 AMP INT
FLG 0 - 24VDC 33.5 - 240OHM
CB 0 - 30VDC 10 - 175 AMP

DESCRIPTION
CR 12VDC 10AMP
8 PIN 24VDC 20AMPS@28VDC
The following table may not show every compo-
CR 0 - 24VDC 10AMPS
nent and may be modified if needed. 11 PIN
LTPS (500) 0 - 12VDC 25 - 29OHM

Engineers are always looking new or improved
RTPS (500) 0 - 12VDC 25 -29OHM
components and will update them as they
become available. FVS 0 - 24VDC 33 - 45OHM
RRP 12/48VDC 200MA/200Hz

Component abbreviations and descriptions will FRP 12/48VDC 200MA/200Hz
be shown and the specifications will be given for
CAT 0 - 24VDC 5AMP@24VDC
troubleshooting purpose only.
. CIT 0 - 24VDC 5AMP@24VDC
PVS (19.2/28.8) 24VDC 20MA/31W
ABREVIATION AC/DC VOLTAGE RESISTANCE LBS 0 - 24VDC 33 - 45OHM
FLS 24/28VDC FULL 33.5 + 6 RBS 0 - 24VDC 33 - 45OHM

EMPTY 240 + 20
FLS 2 24/28VDC 4 - 20 MA Purchased electrical components need to be

ATS 0 - 24VDC 25- 29 OHM properly connected into the blasthole drill wire
WTS 0 - 24VDC 25 - 29 OHM
systems.
ESS
Common electrical components connections.
RSS 2 24/28VDC
BAT 8D/12VDC/1400CCA Compressor filter pressure switch 007947-073

CR 0 24VDC 51 MA/472OHM has three wires and in this application only two
FOS 0 - 24VDC 33 - 45OHM
wires are needed.
LTR 0 - 24VDC 10 AMP INRUSH
1 AMP MAX
CLO 1.8 - 265VDC 9.5WATT
CHI 1.8 - 265VDC 9.5WATT
FHP 24/ 8VDC 4 - 20 MA
RAP 24/28VDC 4 - 20 MA
RHP 24/28VDC 4 - 20 MA
WAP 24/28VDC 4 - 20 MA
EDC 12 AND 24 VDC
Component Specifications Page 55

It is recommended to make secure sealed con-
nections with approved Deutsch type two and
007947-073 CFP2
USE BLACK AND WHITE WIRE three pin connectors.
DISREGARD RED WIRE
Deutsch kit part number 019244-112.
The engine coolant level sensor differ from the

hydraulic and diesel fuel sensors. Oil and water
type sensors are not interchangeable.
019244-112
CATERPILLAR ENGINE CLS

RED WIRE - PIN A + 8 VDC ECM PIN 8
BLACK WIRE - PIN B RETURN ECM PIN 15
GREEN WIRE - PIN C SUPPLY ECM PIN 36
BLUE WIRE - NOT UTILIZED
Level sensors for engine coolant, diesel fuel

and hydraulic oil have three wire connectors.
Tier II and Tier III Caterpillar C15, C16 and C18

