Perforadora MD6240 - 6290+OMM - C+ (412450) Mantenimiento PDF

February 2012
BI006752
Operation and
Maintenance
Manual
MD6240 and MD6290
Rotary Blasthole Drill
412450 Rev. 06
SAFETY.CAT.COM
PARTS ORDERING AND PRODUCT SUPPORT

Use only genuine Cat parts in the maintenance, rebuild or repair of these machines. The manufacturer
shall have no liability as to any unauthorized modification of machines or parts. The manufacturer is also
not obligated or liable for any machines or parts that have been improperly handled; that have not been
operated, maintained or repaired according to furnished manuals or other written instructions, and that
have been operated with other than genuine Cat parts or authorized OEM components.
IDENTIFICATION OF THE MACHINE

Always furnish the Model Number and Serial Number when ordering parts. This information is found
on the machine nameplate.
PART NUMBER AND DESCRIPTION

In addition to the Model and Serial Number, always give the part number and description of each part
ordered. If there is any doubt as to the correct part number and description, furnish a dimensional
sketch or return the part to be replaced, transportation charges prepaid. Your cooperation in furnishing
as much information as possible will assist us in filling your orders correctly and in the shortest possible
time.
SHIPMENT
Unless otherwise instructed, all shipments will be made via motor freight collect, freight forwarder or
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has been approved by our accounting department.
PARTS ORDERING
In North America Telephone 1-800-854-9030
or Telefax 1-800-582-6570
Telephone (903) 786-2981
Telefax (903) 786-6407
PRODUCT SERVICE AND WARRANTY

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

Mining Products Division
3501 S. FM Hwy 1417, Denison, TX 75020
Mining.cat.com
2012 Caterpillar All Rights Reserved. CAT, CATERPILLAR, their respective logos, Caterpillar Yellow,
the Power Edge trade dress as well as corporate and product identity used herein, are trademarks of
Caterpillar and may not be used without permission.
Printed in U.S.A.
Safety Information
This safety alert symbol indicates important safety messages in this manual.
When you see this symbol, carefully read the message that follows and be alert to
the possibility of personal injury or property damage.
Before Starting Engine, Study Operators Manual

* Read and understand the warnings and cautions shown in Section 2
* Practice All Safety Precautions
* Make Pre-Operations Check
* Learn Controls Before Operating
It is Owner/Operators responsibility to understand and follow manufacturers instructions on machine operation and maintenance, and to observe pertinent safety
precautions, laws and regulations.
California Proposition 65 Warnings
The following warning applies to equipment supplied with lead-acid batteries:
Battery posts, terminals and related accessories contain lead and lead compounds,
chemicals known to the State of California to cause cancer and reproductive harm.
Wash hands after handling.
The following warning applies to equipment supplied with diesel powered engines:
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Drill Model : ___________________________________

Drill Serial No. : ________________________________
Date Delivered : ________________________________
Dealer : _______________________________________
Customer : ____________________________________
B1006752
Rev. 06
02/15/2012
Introduction
Product Description
Rotary blasthole drills are designed for blasthole drilling purposes only. DO NOT
use these machine for any other purpose than blasthole drilling. Any other use
could result in personal injury, property damage and will void the warranty.
These machines are crawler mounted drill rigs, consisting of two (2) major assemblies:
1. Rotary Drill Assembly
2. Excavator Type Undercarriage (Crawlers)
The rotary drill assembly is made up of the engine package, compressor package, hydraulic system,
rotary drive, pulldown and hoisting system and drill pipe handling mechanism.
The crawlers are powered by two (2) hydrostatic motors. Each crawler has its own independent, variable and reversible speed control, and is equipped with 33.5 inch (85 cm) wide triple cleated grousers.
Manual Contents
This manual is furnished to acquaint operators with the machine specifications, safety and operating
procedures, machine controls and daily maintenance activites.
NOTE
This manual should be considered a permanent part of the machine and must remain with the machine at all times.
The instructions in this manual are not intended to cover all details about these machines, nor do
they intend to provide for every possible contingency that may be encountered in connection with the daily
operation or maintenance of these machines.
Continuing improvement and advancement of product design might have caused changes to your
machine which are not included in this manual.
Periodic additions or revisions may be made to this manual. The right is reserved to make changes
at any time without notice and without obligation. Should further information be desired or should particular problems arise which are not covered sufficiently in this manual, the matter should be referred to the
manufacturer.
ii
Introduction
Contents
MACHINE SPECIFICATIONS .............................................................SECTION 1
SAFETY ..............................................................................................SECTION 2
OPERATOR CONTROLS ...................................................................SECTION 3
OPERATING INSTRUCTIONS ...........................................................SECTION 4
DRILLING PRACTICES ......................................................................SECTION 5
MACHINE TRANSPORT ..................................................................SECTION 6
OPTIONS AND ACCESSORIES.........................................................SECTION 7
LUBRICATION AND PREVENTATIVE MAINTENANCE ....................SECTION 8
Introduction
iii
Notes
iv
Introduction
Section 1
Machine Specifications
\Machine Specifications
1-1
MD6290 Specifications
Pull-down/Hoisting Capacity
Rated pull-down capacity
Cooler Assembly
Up to 22,680 kg (50,000 lb);

optional 27,216 kg (60,000 lb)
Rated hoist capacity
Up to 21,364 kg (47,100 lb)
Feed rate
0-42.9 m/min (0-141 fpm)
Retract rate
0-44.8 m/min (0-147 fpm)
Pull-down cylinder stroke
513.08 cm (202 in) for 30 ft configuration
Head travel (30 foot config)
1,026.16 cm (404 in)
589.28 cm (232 in) for 35 ft configuration
Head travel (35 foot config)

1,178.56 cm (464 in)

624.84 cm (246 in) for 11 m configuration
Head travel (11 m config)
1,249.68 cm (492 in)
Type
Radiator-CAC-Oil Cooler Assembly

for Cat C15
(Tier III) 540 hp, single, front-end mounted
Air-finned, three-core, radiator/aftercooling/hydraulic side-by-side
compressorstacked, CAC-stacked
Cooler height
139.70 cm (55 in)
Cooler width
269.24 cm (106 in)
Fan
121.92 cm (48 in) diameter; 10 blades
Fan speed
1,525 rpm
Fan guard
Welded
Engine radiator
Top tank
Sealed top tank, pressure cap,

overflow tube and sight glass
63.5 mm (2.5 in) top tank;
88.9 mm (3.5 in) bottom tank
Hydraulic
Number of cylinders
Cylinder bore
17.78 cm diameter (7 in)
Cylinder rod
12.70 cm diameter (5 in)
Cable type
1 in DYFORM 8
Nominal line tension
5 to 1 factor against working
Cable sheaves (cylinder)
40.64 cm OD (16 in)
Cable sheaves (top and bottom)
55.88 cm OD (22 in)
Sheave pins
5.08 cm (2 in) diameter with roller bearing
Sheave guards
Adjustable head guide shoes
Standard at bottom plate

Steel with replaceable Nylatron
Coolant connections
Compressor oil core hose connection
Hydraulic oil cooler
Hose connections
Air-to-air cooler
Standard ambient rating
63.5 mm (2.5 in) O-ring boss

41.28 mm (1.625 in) O-ring boss
114.30 mm (4.5 in) O.D.
52 C (125 F)

for Cat C27
(Tier II) 800 hp, single, front-end mounted
Air-finned, four-core, radiator/hydraulic side-by-side compressor
CACstacked
Rotary Drive System

Rotation speed
Torque
Horsepower capacity
Gearbox
Cooler width
0-220 rpm
12,880 Nm max (0-9,500 ft-lb)
Fan
165.01 cm (65 in) dual fan

116.84 cm (46 in) diameter, two fans, 16 blades
Fan speed
1,700 rpm
Casting design
Fan guard
Welded
Taper roller
Lubrication
Oil flooded
Gearing
Drive motor
Cooler height
138.7 kW (186 hp)
Main thrust bearing
Ratio
Spur
Engine radiator
Top tank
Sealed deaeriation tank, pressure cap,

52 C (125 F)
16:04 to 1
See Hydraulic System
Performance ratings are based on 100% efficiency and on engineering

specifications and calculations in accordance with accepted industry
standards. These capacities will vary with drilling conditions. All
specifications are subject to change without notice.
1-2
Cooler Assembly
Compressor

for Cummins QXR-15
Compressor (Standard)
Type
Tier III; 485 hp or 535 hp, single, front-end mounted

Air-finned, three-core, radiator/aftercooling/hydraulic side-by-side
compressorstacked, CAC-stacked
139.70 cm (55 in)
Cooler width
269.24 cm (106 in)

121.92 cm (48 in) diameter; 10 blades
Fan speed
1,525 rpm
Fan guard
Welded
Engine radiator
Top tank
Sealed-top tank, pressure cap,

63.5 mm (2.5 in) top tank;
88.9 mm (3.5 in) bottom tank
63.5 mm O-ring boss (2.5 in)
Coolant connections
Compressor oil core hose connection
41.28 mm O-ring boss (1.625 in)

114.3 mm (4.5 in) O.D.
52 C (125 F)
Radiator-Coolant-Oil Cooler Assembly

for QSK-19
Type
Dry-type with safety element/STG 16
Oil cooling
Air-to-oil cooler, thermostatically controlled
Oil separation
Vertical barrier element, pre-separation

in 136 l (36 gal) (T-tank)
Oil filtration
12 micron replaceable element
Drive
Direct coupled to engine flywheel
Controls
Air shut-off
Automatic with safety shut-down

Hydraulic cylinder-operated from operators seat
Compressor (Optional)
Max operating pressure
8.6 bar (125 psi)
Air cleaner
Dry type with safety element/STG16
Type
Oil-flooded, single-stage screw
Discharge air flow (sea level)
258.10 cm (101.625 in) single fan

154.94 cm (61 in) single fan
121.92 cm (48 in) diam, 10 blades
Fan speed
1,525 rpm
Fan guard
Welded

52 C (125 F)

for QSK-19
48.1 m 3/min (1,700 cfm)

6.9 bar (100 psi)
Air cleaner
Type
Dry-type with safety element/SRG 20
Type (high-pressure)
Oil-flooded, two-stage screw
Engine radiator
Top tank
35.4 m 3/min (1,250 cfm)
Air-finned, three-core, radiator/hydraulic side-by-side compressorstacked
Cooler height
Type
Tier I; 750 hp, single, front-end mounted
Fan
8.6 bar (125 psi)
Air cleaner
Type
Hydraulic oil cooler

Hose connections
Air-to-air cooler
Cooler width
29.7 m 3/min (1,050 cfm)
Cooler height
Fan
32.6 m 3/min (1,150 cfm)

38.2 m 3/min (1,350 cfm)
42.5 m 3/min (1,500 cfm)
10.3/24.1 bar (150/350 psi)
Air cleaner
Type
Tier II; 760 hp, single, front-end mounted

Air-finned, four-core, radiator/hydraulic side-by-side compressor
CACstacked
Cooler width
Cooler height
Fan

116.84 cm (46 in) diameter, two fans, 16 blades
Fan speed
1,700 rpm
Fan guard
Welded
Engine radiator
Top tank

52 C (125 F)
1-3
Engine
Engine (cont.)
Engine (Standard)
Manufacturer
Model
Rated horsepower
Full load
Starting system
Safety shut-down system
Engine (Optional)
Caterpillar
C15 electronic (Tier III)
403 kW (540 hp)
2,100 rpm
24 V DC
Energized to run
Air cleaner
Type
Model
Batteries
Muffler
Muffler guard
Jacket water cooling/CAC
Manufacturer
Model
Rated horsepower
Starting system
STG 16
Two (2) 8-D
127 mm (5.0 in) inlet and outlet
10 ga. for personal protection
Radiator
52 C (125 F)
Type
Muffler
Model
Batteries
Muffler
Muffler guard
Caterpillar
C27 electronic (Tier II)
597 kW (800 hp)
2,100 rpm
24 V DC
Energized to run
Radiator
Fuel tank
1,382 l (365 gal)

optional tank 1,071 l (283 gal)
Blankets and/or exhaust wrap
Cummins
Model
QSK-19 (Tier I) electronic
Rated horsepower
559 kW (750 hp)
Full load
2,100 rpm
Starting system
24 V DC
Energized to run
Air cleaner
Type
Dry-type with safety element

SRG 20
Four (4) 8-D
Radiator
Fuel tank
1,382 l (365 gal)

(optional tank) 1,071 l (283 gal)
Turbo and manifold covers
1-4
Manufacturer
Air cleaner
Type
Four (4) 8-D

Muffler guard
Engine (Optional)
Full load
SRG 20
Batteries
Engine (Optional)
Dry type with safety element
Model
Starting system
24 V DC
Energized to run
Air cleaner
Rated horsepower
2,100 rpm
1,382 l (365 gal)

(optional tank) 1,071 l (283 gal)
Model
QSX-15 (Tier III) electronic

362 kW (485 hp) or 399 kW (535 hp)
Full load
Fuel tank
Manufacturer
Cummins
Model
SRG 20
Batteries
Muffler
Four (4) 8-D

Muffler guard
Jacket water cooling (Two pump, two loop)
Fuel tank

Radiator
1,382 l (365 gal)
Operators Cab
Engine (cont.)
Engine (Optional)
Location
Manufacturer
To the right from the mast

if facing rear deck from the rear end
Cummins
Model
QSK-19 electronic (Tier II)
Rated horsepower
566 kW (760 hp)
Full load
2,100 rpm
Starting system
24 V DC
Energized to run
Air cleaner
Type
Shock-mounted; two-man,
integrated FOPS certified
Length at floor
198.12 cm (78 in)
Width at floor
151.76 cm (59.75 in)

3 m 2 (32.40 ft 2)
Floor area
Height inside
194.51 cm (76.50 in)
Construction
Type
12 ga. steel welded to formed

12 ga. channel and angle supports
Model
SRG 20
Batteries
Four (4) 8-D
Muffler
127 mm (5 in) inlet and outlet
Muffler guard
1,382 l (365 gal)

.64 cm (0.25 in) tinted safety glass in rubber mounting
Number of windows
10
Number of doors
2 with windows (included in above)
Left door to work deck
Radiator
Fuel tank
Windows
Swing-type HD hinge
Right door
Swing-type HD hinge
Operators seat
One swivel-type with armrests,

headrest and retractable seat belt
Helpers seat
Fixed folding jump seat
Insulation, wall and ceiling
Mast
Construction
Insulation, floor
ASTM 500 grade B rectangular tubing, welding
Main chord size
Pivot and raising area

Hydraulic lines
Hose rack
Table hole diameter
Front 20.32 cm (8 in) x 10.16 cm (4 in)

x 0.64 cm (0.25 in);
Rear 10.16 cm (4 in) x 10.16 cm (4 in)
x 1.27 cm (0.5 in)
Rectangular tubing A frame;
reinforced in high-stress areas
Location
Sheet steel trough for moving hoses

27.90 cm (11.0 in) diameter
deck hole for guide bushing
Cylinder rod
Cylinder connection pins
Wall-mounted
Window wipers and washers
Operators Controls
Lift capacity each cylinder
82 dB(A) or less
Air conditioner, heater, pressurizer
Pressure-rated steel hydraulic tubing
Cylinder bore
Cylinder stroke
Heavy-duty latches with lockable handles
Sound levels
Other
Mast-Elevating Cylinders
Number of cylinders
Door latches
2.54 cm (1 in) thermal

.95 cm (0.375) in closed-cell foam
with .318 cm (0.125 in) pyramid vinyl surface
96.52 cm (38 in)
Console at front and side cab wall,

placed 45 to the deck
Standard Engine Controls

Coolant temperature/high temperature shut-off, oil pressure, (low
pressure shut-off), auto shut-down bypass, start button, stop button,
tachometer, throttle control, engine hourmeter, fuel level, voltmeter
Standard Compressor Controls

Compressor temperature, air pressure gauge, air shut-off control
(electric) (high air temperature)
47,990 kg (105,800 lb)

45 mm (1.75 in) diameter
1-5
Operators Controls (cont.)
Mainframe
Standard Drilling Controls
Main rails
20.32 cm (8 in) x 40.64 cm (16 in) x 1.27 cm (0.5 in)

ASTM 500 grade B
Leveling jack controls (hydraulic)
Rectangular tubing heavily cross-braced and reinforced

at high-stress areas
HOBO/Break-out wrench control (electric)

Mast elevation control (hydraulic)
Construction
Pull-down control (electric over hydraulic)
Electric welded
Jacks, mast pivot and deck
Pull-down pressure control (pilot hydraulic)
Toolbox
Rotation control (electric over hydraulic)
Welded integrally to mainframe

Lockable door, below front deck
Machine deck
Propel controls (electric over hydraulic)

Carousel in/out control (electric)
Access both sides
Hand rails
4.80 cm (1.9 in) diameter x 1.22 m (48 in) high
Tow hooks
Welded, two (2) front
Carousel indexing control (electric)

Carousel lock (electric)
Leveling Jacks
Mast lock (electric)

Dust/water injection (electric)
Dust curtain (electric)
Location
2 front; 2 rear
Cylinder bore
Deck wrench control (electric)
13.97 cm (5.5 in)
Cylinder rod diameter
Level indicator (bubble)
Cylinder stroke
On/off light switch (electric)

Drill hourmeter (gauge)
7.62 cm (3 in)
121.92 cm (48 in) 152.40 cm (60 in)
optional front and rear
Lift capacity
Wiper/washer controls (electric)
29,620 kg (65,300 lb) each
Pad connection
Optional
Link pad
Pad diameter
Filter indicators for engine and compressor intake, filter indicators for
hydraulic fluid system, indicator lights for interlocks, water injection
flow control, rotary torque control, rotary head rpm gauge and heating
systems control
Type
Inner extension boot
Triple grouser
Rollers
Sealed, oil-flooded
Number of rollers on each side

Upper track chain support
Rock guards/chain guides
Overall length
Width over tracks
Final drive
Drive horsepower per track
Brakes
Brake release
Tram speed max
Gradeability mast down
Rear axle
Front
Track adjustment means
Track drive disconnect
21.90 cm (8.625 in) OD 0.81 cm (.322 in) wall
Drill Table & Work Deck

750 mm (29.5 in)
Pad type
Internal at each cylinder
Table height off ground

Excavator type
Pad width
60.96 cm (24 in)
Safety check valves
Undercarriage
1-6
Number
10
Two (2) carrier rollers
Standard full-length guards
508.00 cm (200 in) (variable with adjustment)

391.16 cm (154 in)
Independent hydrostatic, 2-speed motors
Maximum 152 kW (204 hp)
Deck floor material
Non-skid sheet metal
Drill deck length
266.06 cm (104.75 in)
Drill deck width
257.81 cm (101.5 in)

6.86 m 2 (73.8 ft 2)
Drill deck area

Hand rails
48 mm x 1.22 m (1.9 in diameter x 48 in height)
Dust Curtain
(Optional Hydraulic Lifters, Front and Rear)
Material
6.4 mm (0.25 in) rubber nylon reinforced

4.2 m 2 (45.14 ft 2)
Enclosed area
Split for excess
Front and rear with 30.50 cm (12 in) overlap
Dust deflector
Natural rubber seal,

1.27 cm (0.5 in) thick, 35.56 cm (14 in) diameter
Spring set, hydraulic release

Automatic
132.08 cm (52 in)
Location
Directly below table bushing
3.14 km/h (1.95 mph)
Hydraulic System
66%
20.32 cm (8 in) solid
Three-point oscillating type
Hydraulic with grease gun
Standard (Manual)
Left Track/Rotation
Type
Max flow
Pressure rating
Axial piston, variable volume

283 l/min (75 gpm)
413.7 bar (6,000 psi)
Hydraulic System (cont.)
Accessories, Tools & Handling

Equipment
Right Track
Type
Max flow
283 l/min (75 gpm)
Pressure rating
413.7 bar (6,000 psi)
Max flow
283 l/min (75 gpm)
Pressure rating
344.7 bar (5,000 psi)
Fan Circuit Pump(s)

Type
Gear
Max flow
216 l/min (57 gpm) single fan;

246 l/min (65 gpm) dual fan
Pressure rating
206.8 bar (3,000 psi)
Track Drive Motors

(2)Two-speed
Type
Pressure rating
Length
9.14 m (30 ft); Optional 10.67 m (35 ft)
Diameter
Wall Thickness
11.43 cm (4.5 in)
1.91 cm (0.75 in)
3 Beco
9.14 m (30 ft)
11.43 cm (4.5 in)
1.91 cm (0.75 in)
3 Beco
10.67 m (35 ft)
12.70 cm (5 in)
1.91 cm (0.75 in)
3.5 Beco
9.14 m (30 ft)

10.67 m (35 ft)
12.70 cm (5 in)
1.91 cm (0.75 in)
3.5 Beco
13.97 cm (5.5 in)
1.91 cm (0.75 in)
4 Beco
9.14 m (30 ft)
13.97 cm (5.5 in)
1.91 cm (0.75 in)
4 Beco
10.67 m (35 ft)
1.91 cm (0.75 in)
4.5 Beco
9.14 m (30 ft)
Bent axis fixed volume
4.5 Beco
10.67 m (35 ft)
344.7 bar continuous (5,000 psi);