engines require the engine coolant sensor be
configured to the engine control module. Low
coolant level creates a logged code in the ECM.
Page 56
ELECTRICAL SYSTEMS COMPONENT DESCRIPTIONS
Blasthole drill abbreviated nomenclature and components for 12 and 24 vdc systems.
ABREVIATION/COMPONENT ABREVIATION/COMPONENT ABREVIATION/COMPONENT
A B COP COMPRESSOR OIL PRESSURE SW.
ACB ALTERNATOR CIRCUIT BREAKER BAT BATTERY CP CONTROL PANEL
ACC AIR CONDITIONING CLUTCH BCH BOOM CONTROL HORIZONTAL CPM CIRCULATING PUMP/MOTOR
ACH AUXILLARY CAB HEATER BCV BOOM CONTROL VERTICLE CPS CENTRALIZER PROXIMITY SWITCH
ACT ACTUATOR 3508 BDS1 BATTERY DISCONNECT SWITCH 1 CR CONTROL RELAY
ACT ANALOG COOLANT TEMPERATURE BDS2 BATTERY DISCONNECT SWITCH 2 CSP COMPRESSOR SEPERATOR PRESS.
ACV AIR CONTROL VALVE BL BOOM LOWER CSW COMPRESSOR HI/LO SWITCH
AD ANGLE DISPLAY BMS BLOWER MOTOR SWITCH CTS COMPRESSOR TEMPERATURE SW.
ADH ANGLE DISPLAY HORIZONTAL BPS BYPASS SWITCH CUP CAB RAMP UP PUSHBUTTON
ADV ANGLE DISPLAY VERTICLE BR BOOM RAISE D
AET ANALOG ENGINE TEMPERATURE BS BASE STACKER DCJB DATA COLLECTION JUNCTION BOX
AJO ANTI JAM ON SWITCH BS BOTTOM STACKER DCP DUST COLLECTOR PURGE SWITCH
AJP ANTI JAM PRESSURE SWITCH BSL BOOM SWING LEFT DCS DUST COLLECTOR SOLENOIDS
ALB AUTO LEVEL BOX BSR BOOM SWING RIGHT DCT DUST COLLECTOR TIMER
ALC AUTO LEVEL CONTROLS DH DOG HOUSE
ALF AUTO LEVEL OFF SWITCH C DHL DUST HOOD LIGHT
AJP ANTI JAM PRESSURE SWITCH CAC CAB AIR CONDITIONER DHU DUST HOOD UP PROXIMITY SW.
ALT ALTERNATOR CAP CAPACITOR DI DIODE
AOF AIR VALVE OFF CAT COMPRESSOR AIR TEMPERATURE DIA DIAGNOSTIC LIGHT
AON AIR VALVE ON CB CIRCUIT BREAKER(S) DIS DIAGNOSTIC SWITCH
APS1 AIR PRESSURE SWITCH 2 CBD COMPRESSOR BLOWDOWN SWITCH DL DOME LIGHT
APS2 AIR PRESSURE SWITCH 2 CBS COMPRESSOR BYPASS SOLENOID DLS DOME LIGHT SWITCH
AR AUTO LEVEL RELAY CBV COMPRESSOR BLOWDOWN VALVE DMS DRILL MONITOR SYSTEM
AS ANGLE SENSOR CC COMMON CONNECTOR DNR DOWN RELAY
ASI AUTO TONG SWING IN CDN CAB RAMP DOWN PUSHBUTTON DP DRILLER PANEL
ASO AUTO TONG SWING OUT CFL COMPRESSOR FILTER LIGHT DPH DIESEL PREHEATER
ASW AIR ON/OFF SWITCH CFP1 COMPRESSOR AIR FILTER PRESS. DPL DIESEL PREHEATER LIGHT
ATC AUTO TONG CLAMP CFP2 COMPRESSOR OIL FILTER PRESS. DPS DIESEL PREHEATER SWITCH
ATG AIR TEMPERATURE GAUGE CFS CONTROL OFF SWITCH DPS DRILL PROPEL SELECTOR SWITCH
ATR ANTI JAM TIMER RELAY CHI COMPRESSOR HIGH SOLENOID DR DRILL RELAY(S)
ATS AIR TEMPERATURE SENSOR CIT COMPRESSOR INTERSTAGE TEMP DSW DUST/WATER SOLENOID
ATU AUTO TONG UNCLAMP CKE CHECK ENGINE LIGHT E
AVC AIR VALVE CONTROLER CLO COMPRESSOR LOW SOLENOID ECF ENGINE COOLANT FLOW SW.
AVS AIR VALVE SWITCH COL CONSOLE ON LIGHT ECL ENGINE COOLANT LEVEL SW
Component Descriptions Page 57