413.7 bar intermittent (6,000 psi)
16.51 cm (6.5 in)
1.91 cm (0.75 in)
4.5 Beco
9.14 m (30 ft)
16.51 cm (6.5 in)
1.91 cm (0.75 in)
4.5 Beco
10.67 m (35 ft)
17.78 cm (7 in)
1.91 cm (0.75 in)
4.5 Beco
9.14 m (30 ft)
17.78 cm (7 in)
1.91 cm (0.75 in)
4.5 Beco
10.67 m (35 ft)
Top Adapter Sub

Diameter
Dual fan: 2
Type
Piston
Pressure rating
413.7 bar continuous (6,000 psi)
Depends on pipe diameter
Length
71.12 cm (28 in)
Top thread
13.97 cm (5.5 in) API Reg.
Bottom thread
Bit Sub
Pump Drive Gearbox

Type
l3 pad
Rubber coupler/drive shaft to front of engine
Diameter
Length
76.20 cm (30 in) for 30 and 35 ft mast,

152.40 cm (60 in) for 11 m mast
Filtration
Top thread
All filters have indicators and bypass

Loop
12 micron 2 per loop (optional)
Charge
3 micron 1 per loop
Main return
12 micron absolute
Case return
12 micron absolute
Oil-Cooling System (Hydraulic Tank)

Reservoir
Pipe Length
1.91 cm (0.75 in)
Axial piston var. 9.76 cubic inch displacement
Single fan: 1
Thread
15.24 cm (6 in)
Fan Drive Motor(s)
Drive
1.91 cm (0.75 in)
15.24 cm (6 in)
Rotation Drive Motor

Pressure rating
Customer specification, 11.43-17.78 cm (4.5 in-7.0 in)
Wall thickness
107/125 cc
413.7 bar (6,000 psi)
Type
Drill Pipe (optional)

Diameter
Accessory Circuit Pump/Hoist/Pull-down

Type
Note: 4-pod carousel for 9.14 m (30 ft) and 10.67 m (35 ft) mast,
2-pod carousel for 11 meter mast
644 l (170 gal) with sight and temperature gauge
Reservoir pressure
Atmospheric, filtered breather
Reservoir refill system
871 l (230 gal) through return filter
Lubrication
Centralized manual (optional auto lubrication)
Bottom thread
Table bushing
Optional:
One (1) piece insert standard,

roller bushing or two-piece
Deck Wrench
Location
Drill deck
Wrench plate
7.62 cm (3 in) T1- Steel
Wrench positioning
Hydraulic cylinder
Impact means
Stationary jaw
HOBO Break-Out Wrench

Location
Support
Wrench type
Power
Outside mast, under pipe rack

Pivot
Patented HOBO (Hydraulically Operated Break-Out)
Hydraulic Cylinders
1-7
Accessories, Tools and Handling
Equipment (cont.)
Pipe Rack
Type
Carousel, with stationary pods and breaker plates
Size of drill pipe/capacity
11.43 cm to 17.78 cm (4.5 in to 7 in)/

9.14 m (30 ft) and 10.67 m (35 ft) mast 4 pipes
11.43 cm to 17.78 cm (4.5 in to 7 in)/

11 m (36 ft 1 in) mast 2 pipes
Length of drill pipe
9.14 m (30 ft); optional 10.67 m (35 ft)
Pipe rack swing

Pipe rack index
Hydraulic cylinders (2)

Hydraulic motor through chain drive
Location
Outside mast
WinchMounted on the mast

Rating
Cable size
Safety hook
3,629 kg (8,000 lb)

12.7 mm (0.5 in)
Swivel-type positive lock
Performance ratings are based on 100% efficiency, and on engineering specifications and calculations in accordance
with accepted industry standards. These capacities will vary with drilling conditions. All specifications are subject to
change without notice or obligation.
1-8
Cooler Assembly
Pull-Down/Hoisting Capacity
Rated pull-down capacity
Up to 22,680 kg (50,000 lb)
Rated hoist capacity
Up to 22,680 kg (50,000 lb)
Feed rate
0-38.1 m/min (0-125 fpm)
Retract rate
0-38.1 m/min (0-125 fpm)
Pull-down cylinder stroke (12 meter)

Head travel (12 meter)
Head travel (15 meter)
880.11 cm (346.5 in)
Compressor cooler width

Fan
187.88 cm (72 in)/162.56 cm (64 in)
121.92 cm (48 in) diam. one fan per cooler, 10 blades

Maximum 1,525 rpm
Hydraulic
Fan guard
Welded
Engine radiator, top tank

Cylinder rod
10.16 cm (4 in) diameter
Cable type
5 to 1 factor against working
Cable sheaves (cylinder)
40.64 cm (16 in) OD
Cable sheaves (top and bottom)
50.80 cm (20 in) OD
Sheave pins
5.10 cm (2 in) diameter with roller bearing
Sheave guards
Adjustable head guide shoes
Automatic cable tensioning system
Standard at bottom plate

Steel with replaceable Nylatron
Hydraulic cylinder,
powered by fan circuit
Torque
Horsepower capacity
Gearbox
Compressor (Standard)
Type

0-220 rpm
12,880 Nm max (0-9,500 ft-lb)
138.7 kW (186 hp)
Casting design
Type

SRG 20
Oil cooling
Air-to-oil cooler, thermostatically controlled

Vertical barrier element, pre-separation
in 189 l (50 gal) horizontal sump (T-tank)
Oil filtration
12 micron replaceable element
Drive
Direct coupled to engine flywheel
Controls
Automatic with safety shut-down
Air shut-off
Hydraulic cylinder-operated from operators seat
Main thrust bearing
Taper roller
Lubrication
Oil-flooded
Type (high pressure)
Ratio
Drive motor
6.9 bar (100 psi)
Model
Gearing
Spur
48.1 m 3/min (1,700 cfm)
Air cleaner
Oil separation
Rotary Drive System

Rotation speed
52 C (125 F)
Compressor
1 in DYFORM 8
Nominal line tension
147.32 cm (58 in)/

147.32 cm (58 in)
Fan speed
1 (stationary rod, moving barrel)
Cylinder bore
Radiator/hydraulic cooler height/width
1,760.22 cm (693.0 in)
Type
Number of cylinders
Air-finned, three- or four-core, radiator/hydraulic stacked, compressor

separate
726.94 cm (286.2 in)

1,453.89 cm (572.4 in)
Pull-down cylinder stroke (15 meter)
For Cat C27 or Cummins

QST-30
EnginesSplit Coolers

32.6 m 3/min (1,150 cfm);
16:04 to 1
38.2 m 3/min (1,350 cfm);
See Hydraulic
42.5 m 3/min (1,500 cfm)
Performance ratings are based on 100% efficiency and on engineering

specifications and calculations in accordance with accepted industry
standards. These capacities will vary with drilling conditions. All
specifications are subject to change without notice.

Air cleaner
10.3/24.1 bar (150/350 psi)

Type (high pressure)

32.6 m 3/min (1,150 cfm);
38.2 m 3/min (1,350 cfm);
42.5 m 3/min (1,500 cfm)

Air cleaner
10.3/24.1/34.5 bar (150/350/500 psi)

1-9
Engine (cont.)
Engine
Engine (Optional)
Engine (Standard)
Caterpillar
Manufacturer
Model
C27 Tier II
Rated horsepower
597 kW (800 hp)
Full load
2,100 rpm
Starting system
24 V DC
Energized to run
Cummins
Model
QST-30 (Tier II)
Rated horsepower
671 kW (900 hp) or 783 kW (1,050 hp)
Full load
2,100 rpm
Starting system
24 V DC
Energized to run
Air cleaner
Air cleaner
Type
Model
SRG 20
Batteries
Four (4) 8-D
Muffler
Muffler guard

Fuel tank
Manufacturer
Radiator
1,325 l (350 gal), optional tank 1,571 l (415 gal)
Type
Model
SRG 29
Batteries
Four (4) 8-D
Muffler
Muffler guard

Fuel tank
Radiator
Engine (Optional)
Manufacturer
QST-30 (Tier I)
Rated horsepower
634 kW (850 hp) or 783 kW (1,050 hp)
Full load
Construction
Main cord size
2,100 rpm
Starting system
24 V DC
ASTM 500 grade B rectangular tubing, welding

Front 20.3 cm x 10.1 cm x 0.6 cm (8 in x 4 in x 0.25 in);
Rear 10.1 cm x 10.1 cm x 1.2 cm (4 in x 4 in x 0.5 in)
Pivot and raising area
Energized to run
Hydraulic lines
Air cleaner
Type
Model
SRG 29
Batteries
Hose rack
Table hole diameter
Muffler guard
Jacket water cooling
Radiator
Pressure-rated steel hydraulic tubing

Sheet steel trough for moving hoses
27.9 cm (11 in) diameter deck hole
for guide bushing
Mast-Elevating Cylinders
Number of cylinders
Cylinder bore
Cylinder rod
Cylinder stroke
1-10
Rectangular tubing A frame;

reinforced in high-stress areas
Four (4) 8-D
Muffler
Fuel tank
Mast
Cummins
Model
108.2 cm (42.6 in)
Lift capacity each cylinder
56,728 kg (125,065 lb) at 2,500 psi
Cylinder connections pins
Undercarriage
Type
Operators Controls
Excavator type
Pad width
750 mm (29.5 in)
Pad type
Triple grouser
Rollers
Sealed, oil flooded
Number of lower rollers on each side

Upper track chain support
12
Two (2) carrier rollers
Rock guards/chain guides
570.48 cm (224.6 in)
Width over tracks
391.16 cm (154 in)
Final drive
Maximum 152 kW (204 hp)
Brakes
Spring set, hydraulic release
Brake release
Automatic
Tram speed max
2.0 km/h (1.25 mph)
Gradeability mast down
66%
Rear axle
20.32 cm (8 in) solid
Front
Hydraulic with grease gun
Track drive disconnect
Coolant temperature/high temperature shut-off, oil pressure, (low

pressure shut-off), auto shut-down bypass, start button, stop button,
tachometer, throttle control, engine hourmeter, fuel level, voltmeter
Standard Compressor Controls
Standard Drilling Controls