CON CONNECTOR ECM ENGINE CONTROL MODULE
ECP ENGINE COOLANT PREHEATER FEU FEED EXTEND UP STROKER G
ECT ENGINE COOLANT TEMPERATURE FFR FAST FEED RELAY GCS GROUND/CAB SELECTOR SWITCH
EDC ELECTRONIC DEPTH COUNTER FFS FAST FEED SWITCH GDN GRND/RAMP DOWN PUSHBUTTON
EFFL ENGINE FUEL FILTER LIGHT FFV FAST FEED SOLENOID VALVE GEN GENERATOR SWITCH
EFFS ENGINE FUEL FILTER SWITCH FIL FOAM INJECTION LIGHT GL GAUGE LIGHT
EFL ENGINE FUEL LEVEL FIP FOAM INJECTION PUMP GLS GAUGE LIGHT SWITCH
EFP ENGINE AIR FILTER PRESSURE FIS FOAM INJECTION SWITCH GOV ELECTRONIC GOVERNOR MODULE
EIS ETHER INJECTION SWITCH FJC FRONT JACK CONTROLLER GP GAUGE PANEL
EMB ENGINE MODULE BREAKER FJL FRONT JACK LIGHT GS GENERATOR SOLENOID
ENC ENCODER FJS FRONT JACKS PRESSURE SWITCH GUP GRND/RAMP UP PUSHBUTTON
EOP ENGINE OIL PRESSURE FL FLOOD LIGHT
EOT ENGINE OIL TEMPERATURE FLG FUEL LEVEL GAUGE H
EP ENGINE PANEL FLS FUEL LEVEL SENDER HBS HOLDBACK SOLENOID
EPB ETHER PUSHBUTTON FOR FEED OVERRIDE RELAY HC HOIST CONTROL
EPS ENGINE PRESSURE SWITCH FOS FEED OVERRIDE SOLENOID HDS HOOD DOOR SWITCH
ER ETHER RELAY FPA FEED PRESSURE AMPLIFIER BOARD HFP HYD FILTER PRESSURE SWITCH
ESL ENGINE STOP LIGHT FPC FEED PRESSURE CONTROL HIR HEAD INTERLOC RELAY
ESM ENGINE SPEED METER FPD FEED PUMP DOWN COIL HMS HOUR METER SENDER
ESO ETHER SOLENOID FPL FRONT JACK PRESSURE LIGHT HOL HYDRAULIC OIL LEVEL
ESPB EMERGENCY STOP PUSHBUTTONS FPL FILTER PRESSURE LIGHT HOT HYDRAULIC OIL TEMPERATURE
ESS ENGINE SPEED SENSOR FPS FILTER PRESSURE SWITCH HPP HEAD POSITION PROXIMITY
ETR ETHER TIMER RELAY 3508 FPS FEED PUMP STROKER HPP1 HEAD POSITION PROXIMITY 1
ETS1 ENGINE TEMPERATURE SWITCH FPU FEED PUMP UP COIL HPP2 HEAD POSITION PROXIMITY 2
ETS2 ENGINE TEMPERATURE SWITCH FPV FEED PRESSURE VALVE HRS HOOD RETRACT SWITCH
F FRF FEED REPLENISHMENT FILTER HSW HOLDBACK SWITCH
FBPB FAN BYPASS PUSHBUTTON FRHL FRONT/REAR HI/LO LEVEL SENSOR HWI HOLDING WRENCH IN CONTROL
FBS FAN BYPASS SOLENOID FRL FRONT JACK LIGHT HWO HOLDING WRENCH OUT CONTROL
FC FEED CONTROLLER FRP FRONT JACK PROXIMITY SWITCH HWS HOLDING WRENCH SWITCH
FCH FEED CONTROLLER HORIZONTAL FRS FEED RETRACT SWITCH HVS HOLDING VALVE SOLENOID
FCM FEED CONTROL MODULE FS FUEL SOLENOID HWI HOLDING WRENCH IN CONTROL
FCS FEED CYLINDER SWITCH FSP SIRE SUPPRESSION PRESSEURE SW
FCV FEED CONTROLLER VERTICLE FSR FUEL SOLENOID RELAY I
FDF FEED DUMP FORWARD SOLENOID FSSV FEED STACKER VALVE IL INSTRUMENT LIGHT
FDR FEED DUMP REVERSE SOLENOID FTC FEED TRAM CONTROLLER ILS INSTRUMENT LIGHT SWITCH
FEC FEED EXTEND CONTROLLER FTL FEED TILT LEFT CONTROLLER INC INCREMENT/DECREMENT SWITCH
FECH FEED EXT CONT HORIZONTAL FTR FEED TILT RIGHT CONTROLLER IP INSTRUMENT PANEL
Page 58
FED FEED EXTEND DOWN STROKER FVS FEED VENT SOLENOID IRS IDLE RUN SWITCH
ILS INSTRUMENT LIGHT SWITCH LT LUBE TIMER P
INC INCREMENT/DECREMENT SWITCH LTC LEFT TRAM CONTROLLER PBI POWER BREAK IN CONTROL
IP INSTRUMENT PANEL LTPS LEFT TRAM PUMP STROKER PBC POWER BREAKOUT CLAMP
IRS IDLE RUN SWITCH LTR LUBE TIMER RELAY PBL PLUGGED BIT LIGHT
ITR IDLE TIMER RELAY LTS LUBE TIMER SOLENOID PBS PLUGGED BIT SOLENOID
LU LOADER UNLOCK CONTROL PBU POWER BREAKOT UNCLAMP
J M PGI PIPE GUIDE IN CONTROL
JB JUNCTION BOX 1 (CAB) MCB MAIN CIRCUIT BREAKER PGO PIPE GUIDE OUT CONTROL
JB JUNCTION BOX 2 (ENGINE) MCS MODE CONTROL SOLENOID PGS PIPE GUIDE SWITCH
JB JUNCTION BOX 3 (COMPRESSOR) MDS MOTOR DISPLACEMENT SOLENOID PHDL PRESET HOLE DEPTH LIGHT
JB JUNCTION BOX (MAST) MJB MAST JUNCTION BOX PITH PIPE IN THE HOLE SWITCH/LIGHT
K ML MAP LIGHT PL PANEL LIGHTS
KS KEY SWITCH MLC MAST LOCK CONTROLLER PL1 PANEL LIGHT1
L MLD MAST LOCK DISENGAGE LIGHT PL2 PANEL LIGHT 2
LBS LEFT BRAKE SOLENOID MLE MAST LOCK ENGAGE LIGHT PLC PROGRAM LOGIC CONTROLLER
LEL LEVEL LIGHT MLS MAIN LIGHT SWITCH PLP PIPE LOADER PROXIMITY
LFP LEFT FRONT PROXIMITY SWITCH MP MONITOR PANEL (DMS) PLS PANEL LIGHT SWITCH
LFS LEFT FRONT JACK LIMIT SWITCH MR MAIN RELAY PM PRESSURIZATION MOTOR
LIP LEFT INSIDE PROXIMITY SWITCH MRC MAST RAISE/LOWER CONTROLLER POS PRESSUR OVERRIDE SWITCH
LL LOADER LOCK CONTROLLER MS MIDDLE STACKER PPD PICKUP POT DOWN CONTROL
LLS LOADER LOCK SWITCH MS MICROSWITCH PPU PICKUP POT UP CONTROL
LLT LUBRICATOR LIGHT MSS MODE SELECTOR SOLENOID PS PRESSURE SWITCH
LOP LEFT OUT PROXIMITY SWITCH MSW MODE SELECTOR SWITCH PTS PRELUBE TIMER SOLENOID
LPS LUBE PRESSURE SWITCH O PVS PUMP VENT SOLENOID
LRHL LEFT/RIGHT HI/LO LEVEL SENSOR OFS ON/OFF SOLENOID R
LRJC LEFT REAR JACK CONTROLLER OPG OIL PRESSURE GAUGE RAD RADIO
LRL LOADER ROTATE LEFT CONTROL OPS OIL PRESSURE SENDER RBS RIGHT BRAKE SOLENOID
LRL LEFT REAR JACK LIGHT ORS OVERRIDE SWITCH RC ROTATION CONTROLLER
LRP LEFT REAR PROXIMITY SWITCH OTA OVER TILT ALARM RCS ROTARY CONTROL SWITCH
LRR LOADER ROTATE RIGHT CONTROL OTL OVER TILT LIGHT RDS REMOTE DEADMAN SWITCH
LRS LEFT REAR JACK LIMIT SWITCH OTM OVER TILT MODULE RES RESISTER
LS LUBE SOLENOID OTP OVER TILT PRESSURE SWITCH RFL RIGHT FRONT JACK LIGHT
LSB LIGHT SWITCH BREAKER OTR OVER TILT RELAY RFP RIGHT FRONT PROXIMITY SWITCH
LSI LOADER SWING IN CONTROL OTS OVER TILT SENSOR RFS RIGHT FRONT JACK LIMIT SWITCH
LSO LOADER SWING OUT CONTROL RHE RHEOSTAT
LSS LOAD SENCE SOLENOID RHM ROTARY HOUR METER
Component Descriptions Page 59