HOBO/Break-out wrench control (electric)
Mast elevation control (hydraulic)
Pull-down control (electric over hydraulic)
Pull-down pressure control (pilot hydraulic)
Rotation control (electric over hydraulic)
Propel controls (electric over hydraulic)
Carousel in/out control (electric)
Three-point oscillating type
Track adjustment means
Standard Engine Controls
Leveling jacks controls (hydraulic)
Independent hydrostatic motors
Drive horsepower per track
Console at front and side cab wall, placed 45 to the deck
Compressor temperature, air pressure gauge, air shut-off control

(electric) (high air temperature)
Standard full-length guards
Overall length
Location
Standard (manual)
Carousel indexing control (electric)

Carousel lock (electric)
Mast lock (electric)
Dust/water injection (electric)
Operators Cab
Dust curtain (electric)

Location
Type
To the right from the mast

if facing rear deck from the rear end
198.12 cm (78 in)
Width at floor
151.76 cm (59.75 in)

2
3 m (32.4 ft )
Floor area
Height inside
194.31 cm (76.5 in)
Construction
Windows
Level indicator (bubble)
Shock-mounted; two-man, integrated FOPS certified
Length at floor
12 ga. steel welded to formed 12 ga. channel

and angle supports
0.6 cm (0.25 in) tinted safety glass in rubber mounting
Number of windows
Wiper/washer controls (electric)
Optional
Filter indicators for engine and compressor intake, filter indicators for
hydraulic fluid system, indicator lights for interlocks, water injection
flow control, rotary torque control, rotary head rpm gauge and heating
systems control
Swing-type HD hinge
Right door
Swing-type HD hinge
Operators seat
One swivel-type with armrests,

headrest and retractable seat belt
Helpers seat
Fixed folding jump seat
Insulation, wall and ceiling
2.5 cm (1 in) thermal
Insulation, floor
0.9 cm (0.375 in) closed cell foam with

0.3 cm (0.125 in) pyramid vinyl surface
Heavy-duty latches with lockable handles
Sound levels
Air conditioner/heater/pressurize
Drill hourmeter (gauge)
2 with windows (included in above)
Left door to work deck
Other
On/off light switch (electric)
10
Number of doors
Door latches
Deck wrench control (electric)
82 dB(A) or less
Wall-mounted
Window wipers and washers
1-11
Mainframe
Main rails
Hydraulic System
20.32 cm x 40.64 cm x 1.27 cm (8 in x 16 in x 0.5 in)

ASTM 500 grade B
Rectangular tubing heavily cross-braced
and reinforced at high-stress areas
Construction
Electric welded
Left Track/Rotation
Type
Closed-loop, axial piston, variable volume
Max flow
283 l/min (75 gpm)
Pressure rating
413.7 bar (6,000 psi)
Jacks, mast pivot and deck
Welded integrally to main frame
Right Track/Pull-down/Hoist
Toolbox
Lockable door, below front deck
Type
Machine deck
Access both sides
Hand rails
4.80 cm (1.9 in) diameter x 1.22 m (48 in) high
Tow hooks
Welded, two (2) front
Mast rests
Between front jacks, and additional mast rests

off front end of frame
Leveling Jacks
283 l/min (75 gpm)
Pressure rating
413.7 bar (6,000 psi)
Fan/Accessory Circuit
Type
Open loop, axial piston, variable volume
Max flow
273 l/min (72 gpm) dual fan (one per cooler)
Pressure rating
Number
Location
2 front; 2 rear
Cylinder bore
13.97 cm (5.5 in)
Cylinder rod diameter
7.62 cm (3 in)
Cylinder stroke
152.40 cm (60 in)
206.8 bar (3,000 psi
Track Drive Motors (2)-Single Speed 107cc

Type
Bent-axis fixed volume
Pressure rating
413.7 bar (6,000 psi)
Rotation Drive Motor

Type
Lift capacity
Closed-loop, axial piston, variable volume
Max flow
Axial piston var. 9.76 cubic inch displacement
29,620 kg (65,300 lb) each

Pressure rating
Pad connection
Pad diameter
Safety check valves
Inner extension boot
60.96 cm (24 in)

Internal at each cylinder
21.90 cm (8.625 in) OD, 0.81 cm (0.322 in) wall
Drill Table & Work Deck

Table height off ground
152.08 cm (52 in)
Fan Drive Motor(s)-Single Fan

Fan drive motor(s)
Type
Drill deck length
266.06 cm (104.75 in)
Filtration
Drill deck width
257.81 cm (101.5 in)
4.8 cm (1.9 in) diameter x 121.9 cm (48 in) high
Dust Curtain (Optional Hydraulic Lifters,

Front and Rear)
Material
Enclosed area
Split for excess
Dust deflector
Location
1-12
413.7 bar continues (6,000 psi)
Pump Drive Gearbox

Drive
6.8 m 2 (73.8 ft 2)
Piston
Pressure rating
Non-skid sheet metal
Drill deck area
Single fan: 1
Type
Deck floor material
Hand rails
344.7 bar continuous (5,000 psi);

413.7 bar intermittent (6,000 psi)
Link pad
3 pad
Rubber coupler/drive shaft to front of engine
All filters have indicators and bypass

Loop
12 micron 2 per loop (optional)
Charge
3 micron 1 per loop
Main return
12 micron absolute
Case return
12 micron
6.4 mm (0.25 in) rubber nylon reinforced

4.2 m 2 (45.14 ft 2)
Front and rear with 30.50 cm (12 in) overlap
Natural rubber seal, 1.27 cm (0.5 in) thick,
35.56 cm (14 in) diam.
Directly below table bushing
Lubrication

Equipment (cont.)
Centralized manual (optional auto lubrication)
Oil Cooling System (Hydraulic Tank)

Reservoir
643 l (170 gal) with sight and temperature gauge
Reservoir pressure
Atmospheric, filtered breather
Reservoir refill system
871 l (230 gal) through return filter
Top Adapter Sub

Diameter
Length
71.12 cm (28 in)
Top thread
13.97 cm (5.5 in) API Reg.
Bottom thread
Bit Sub

Equipment
Diameter
Length
Up to 342.90 cm (135 in)
Drill Pipe (Optional, Price-Adder)
Top thread
12 meter mast arrangement

Diameter
Customer specification 11.43-17.78 cm (4.5-7.0 in)
Wall thickness
1.91 cm (0.75 in)
Length
10.67 m (35 ft)
Threads
Diameter
Wall Thickness
Thread Pipe
Length
Bottom thread
11.43 cm (4.5 in)
1.91 cm (0.75 in)
3 Beco
10.67 m (35 ft)
Wrench plate
12.70 cm (5 in)
1.91 cm (0.75 in)
3.5 Beco
10.67 m (35 ft)
13.97 cm (5.5 in)
1.91 cm (0.75 in)
4 Beco
10.67 m (35 ft)
15.24 cm (6 in)
1.91 cm (0.75 in)
4.5 Beco
10.67 m (35 ft)
Table bushing
One (1) piece insert, roller deck bushing or two-piece
Deck Wrench
Location
Drill deck
7.6 cm (3 in) T1- Steel
Wrench positioning
Hydraulic cylinder
Impact means
Stationary jaw
16.51 cm (6.5 in)
1.91 cm (0.75 in)
4.5 Beco
10.67 m (35 ft)
HOBO Break-Out Wrench
17.78 cm (7 in)
1.91 cm (0.75 in)
4.5 Beco
10.67 m (35 ft)
Location
15 meter mast arrangement

Diameter
Customer specification 11.43-17.78 cm (4.5-7.7 in)
Wall thickness
1.91 cm (0.75 in)
Length
7.62 m (25 ft)
Threads
Diameter
Wall Thickness
Thread Pipe
Length
Support
11.43 cm (4.5 in)
1.91 cm (0.75 in)
3 Beco
7.62 m (25 ft)
Type
12.70 cm (5 in)
1.91 cm (0.75 in)
3.5 Beco
7.62 m (25 ft)
13.97 cm (5.5 in)
1.91 cm (0.75 in)
4 Beco
7.62 m (25 ft)
15.24 cm (6 in)
1.91 cm (0.75 in)
4.5 Beco
7.62 m (25 ft)
Wrench type
Outside mast, under pipe rack

Pivot
Patented HOBO (Hydraulically Operated Break-Out)
Power
Hydraulic cylinders
Carousel
Carousel, with stationary pods and breaker plates
11.43-17.78 cm (4.5-7 in)
12 meter mast arrangement (4 pod)
16.51 cm (6.5 in)
1.91 cm (0.75 in)
4.5 Beco
7.62 m (25 ft)
15 meter mast arrangement (2 pod)
17.78 cm (7 in)
1.91 cm (0.75 in)
4.5 Beco
7.62 m (25 ft)
Length of drill pipe
Pipe rack swing

Pipe rack index
Location
Mounting
10.67 m (35 ft) for 12 meter mast,

7.62 m (25 ft) for 15 meter mast
Hydraulic cylinders (2 )
Hydraulic motor through chain drive
Outside mast
Upper, lower pillow-block bearing
Winch
Rating
Cable size
Safety hook
3,629 kg (8,000 lb)

12.70 mm (0.5 in)
Swivel-type positive lock
1-13
MD6290 Component Locator

FRONT OF MACHINE
COMPRESSOR OIL COOLER
HYDRAULIC OIL COOLER
ENGINE RADIATOR
ENGINE AIR FILTER
COMP. AIR CLEANER

RH FRONT JACK
LH FRONT JACK
COMPRESSOR AIR/OIL SEPARATOR

MAST ACCESS LADDER
AIR COMPRESSOR
FUEL TANK
DIESEL ENGINE
MUFFLER
FUEL FILL
DRIVELINE
PUMP DRIVE
RETURN FILTERS
DUST COLLECTOR
HYDRAULIC OIL RESERVOIR
CHARGE FILTERS
(LOOP FILTERS OPTIONAL)
MAIN ELECTRIC CABINENT

PRESSURE/VACUUM FILTER
MAST ELEVATING CYLINDERS

RH REAR JACK
LH REAR JACK
WINDOW WASHER BOTTLE

PIPE CAROUSEL
OPERATORS CAB
IN DECK PLENUM CHAMBER
A/C CONDENSER
IN DECK TOOL BOX
CRANE (OPT)
DRILLING PLATFORM
CRANE CONTROLS (OPT)
VIEWING HATCH
1-14

TOP MAST SHEAVE
ROTARY DRIVE
CAROUSEL
BATTERY BOX
TRACK FINAL DRIVE
CRAWLER
HYDRAULIC OIL FILL PUMP
LIGHTS
DUST CURTAINS
A/C/ UNIT
1-15