LSW LUBRICATOR SWITCH RHU ROTARY HEAD UP PROXIMITY SW.
RIP RIGHT INSIDE PROXIMITY SWITCH S U
RJL RIGHT JACK UP LIGHT SDR SHUTDOWN RELAY UPR UP RELAY
RLS RAISE/LOWER SELECTOR SWITCH SJB STROKER JUNCTION BOX
RMS ROTARY MOTOR SOLENOID SL STROBE LIGHT V
ROP RIGHT OUSIDE PROXIMITY SWITCH SLS STROBE LIGHT SWITCH VC VOLTAGE CONVERTER
ROS ROTATION OVERRIDE SOLENOID SMS1 STARTER MAGNETIC SWITCH VM VOLT METER
RPA ROTATION PRESSURE AMPLIFIER SMS2 STARTER MAGNETIC SWITCH VSF VARIABLE SPEED FAN SWITCH
RPC ROTATION PRESSURE CONTROL SPB STARTER PUSH BUTTON VSS VARIABLE SPEED SOLENOID
RPF ROTATION PUMP FORWARD COIL SPS STACKER PRESSURE SWITCH VVS1 VARIABLE VOLUME SOLENOID 1
RPR ROTATION PUMP REVERSE COIL STB SOLENOID TERMINAL BOARD VVS2 VARIABLE VOLUME SOLENOID 2
RPS ROTARY PRESSURE SWITCH STR1 STARTER MOTOR
RPV ROTARY PRESSURE VALVE STR2 STARTER MOTOR W
RRA ROTATION RATE AMP BOARD STS1 STARTER SOLENOID 1 WAL WARNING ALARM
RRJC RIGHT REAR JACK CONTROLLER STS2 STARTER SOLENOID 2 WAM WASHER MOTOR
RRL RIGHT REAR JACK LIGHT SS SEAT SWITCH WAS WASHER SWITCH
RRP RIGHT REAR PROXIMITY SWITCH WCS WINCH CONTROL SWITCH
RRS RIGHT REAR JACK LIMIT SWITCH T WGB WINCH GROUND CONTROL BOX
RS REMOTE START TA1 TRAM ALARM WIA WATER INJECTION AMPLIFIER
RSD RIGHT STRUT DISENGAGE TA2 TRAM ALARM WS WIPER SWITCH
RSE RIGHT STRUT ENGAGE TAL TRAM ALARM WSW WARNING ALARM SWITCH
RSM ROTARY SPEED METER TAR TRAM ALARM RELAY WTG WATER TEMPERATURE GAUGE
RSS ROTARY SPEED SENSOR TB TERMINAL BOARD WTS WATER TEMPERATURE SENDER
RTC RIGHT TRAM CONTROLLER TCS TORQUE CONTROL SOLENOID
RTPS RIGHT TRAM PUMP STROKER TFS TRAM FOOT SWITCH
RTS REMOTE TRAM SELECTOR TGS THREAD GREASE SOLENOID
TGSW THREAD GREASE SWITCH
TIBP TRAM INTERLOC BYPASS
TIJB TRAM INTERLOC JUNCTION BOX
TIM TAMROCK INTEGRATED MEASURING
TOL TIMER ON LIGHT
TPB TEST PUSHBUTTON
TPL TRAM POWER LIGHT
TR TRAM RELAY(S)
TS TIMER SWITCH
Page 60
SERVICE LITERATURE Amplifier Board Adjustment 015509-000
Drill Monitor System 015702-000