FRONT OF MACHINE
MAST REST
WATER TANKS
BOLTED UNDER DECK
AIR/OIL RECEIVER TANK
LEFT FRONT JACK

COMPRESSOR
AIR CLEANER
RIGHT FRONT JACK

ENGINE AIR CLEANER
OIL INJECTION TANK

AIR COMPRESSOR
FRONT FUEL TANK
ENGINE MUFFLER
ENGINE COOLER
COMPRESSOR OIL COOLER
ENGINE
BATTERY BOX
CENTRAL LUBE
SYSTEM PUMP
FLEX DRIVE COUPLING
(COVER REMOVED)
PUMP DRIVE GEARBOX
FUEL TANKS
BOLTED UNDER DECK
REAR FUEL TANK
HYDRAULIC FILL
HAND PUMP
MAIN RETURN FILTER
CASE DRAIN FILTER
MAIN HYDRAULIC PUMPS
HYDRAULIC TANK
DRILL STEM THREAD

LUBRICATOR
RIGHT REAR JACK
LEFT REAR JACK
DRILLING PLATFORM
OPERATORS CAB
Due to the variety of drill options and requirements, each drill may vary from the configurations shown.
1-16

TOP SHEAVES
ROTARY DRIVE
GEARBOX
TRAVELING SHEAVES
FINAL DRIVE
MAST
CARRIER ROLLERS
TRACK ROLLERS
CRAWLER ASSEMBLY
HYDRAULIC FILL
HAND PUMP
TENSIONER
IDLER
MAST ELEVATING
CYLINDERS
FRONT IDLER
BOTTOM SHEAVES
1-17
SKF ROTARY BLASTHOLE DRILLS

1-18
Based on MD6290 with 11M mast arrangement
MD6290 Dimensions
Based on MD6240 with 12M and 15M mast arrangement
MD6240 Dimensions
1-19
Transient Stability Limits

Maximum Wind Speed = 75 MPH (120.8 Km/h) at which time drilling must be stopped, mast
lowered and machine shut down.
BE SURE to observe if any overhead power lines arein the area. Contact with
overhead high voltage power lines can cause severe injury or death. Follow
the maximum safe distance requirements in Section 2 of this manual.
21
12
25
18
NOTE
18
The values contained here are given only as guidelines, and are not intended as
a recommendation for safe operation. Safe operation is dependent on operator
experience and judgement, ground conditions and proper preparation of ground
surfaces, and accelerations due to sudden change of direction or speed of
movement, either from operator input or ground conditions on which machines
are operating.
Machines are typically much more stable operating with the mast down anytime
a machine is operating on rough ground conditions, significant slopes, or there
is any doubt about the machine stability or its ability to be operated safely in the
conditions in question.
1-20
Line of Sight Limits

17
30
13
52
Defines the Operators general

line of sight when in the seated
position.
10
23
)
5
2
1
7
2
)
0
$
&
+
,
1
(
23
TRAMMING
25
31
14
30
27
13
66
52
17
10
23
23
DRILLING
1-21
Safety Stand Placement

Support (Jack Stand) Guidelines for Rotary Drills
MD6240 AND MD6290

IF DURING MAINTENANCE MACHINE
REQUIRES ADDITIONAL SAFETY SUPPORTS,
PLACE SUPPORTS (JACK STANDS) AS CLOSE TO
LEVELING JACKS AS POSSIBLE. THESE AREAS
SUPPORT THE MACHINE DURING DRILLING OPERATIONS.
NEVER SUPPORT THE MACHINE BY PLACING

SUPPORTS UNDER MEMBERS OF THE REAR DECK
OR COOLER SUPPORT DECK. THESE AREAS ARE
NOT STRUCTURALLY ROBUST AND ARE NOT INTENDED
TO SUPPORT THE ENTIRE MACHINE WEIGHT.
1-22
Section 2
Safety
Maximum Wind Speed = 75 MPH (120.8 Km/h) at which time drilling must be
stopped, mast lowered and machine shutdown.
Safety
2-1
Hazard Classification
The Rotary Blasthole Drill is a heavy moving machine with a mast which raises vertically for drilling.
Like all moving objects and reach extending devices, there are potential hazards associated with its use.
These hazards will be minimized if the machine is properly operated, inspected and maintained. Operator's
must read this manual and have been trained to use the machine in an appropriate and safe manner.
Non-English speaking persons must have an interpreter explain all safety and operating procedures in this
manual. Should any questions arise concerning the maintenance or operation of the machine contact the
manufacturer at 1-800-258-0009.
Safety Alert Symbol

The safety alert symbol is used to alert you to potential personal injury hazards. Obey all safety messages
that follow this symbol to avoid possible injury or death.
Safety Alert Symbol
Hazard Classification
A multi-tier hazard classification system is used to communicate potential personal injury hazards. The
following signal words used with the safety alert symbol indicate a specific level of severity of the potential
hazard. All are used as attention-getting devices on decals and labels fixed to the machine to assist in
potential hazard recognition and prevention.
Indicates an imminently hazardous situation which, if not avoided, will result in

death or serious injury.
Red
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
Orange
Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
Yellow
Indicates a potentially hazardous situation which, if not avoided, may result in
property or equipment damage.
Blue
2-2
Safety
Overview of Potential Hazards

Potential Hazard
Safety
Prevention
Crush Hazard. Falling objects

can cause severe injury or
death.
Do not exceed hoist capacity &

stay away from lifted loads. (3500
lbs./1587 kg.) Do not use damaged cable.
Crush Hazard. Falling pipe carousel can cause severe injury

or death.
Place carousel against lower

stops before servicing hydraulic
circuit. Purge air from circuit after
servicing carousel circuit.
Entanglement Hazard. Death

or serious injury can result from
contact with rotating drivelines.
Keep clear of rotating drivelines.

Switch off engine before performing service. Do not operate with
guard removed.
Entanglement Hazard. Rotating parts can cause personal

injury.
Keep away from fan and belt

when engine is running. Stop
engine before servicing.
Crush Hazard. Falling mast can

cause severe injury or death.
Purge air from circuit after servicing mast raising cylinder(s).
Burn Hazard. Hot pressurized

fluid can cause severe burns.
Allow to cool before opening.
2-3

Potential Hazard
Prevention
Fall Hazard. Death or serious

injury may result from climbing
raised mast.
Do not climb raised mast. Lower

mast completely to service.
Improper operation or maintenance can result in serious injury

or death.
Read and understand operator's

manual and all safety signs before
using or maintaining machine.
If you do not understand the information in the manuals, consult
your supervisor, the owner or the
manufacturer.
2-4
Electrocution Hazard. Death

or serious injury can result from
contacting electric power lines.
Maintain required clearance.
Crush / Fall Hazard. Riding

rotary head can cause severe
injury or death.
Do not ride rotary head. Lower

mast completely to service.
Flying Object & Spray Hazard.

Death or serious injury can result from release of pressurized
liquids.
Shut off live air at source, and relieve all pressure before removing
filler plug.
Entanglement Hazard. Rotating

parts can cause severe injury.
Do not operate with guard removed. Keep all guards in

place.
Crush Hazard. Falling rotary

head can cause severe injury
or death.
Purge air from circuit after servicing feed cylinder(s).
Always contact the electric power

line owner. The electric power
shall be disconnected or the power lines moved or insulated before
machine operations begin.
Safety

Potential Hazard
Explosion / Burn Hazard. Can
cause death, burns or blindness
due to ignition of explosive gases
or contact with corrosive acid.
Prevention
Keep all open flames and sparks
away. Wear personal protective
equipment, including face shield,
gloves and long sleeve shirt.
READ MANUALS
Read all manuals prior to operation.
DO NOT OPERATE equipment if
you do not understand the information in the manuals.
Consult your supervisor, the
owner or the manufacturer.
Explosion Hazard. Combustible

gas can cause severe injury or
death.
Do not spray "High Energy" starting aid into compressor air inlet or
engine grid heaters.
Fall Hazard. Death or serious

injury can result from falling.
Use the access system provided

when servicing the machine.
Crush Hazard. Standing on

stairway when raising or lowering can cause severe injury or
death.
Keep clear of moving stairway.
Electrical Shock Hazard. Can Disconnect battery prior to electrical system service
work or any welding to avoid electrical shock and machine damage. Refer to service operator manual.
Safety
2-5
Safety Guidelines
Before Operation
Do study this manual and fully understand the controls.
Do be sure all safety guards are securely in place and all access doors are closed and locked.
Do wear safety helmet, glasses and hearing protection when operating or working on machine.
Do be sure all personnel are clear of the machine and work area before starting the engine or operating machine.
Do be sure drill area is clear of all obstructions before operating and know the size limitations of the
machine.
Do attach safety chain when using towbar.
Do Not operate machine with:

A hydraulic leak
Broken or damaged electrical wiring
Damaged hydraulic hoses or fittings
Operation
Do provide sufficient ventilation when running the engine in an enclosed area. Exhaust gasses
contain carbon monoxide, a deadly poison, which is colorless and odorless.
Do make sure the drill pipe is secured in the loader before raising or lowering the mast, if your
machine is equipped with a drill pipe loader.
Do make sure the mast lock pins are engaged in the mast base before starting drilling operations.
Do examine the surface before drilling to determine the possible presence of unfired explosives.
Do use PPE (personal protection equipment) appropriate for the conditions you are working in; e.g.
safety helmet, safety glasses, hearing protection, gloves, respirator.
Do Not wear jewelry or loose fitting clothing when working on machinery. Keep clothing, hands
and hair clear of moving parts.
Do Not drill into or near a "bootleg" hole or any hole that may contain explosives.
Do Not use the machine for any other purpose than what it was designed for. This machine is designed for rotary blasthole drilling operations only.
Do Not travel on steep inclines soft or unstable ground or close to unsupported excavations.
Do Not move machine if drill is in a potentially unstable position.
After Operation
Normal Shut Down
1.
Be sure machine is on solid level ground. Lower jacks, so the jack pads just touch the ground, but
do not lift machine up.
2.
Be sure all controls are in the OFF or NEUTRAL position.
3.
Allow engine to idle for a minimum of five (5) minutes before stopping.
4.
Turn the ignition key to OFF position.
5.
Check machine for any unusual conditions.
6.
Report any defects to your immediate supervisor.
2-6
Safety
Safety Guidelines
Maintenance
Do be sure two people are present when performing service work, both being fully trained on the
safety issues. One person shall supervise from the operator's position and have immediate access
to an emergency stop in all situations. Visual, audible or verbal communication signals must be
established and understood by both persons.
Do be sure each person is adequately trained to perform service and maintenance procedures.
Do place a warning tag on starting controls to alert personnel that someone is working on the machine and disconnect battery before making repairs or adjustments to machine.
Do be sure you have adequate lighting when performing service work at night.
Do relieve pressure on hydraulic or pneumatic systems before loosening connections or parts.
Do be sure machine and components are well supported before servicing or replacing parts.
Do maintain a metal-to-metal contact between the fill nozzle and fuel tank when filling the fuel tank.
This will prevent sparks and the possibility of an explosion.
Do Not hammer bit or drill pipe. Use only proper tools to make repair or adjustments.
Do Not weld or grind near oil lines.
Do Not attempt to remove radiator cap when engine is hot or has overheated.
Do Not smoke or use an open flame near batteries, when servicing the batteries. Batteries can
give off hydrogen which is a highly explosive gas.
Do Not leave tools or other loose objects on the engine, drive mechanisms or drilling platform.
They could be thrown by this equipment with a powerful force.
Equipment Transfer
If all or part of the equipment is shipped to a new destination, always include a complete instruction
manual or a copy of the following topics from the operator's manual:
Safety Section
Operation Instructions including:
Pre-Start Checks
Start-up
After Start Checks
Shutdown Procedure
Propelling Machine
Clearances from High Voltage Lines

Line Voltage
Minimum Clearance
0 to 50 kv
10 ft (3 m)
50 to 200 kv
15 ft (4.6 m)
200 to 350 kv
20 ft (6.1 m)
350 to 500 kv
25 ft (7.6 m)
500 to 750 kv
35 ft (10.7 m)
750 to 1000 kv
45 ft (13.7 m)
Table 2-1
Safety
2-7
Safety Sign List

Refer to Figures 2-1 and 2-2 for locations
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Description
WARNING - Falling Objects (Winch)
WARNING - Falling Objects (Carousel)
WARNING - Rotating Shaft
WARNING - Entanglement
WARNING - Falling Mast
WARNING - Hot Pressurized Fluid
WARNING - Climbing Raised Mast
WARNING - Modification or Alteration
WARNING - Hazardous Voltage
WARNING - Riding Rotary Head
WARNING - Flying Objects & Spray
WARNING - Rotating Parts
WARNING - Falling Rotary Head
WARNING - Combustible Gas (Batteries)
WARNING - Combustible Gas (Ether)
Part No.
429414
429448
429406
428893
429418
429449
429404
429445
429437
429420
429141
429431
429426
429439
429444
Qty.
1
2
2
5
2
1
2
1
1
1
1
2
2
2
1
(ref. 429469)
Safety Sign Maintenance

Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap
and water to clean safety signs. Do not use solvent-based cleaners as they may damage the safety sign
material.
2-8
Safety
Safety Sign Locator
Fig. 2-1
Safety
2-9
Safety Sign Locator
Fig. 2-2
2-10
Safety
Safety Signs
WARNING
WARNING
Entanglement
Hazard
Rotating parts can
cause personal injury.
3500 lbs/
1587 kg
Crush Hazard
Falling objects can cause
severe injury or death.
Keep away from fan

and belt when engine
is running. Stop engine
before servicing.
Do not exceed hoist

capacity & stay away
from lifted loads.
(3500 lbs./1587 kg.)
Do not use damaged
cable.
429414
428893
428893
429414
WARNING
WARNING
Crush Hazard
Crush Hazard
Falling pipe carousel can
Place carousel against

lower stops before
servicing hydraulic circuit.
Purge air from circuit after
servicing carousel circuit.
Falling mast can cause

severe injury or death.
Purge air from circuit

after servicing mast
raising cylinder(s).
429418
429448
429418
429448
WARNING
WARNING
Entanglement Hazard
Death or serious injury
can result from contact
with rotating drivelines.
Keep clear of rotating drivelines.

Switch off engine before performing
service. Do not operate with guard
removed.
Burn Hazard
429406
429406
Hot pressurized fluid can

cause severe burns.
Allow to cool before

opening.
429449
429449
Safety
2-11
Safety Signs
DANGER
WARNING
Maintain required clearance.

Electrocution Hazard
Death or serious injury can result from contacting
electric power lines.
Fall Hazard
Always contact the electric power line owner.

The electric power shall be disconnected or the
power lines moved or insulated before machine
operations begin.
Death or serious injury

may result from climbing
raised mast.
429437
Line voltage
Required clearance
0 to 50 kv
10 ft (3 m)
50 to 200 kv
15 ft (4.6 m)
200 to 350 kv
20 ft (6.1 m)
350 to 500 kv
25 ft (7.6 m)
500 to 750 kv
35 ft (10.7 m)
750 to 1000 kv 45 ft (13.7 m)
429437
WARNING
Do not climb raised
mast. Lower mast
completely to
service.
429404
429404
Crush / Fall Hazard
Riding rotary head can
cause severe injury or
death.
Do not ride rotary head.

Lower mast completely
to service.
429420
429420
WARNING
WARNING
Flying Object & Spray Hazard
Improper operation or
maintenance can result
in serious injury or
death.
Read and understand

operator's manual and all
safety signs before using
or maintaining machine.
Death or serious injury can

result from release of
pressurized liquids.
If you do not understand

the information in the
manuals, consult your
supervisor, the owner or
the manufacturer.
Shut off live air at source, and

relieve all pressure before
removing filler plug.
429445
429141
429445
429141
2-12
Safety
Safety Signs
WARNING
WARNING
Explosion / Burn Hazard

Can cause death, burns or blindness due to
ignition of explosive gases or contact with
corrosive acid.
Entanglement Hazard
Rotating parts can cause
severe injury.
Keep all open flames and sparks away. Wear

personal protective equipment, including face
shield, gloves and long sleeve shirt.
READ MANUALS
Read all manuals prior to operation.
Do not operate with

guard removed.
Keep all guards in place.
DO NOT OPERATE equipment if you do not

understand the information in the manuals.
Consult your supervisor, the owner or the
manufacturer.
429431
429431
429439
429439
WARNING
Crush Hazard
Falling rotary head can
cause severe injury or
death.
WARNING
Purge air from circuit

after servicing feed
cylinder(s).
Explosion Hazard
Combustible gas can
cause severe injury
or death.
429444
429426
429426
Safety
Do not spray "High Energy"

starting aid into
compressor air inlet
or engine grid heaters.
429444
2-13
Safety Signs (International)
429740
Flying Object & Spray Hazard (429740)
429720
Fall HazardMast (429712)
Explosion/Burn Hazard (429720)
T104915
Fall Hazard (T104915)
429713
Explosion HazardEther (429713)
429705
Entanglement Hazard (429705)

2-14
Safety
3500 lbs/
1587 kg
429718
Crush HazardCarousel (429718)
429721
Crush HazardWinch (429721)
429715
Crush HazardMast (429715)
Safety
429719
Crush HazardRotary Head (429719)
2-15
429709
Electrocution Hazard (429719)
429722
Modification or Alter Hazard (429722)

429717
Burn HazardPressurized Fluids (429717)
429714
Crush/Fall HazardRotary Head (429714)
429710

429738

2-16
Safety
Section 3
Operator Controls
Operator Controls
3-1
Graphic Symbol Legend

The following is a listing of the graphic symbols found on the cab control consoles and their basic description. The control functions are described in detail following the symbol descriptions.
Drill Functions
HOBO Swing
HOBO Lock
Deck Wrench
Auto Pulldown
Holdback
Hoist Pulldown
Winch
Drill Pipe Support
Oil Injection
Pipe Rack Swing
Pipe Rack Rotate
Pipe Rack Lock
Thread Lube
Mast Lock
Dust Curtain/Blower
Main Air
Drill/Propel
Dust/Water
Mast Lower/Raise
Front JackUP/DOWN
Left Rear/Right Rear JackUp/Down
ON
OFF
3-2
Operator Controls
Graphic Symbol Legend

Drill Functions
Rotation/Left Track Pressure
Pulldown Pressure
Drilling Air Pressure
Hydraulic System Pressure
RotationForward/Reverse
Pulldown PressureIncrease/Decrease
Compressor Discharge Temperature
Engine Coolant Temperature
Engine Oil Pressure
Fuel Level
Battery Charge
Engine Hourmeter
Engine Tachometer
Engine Start
Drill Hourmeter
Ether Injection
Engine Stop
IgnitionOn/Off
Water InjectionIncrease/Decrease
Operator Controls and Indicators
ThrottleFast/Slow
Operator Controls
3-3
Operator Control Panel (standard)
Fig. 3-1 Operator Control Panel
1.
NOTE
"PUSH" LEVER - Move lever AWAY FROM OPERATOR

"PULL" LEVER - Move lever TOWARDS OPERATOR
NOTE
Options are used along with or in place of standard equipment on some machines.
Although every effort has been made to be as complete and thorough as possible in the following pages, not every photo and item described herein may be
used on each machine and your machine may have different controls than those
shown. Consult with manufacturer if unsure about any function or control prior to
use.
Level Indicator
Indicates when the machine is level.
2.
Throttle
Used to control the engine speed. Minimum engine speed is 1300 RPM, Maximum speed is 2100
RPM.
3.
Jack Levers
Used for lowering and raising the jacks to level the machine. Pull the levers to lower the jacks.
Push the levers to raise the jacks.
3a.
Right Rear Jack
3b.
Front Jacks
3c.
Left Rear Jack
3-4
Operator Controls

4.
Mast Lever
Controls the lowering and raising of the mast.
Pull lever to raise mast.
Push lever to lower mast.

DO NOT raise mast close to power lines. See Section 1 for Clearances from High
Voltage Lines.
5.
Propel Levers - Hydraulic pilot operated

Control the speed and the direction of the tracks.
Push levers to propel forward (radiator end).