GENERAL Solenoid Service 017503-000
This section will give reference material specifi-
Auto Level CPU 018009-000
cation numbers for electrical systems that are
available for Sandvik Mining and Construction
Automatic Leveling 018083-000
blasthole drill service procedures.
Sigma Air Conditioner/Heater 018146-000
DESCRIPTION
Sigma Air Conditioner/Heater 018146-001
When component adjustments or repairs are
needed we advise using the service proce- Engine Perkins 3.152 Genset 019105-001
dures from the manufacturer.
Engine Perkins 4.236 Genset 019105-002
This section may be updated as new proce-
dures are written. Sigma Air Conditioner/Heater 019148-000
Hupp Air Conditioner/Heater 002712-051 Auto Level Schematic 019699-000
Engine ETS HP Application 003171-000 DMS Dip Switch Chart 021531-001
Engine ETS LP Application 004318-000
Centralized Lubrication 006113-000
Tachometer Installation Caterpillar 006269-000
Engine ETR LP Application 006814-00
Engine ETR HP Application 006814-002
Tachometer Installation Cummins 007672-000
Air Conditioner - Sigma 008692-000
Voltage Converter 011017-000
Centralized Lubrication 011060-000
Lubricator 011362-000
Controller Adjustment 014441-000
Electronic Monitoring System 014985-000
Engine ETR HP Application 015351-000
Appendix 1 - Electric Systems Service Literature - Page 1