Pull levers to propel in reverse (cab end).
5a.
Right Track Lever
5b.
Left Track Lever
6.
Rotation Lever - Hydraulic pilot operated

Controls rotary head speed and direction.
Push lever for forward rotation.
Pull lever for reverse rotation.
7.
Hoist/Pulldown System Lever - Hydraulic pilot operated

Controls the raising and lowering of the rotary head.
Push lever to raise the rotary head.
Pull lever to lower the rotary head.
8.
Engine Diagnostic Lamp

Light flashes to indicate engine fault.
Refer to engine manual for fault codes and remedy.
9.
Remote Pulldown Relief

Controls the pressure to the feed system to increase or decrease the weight on bit.
Turn control clockwise to increase pressure.
Turn counterclockwise to decrease pressure.
9a.
Holdback System Pressure Control

This valve is used on high pressure machines using down the hole hammers and is used in conjunction with the Holdback System Switch (see switch panel detail) which activates the solenoid
valve. Normally this valve is wide open (all the way out, counterclockwise) when drilling begins. As
pipe sections are added, the weight on the bit increases. To avoid too much pressure on the bit turn
valve IN (clockwise) to increase oil restriction from pulldown cylinder to tank.
Turn control clockwise to decrease pressure on bit.
Turn counterclockwise to increase pressure on bit.
10.
Compressor Start-Run Valvenot shown (cold weather option)

Low Pressure Machines:
When starting machine, valve should be in the "Start" position so compressor is unloaded or in low
pressure mode. When machine is warmed up, turn valve to "Run" position.
High Pressure Machines:
When starting machine, valve should be in the "Low" position. When machine is warmed up, turn
valve to "High" position.
NOTE
Machines without cold weather package do not use this valve.
Operator Controls
3-5
Fig. 3-2 Instrument Panel

3-6
Operator Controls

11.
Main Circuit Breaker Panel

Pull to disconnect, push to reset breakers.
11a. Circuit Breaker Panel

For Air Conditioner and Heater.
12.
Light Switches
Used to turn on and off outside drill and cab interior lights.
13.
Compressor Air Filter Indicator

Shows RED when filter element needs to be changed. Indicates differential pressure across filter
element.
14.
Engine Air Filter Indicator

Shows RED when filter element needs to be changed. Indicates differential pressure across filter
element.
15.
Ignition
The ignition key is used to turn the electrical power ON/OFF.
(a) Turn key ON to supply electrical power.
(b) Turn key OFF to stop engine.
16.
Starter
The Start button is used to start the engine.
(a) Press Start button to start the engine.
(b) Release button once engine is running.
17.
Ether Injection (optional)

Aids in starting cold engine.
(a) Press for 3 seconds.
(b) Release to discharge.
(c) Wait 3 seconds to start engine.
18.
Drill Hourmeter
Meter records actual drilling hours.
19.
Engine Hourmeter
Meter records total engine hours.
20.
Engine Oil Pressure

Gauge indicates engine oil pressure.
21.
Engine Tachometer
Gauge indicates engine revolutions per minute.
22.
Engine Coolant Temperature

Gauge indicates the temperature of the engine coolant.
23.
Compressor Discharge Temperature

Gauge indicates the temperature of the compressor discharge air.
24.
Fuel Level
Gauge indicates fuel level in tank.
25.
Voltage
Gauge indicates voltage output of the electrical charging system.
Operator Controls
3-7
Operator Control Panel (optional)
Fig. 3-3 Optional Control Panel
Fig. 3-4 Water Injection Pump Motor Flow

Control
Controls hydraulic flow to water pump motor.
Turn clockwise to increase flow.
3-8
Operator Controls

1.
Auto Lube Controller

Controls auto lube system. Refer to Section 7 of this manual for operator's manual.
2.
Drill Depth Meter

Monitors drilling depth. Refer to Section 7 of this manual for operator's manual.
3.
Tram Interlock Light

Light ON, indicates drill pipe is still in hole. Machine will not tram until pipe is out of hole.
4.
Test Switch
Turn switch ON to check filter indicator lights.
5.
Filter Indicator Lights

Light ON, indicates that particular filter needs to be changed. Monitors the following fluid filters:
Loop, Charge, Main Return, Case Drain, and Compressor Oil Filter.\
6.
Caterpillar EMS (Engine Monitoring System) Panel

An electronic monitoring system that displays various engine parameters. Each time the engine is
started, the EMS undergoes an automatic self-test. This panel replaces the engine hour meter, engine oil pressure gauge, engine tachometer, engine coolant temperature gauge and voltage gauge.
7.
Caterpillar EMS Scroll Switch

Move switch up or down to scroll through menus on EMS panel.
8.
Horn Button
Push button to sound horn.
9.
Jack Retract Light

Light ON, indicates jacks are fully retracted.
10.
Oil Injection Light

Light ON, indicates oil injection pump is running.
11.
Compressor Low Oil Pressure Light

Light ON indicates low oil pressure at compressor bearings.
12.
Rotary Torque Control

Turn knob clockwise to increase rotary torque.
13.
Hydraulic Oil Temperature Gauge

o
Monitors temperature of oil in hydraulic tank. Oil temperature in tank should not be above 180 F
o
(82 C) during normal operation.
Operator Controls
3-9
Cat EMS Panel

Engine Monitoring System (EMS)
Display
Overview
The main gauge module has ten indicators (two

rows offi ve) that are used to display the system
diagnostics. A digital LCD readout displays the
parameters that are monitored. When metric values
are displayed, the units of measurement are
also displayed. When US values are displayed,
the units of measurement are not displayed. For
example, if metric values are being displayed, the
readout would be 35 kPa. If US values are being
displayed, the readout would be 5. (The unit of
measurement psi is NOT displayed.)
The following parameters are monitored:
Auxiliary pressure
Auxiliary temperature
Battery voltage
Coolant temperature
Engine hours
Engine load (percent)
Illustration 53
g00746960
The EMS display is used to display various engine

parameters. The EMS display supports backlighting
in order to provide excellent visibility in various light
conditions.
Engine oil pressure

Engine speed
Fuel pressure
Fuel rate
The engine ECM processes the operating

parameters and diagnostic information before
sending this information to the EMS display via the
CAT data link. The main gauge module displays
the information that is received from the ECM. Only
two wires are required from the ECM to the display
for communication of all of the engine operating
parameters.
The EMS display incorporates three individual
gauge modules which can be installed in various
locations in order to enhance operation. One main
gauge module is required for each desired operator
station. The tachometer module and the quad
gauge module are optional. These optional modules
will NOT operate without being connected to a main
gauge module.
The following information describes the function
and the requirements for installation of each gauge
module:
3-10
Fuel temperature
Inlet air temperature
Turbocharger outlet pressure (boost)
The quad gauge module has graduated warning
zones that display information in an analog format.
The quad gauge module displays the following
information:
Battery voltage
Coolant temperature
Engine oil pressure
Fuel pressure
The tachometer module displays engine speed
(rpm) on an analog gauge.
Operator Controls
Fig. 3-5 Instrument Panel with optional Murphy

Power View display.
14.
Fig. 3-6 Cummins Engine Panel
Murphy Power View (optional)

The "power view" system is an option in place of the engine hourmeter. It monitors several engine
functions, including: RPM, Engine Hours, Coolant Temperature, Oil Pressure, Fuel Consumption,
Throttle Position, and Engine Service Codes.
15.
Ether Injection (optional)

Aids in starting cold engine.
16.
Engine Pre-Lube Switch

Prior to starting engine, place switch in the START position (toward operator). With ignition switch
ON, push Engine Start Button, this activates the engine pre-lube system. You will hear the pre-lube
pump running, when it stops, the engine starter will activate. After engine starts, flip switch to RUN
position (ISC).
17.
Engine Fault Code Switch

Turn switch ON (towards operator) to activate fault code signals from amber light (80).
18.
Engine Throttle Switch

This is a 3-position switch. Position switch all the way DOWN (toward operator) for LOW IDLE,
MIDDLE position for MEDIUM IDLE, UP for HIGH IDLE.
19.
Engine Protection Light (Green)

Light comes on at start-up to indicated engine systems are normal.
20.
Engine Fault Code Light (Amber)

When light is on, it indicates there is a fault in the engine system.
21.
Engine Stop Light (Red)

Flashes in a sequence to indicate fault codes. The engine fault codes are listed in the engine
operator/maintenance manual. The fault codes can also be accessed using the Power View (14)
display.
Operator Controls
3-11
System Pressure Gauge Panel
Fig. 3-7 System Pressure Gauge Panel
3-12
Operator Controls
System Pressure Gauge Panel

26.
Rotation / Left Track Pressure

Maximum pressure 5000 PSI (344.7 bar). Avoid stalling the rotary head for extended
periods.
Gauge indicates hydraulic pressure required to rotate the drill string and when in propel mode, indicates pressure to left track motor.
27.
Pulldown Pressure
Maximum pressure 2600 PSI (179 bar). Higher pressures may cause the machine to
tip.
Gauge indicates hydraulic pressure at feed cylinder.
28.
Hydraulic System Pressure

Indicates auxiliary pump pressure.
29.
Drilling Air Pressure

Gauge indicates the air pressure in the drilling air line.
When the drilling air is turned OFF, there should be zero pressure on this gauge.
Operator Controls
3-13
Switch Panel (standard)
HOLD BACK
HOBO CLAMP
THREAD LUBE
HOBO SWING
OIL INJECTION
POSITIONER
DUST CURTAIN
DUST/WATER
MAST LOCK
PIPE RACK SWING
PIPE RACK LOCK
AUX. PUMP
MAIN AIR
AUTO TOOL
FAST PULLDOWN
DRILL/PROPEL
AUTO PULLDOWN
WINCH
Fig. 3-8
3-14
PIPE RACK INDEX
Switch Panel
Operator Controls
Switch Panel (standard)

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

The break-out wrench is used to undo tight thread connections. This switch is used to swing the
break-out wrench into or away from the drill pipe.
31.
Push and hold switch up to swing break-out wrench out.
Push and hold switch down to swing break-out wrench in.
Hydraulically Operated Break-Out Wrench (HOBO) - Clamp

The break-out wrench is used to undo tight thread connections. This switch is used to clamp and
unclamp the break-out wrench and to turn the wrench.
32.
Push and hold switch right to disengage (open) break-out and unclamp wrench.
Push and hold switch left to clamp wrench and engage (close) break-out.
Drill Pipe Loader - Interlock

This switch is connected to a proximity switch in the mast. If the pipe rack moves off its stop inside
the mast the proximity switch will activate and stop the pulldown, rotation and auto feed. This is to
prevent the rotary head from hitting the pipe rack. When this happens, use the pipe loader swing
switch (40) to swing pipe rack back against stop, then drilling can resume. When adding drill pipe
however, use pulldown and rotation with the pipe loader out. To do this, place the switch in the
OVERRIDE position (towards the UNLOCK symbol). This will allow the rotation and pulldown functions to work when the pipe loader is out.
33.
Drill Stem Thread Lube
34.
Air Line Lubricator
35.
Push and hold switch down to activate grease pump to lubricate drill pipe threads.
Push switch down to activate lubricator pump to provide lubrication for "In The Hole Hammers"
used on high pressure machines.
Water Injection / Dust Collector

This switch is used to engage the water injection or dust collector systems to control drilling dust.
36.
Push switch up to engage water injection system.
Push switch down to engage dust collector system.
Drill Pipe Support