07-01-99
VARIABLE SPEED CONTROL

(023260-01D)
D40KS, D45KS and D50KS WITH CATERPILLAR ENGINE
023260-01D Sheet 1 of 1

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023501-002

Serial Number 732213 & UP

SANDVIK MINING and CONSTRUCTION D40/45/50KS

Sandvik Mining and Construction

Indicates an imminently hazardous situation which,

Indicates a potentially hazardous situation which,

Indicates a potentially hazardous situation which,

SAFE OPERATING PRACTICES FOR DRILLERS

It is the responsibility of management to:

• Enforce the use of protective clothing, eye and hearing equipment.

The Operator’s Responsibilities

Safe Operating Practices for Drillers iii

• The operator should not operate this equipment if any

• If an unsafe condition exists, the operator must place a

• The operator should not operate the drill without first

Operator's Safety Check

• Check that there are no "lockouts" or "tagouts" attached to the

• Check the machine log book to see that periodic maintenance

• After starting the engine, check all indicators, emergency stop,

• Check the fire extinguisher(s) for charge and accessibility.

• Clean the cab interior windows if necessary.

• Test all controls for proper operation.

• The operator should treat all power lines as live.

Safe Operating Practices for Drillers v

Planning the Job

• Will the drilling take place in wet formations?

• Are there utility lines or structures that must be moved or avoided?

• Are there unusual or extreme weather conditions expected?

• Will drilling be done in night hours?

• Will the machine be propelled on inclines?

• Will drilling be done into difficult formations?

• Has a drilling pattern been developed?

• What is the required depth of the drilling pattern?

• Will special drilling tools be required to complete the job?

• Will vertical or angle drilling be required?

• Operating near or contacting a power line with any part of the

• Before leaving the operator's station, all controls must be in the

Safe Operating Practices for Drillers vii

General Maintenance Safety Practices

While operating and servicing this machine be aware of the following:

• The sudden release of a pressurized lid or hose can spray hot

• Climbing the mast is a crushing and falling hazard.

• Hydraulic oil under extreme pressure from a small opening

• Pressure in hydraulic systems can be retained for long peri-

• Carelessness in getting on and off equipment can result in seri-

Safe Operating Practices for Drillers ix

• Keep the batteries secured in their compartment and covered.

• Do not store flammable fluids on or in the immediate vicinity of the machine.

• Disconnect the battery cables before welding on the machine.

INCLEMENT WEATHER and SAFE DRILLING PRACTICES

It is the responsibility of management to:

• Determine a plan of action relating to expected bad or unexpected weather conditions.

• Consider that drill operators need ample time:

a. to retrieve drill pipe from blastholes and well bottom.

RAINFALL AND FLOODING

When notified of an impending storm, machine operators should:

Safe Operating Practices for Drillers xi

•Move the drill machine to higher ground conditions.

•Move the drill machine to stable ground and away from