The drill pipe support is used to support the drill pipe in the center of the mast when using the drill
pipe loader for multiple pass drilling.
37.
Push and hold switch up to engage drill pipe support.
Push and hold switch down to disengage drill pipe support.
Dust Curtain
Switch is used to raise or lower the dust curtain at the rear of the machine.
Push and hold switch up to lift dust curtain.
Push and hold switch down to lower dust curtain.
Operator Controls
3-15
Switch Panel
38.
Mast Lock
Switch UNLOCKS or LOCKS mast in the vertical or angle drilling positions.
Push and hold switch left to unlock (retract) mast pins.
Push and hold switch right to lock (engage) mast pins into mast.
BE SURE to visually check to see that the mast lock pins are fully engaged in the
holes in the mast before drilling. Also be sure pins are fully retracted from holes
before lowering mast.
39.
Used for Optional Functions
40.
Drill Pipe Loader - Swing

This switch is used to swing the drill pipe loader out from and into the center of the mast when
adding and retracting drill pipe and for storing the drill pipe loader when propelling or lowering the
mast.
41.
Drill Pipe Loader - Rotate

This switch is used to rotate the drill pipe loader left or right to the next position.
42.
Push and hold switch left to rotate drill pipe loader left.
Push and hold switch right to rotate drill pipe loader right.
Drill Pipe Loader - Lock

This switch is used to lock or unlock the drill pipe loader so the loader can be indexed left or right to
the next position.
Push and hold switch down to lock pin IN.
43.
Drilling Air
Turns the air ON/OFF for drilling procedures.
Push switch up to turn drilling air ON.
44.
Push and hold switch up to move pin OUT.
Push switch down to turn drilling air OFF.
Pulldown System (Auto Feed)

The pulldown system switch engages and disengages the pulldown for drilling operations.
Push switch up to disengage pulldown.
Push switch down to engage pulldown.

DO NOT engage this switch on unless you are actually drilling. Once drilling is finished, this switch must be disengaged
45.
Fast Down
Push switch down to activate "fast down". Use this feature to increase speed of rotary head coming
down the mast.
46.
3-16
Winch
Push and hold switch up to raise winch hook.
Push and hold switch down to lower winch hook.
Operator Controls
Switch Panel
47.
Tool (Deck) Wrench

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

Engages the drill controls or propel system.
Push switch up to engage the propel system.
Push switch down to engage the drilling controls.

Drill mode must be selected if not propelling the machine or when the machine is
unattended. Drill mode engages the propel brakes.
49.
50.
TRAM High/Low Switch
Push switch UP for LOW SPEED tram
Push switch DOWN for HIGH SPEED tram.
Holdback System
Push switch down to activate the holdback system solenoid valve. This switch is used in conjunction with the Holdback Pressure Control Valve (53).
51.
Auxiliary Pump
This switch activates the auxiliary pump, which provides power for the drill set-up and tooling functions, i.e. winch, breakout wrench, deck wrench, pipe positioner and pipe rack.
52.
Switch down - Pump loaded
Switch up - Pump unloaded
Remote Pulldown Relief

Controls the pressure to the feed system to increase or decrease the weight on bit.
53.
Turn control clockwise to increase pressure.
Turn counterclockwise to decrease pressure.
Holdback System Pressure Control

This valve is used on high pressure machines using down the hole hammers and is used in conjunction with the Holdback System Switch (50) which activates the solenoid valve. Normally this
valve is wide open (all the way out, counterclockwise) when drilling begins. As pipe sections are
added, the weight on the bit increases. To avoid too much pressure on the bit turn valve IN (clockwise) to increase oil restriction from pulldown cylinder to tank.
Turn control clockwise to decrease pressure on the bit.
Turn counterclockwise to increase pressure on bit.
Operator Controls
3-17
Lights, Circuit Breakers
ADDITIONAL
LIGHTS
DRILL
LIGHTS
FRONT
LIGHTS
ADDITIONAL
LIGHTS
CAB
LIGHTS
CAB
LIGHTS
ECM
ROTATING
BEACON
BEACON
IGN-24V WIPERS
CIRCUIT
BREAKERS
DRILL LIGHTS
MAIN POWER
CONTROL
PANEL
12 VOLT
HEATER &
DRILL LIGHTS
PULL TO
DISCONNECT
NOTE: Not all switches and circuit breakers are used on every
machine. See parts manual for specific switches and breakers.
PUSH
TO RESET
STARTER
Fig. 3-9 Control Panel - Left Side
Fig. 3-10 Control Panel - Right Side

1. 10 AMP Circuit Breaker - Air Conditioner
2. 15 AMP Circuit Breaker - Heater
3-18
Operator Controls
Remote Mounted Cameras

There are two remotely mounted cameras on the machine that allow the operator greater visibility while
tramming. The cameras are switched on by a toggle switch on the cab circuit breaker panel.
The cameras can be positioned for best view but as a minimum should optimize the operator's visibility to
the front and far left side of the machine.
The display is located in the cab so that the operator has full view of the display when the machine is being
trammed. Only one camera is able to be viewed at a time.
1
2
3
4
5
6
7
Fig. 3-11 Camera Display Controls

1. POWER LEDindicates that the monitor has power
2. DAY/NIGHT SENSORsenses available light and adjusts
monitor brightness accordingly
3. MENU BUTTONinitiates display of onscreen user controls
for image contrast, brightness and speaker volume
4. + BUTTON UP button-increases the value for setup menu
items, such as volume
5. - BUTTONDOWN button-decreases the value for setup
menu items, such as volume
6. POWER/CAM SELECT BUTTONwhen pressed and held
for one second, turns the monitor ON or OFF; when pressed
briefly, switches image input
7. NORMAL/MIRROR SWITCHswitches image display to
Normal or Reverse (as it would appear in a rear-view mirror)
8. MONITOR CABLEreceives power and camera images
from the control box
9. BRACKET SLOTaccepts the adjustable mounting bracket
Operator Controls
3-19
Heater/AC/Pressurizer
Fig. 3-12 Heater/Air Conditioner Unit
1.
Heater - A/C Temperature Control

Controls temperature of A/C or heat.
2.
OFF - Heat - A/C Switch

Selects OFF, HEAT, or A/C.
3.
Fan Switch (3 position)

Selects fan speed, LOW - MEDIUM - HIGH
4.
Vent Control
Selects FRESH AIR or RECIRCULATION
Pressurizer w/Air Filter
3-20
Condenser/Dryer
Backpack Combo
Operator Controls
AC/Heater
Cab Heater Fault Isolation
Check out the heater as follows:
a.
Check blower motor by operating console switch, checking all three positions and observing blower
operation. Check for tripped circuit breaker and reset if tripped. Check for possible shorts in wiring
or loose connections.
b.
Check for heating by first allowing diesel engine to warm up thoroughly, then turning on blower and
assuring that the circulated air is warm.
c.
If heater fails to heat, check cutoff valves at plumbing connections to engine to be sure they are
turned on, then check the heater plumbing.
Fig. 3-13 Heater Connections and Cutoff Valves (Cat.

C15)
1. Water Outlet to Heater
2. Water Inlet from Heater
Operator Controls
3-21
Air Conditioner
Maintenance and Servicing Schedule
Although the systems are of heavy duty, industrial design, they still need maintenance and service. They
will not run indefinitely and the warranty is conditional upon these services being carried out.
Daily
Weekly
Monthly
Every 3
Every 6
Yearly
Service
Service
Service
Months
Months
Service
Check for Cleanliness of Condensing

Coil.
Clean Condenser Fan Motor With Dry

Compressed Air.
Check for Correct Setting of Thermostat.
Check Refrigeration and Water Lines

for Damaged Lines
Check Condensing Coil:

1. Refrigerant connections against leakage
2. Fixing bolts and screws
Check Condenser Fan Motor

1. Seal on motor shaft
2. Fixing clamps and screws
3. Inspect motor brushes for wear
4. Electrical Connections
Check Condenser Fan

1. For damage
2. For securing screws
3. For excessive noise
Check Compressor
1. Refrigerant piping and connections
2. Electrical connections
3. Check securing screws & bolts
4. Welds on mounting bracket
Check for Cleanliness of Fresh Air and

Return Air Filters.
Check Compressor Clutch:
1. Fixing screws & bracket
2. Clutch electrical connections
3. Belt tension and wear
3-22
Operator Controls
Air Conditioner
Daily
Service
Every 3
Months
Every 6
Months
Yearly
Service
Check Liquid Receiver/Drier

1. Refrigerant lines & connections
2. Securing bolts
3. For possible need of replacement
4. For refrigerant leakage
5. Sight glass during operation
Check High Pressure & Low Pressure

Controls
1. For correct setting
2. Securing screws tightness
Check Securing Fasteners on Fresh Air

and Return Air Filters
Check Evaporator Fan Motor

1. For tightness of securing screws
2. For electrical connections
Check Evaporator Blower

1. For tightness
2. For damaged blades
3. For excessive noise during operation
Check Electrical Connections of Thermostat
Check Control Switch

2. Operation
Check Heater Control Valve

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

Louvers
Check Evaporator Coil

1. For cleanliness
2. For refrigerant leakage
Check Against Refrigerant Leakage of

the Thermal Expansion Valve
Operator Controls
Weekly
Service
Monthly
Service
3-23
Air Conditioner
Daily
Service
Every 3
Months
Every 6
Months
Yearly
Service
Check Condensate Drip Tray

1. For cleanliness
2. For drain pipe blockage
Check Securing Screws & Bolts for

Tightness on Main Frame & Panels
Check for Leakage of Refrigeration

and Water Lines
Check Evaporator Pressure Regulator

1. For leakage
2. Evaporator pressure setting
Check Fresh Air Fan Motor

1. For excessive noise during operation
2. Brushes for wear
3. For electrical connections
Inspect Motor Brushes for Wear on

Evaporator Fan Motor
3-24
Weekly
Service
Monthly
Service
Operator Controls
Air Conditioner
DO NOT brush fins of coil with wire brush or irreparable damage will occur. If fins are
bent, use a correct coil fin comb to realign them.
Servicing
Condenser Coil - When the cover is removed the condenser coil is exposed, and thus readily available
for examination and cleaning. If cleaning is required, wash with low pressure water in the reverse
direction to air flow.
Condenser Fan Motor - Inspection of the motor is carried out by lifting the cover and removing the
motor from its mounting bracket. The brushes are accessible by removing the brush cover screws.
Inspect brushes for wear and replace if necessary. The motor case should be cleaned using only
moisture free compressed air.
Condenser Fan Blade - If any part appears to be damaged or worn excessively, DO NOT REPAIR, but
replace the fan blade.
Compressor - The compressor is equipped with either pad type or Rotalock suction and discharge
service valves mounted on the cylinder head. The pad type valves and the Rotalock valves are not
interchangeable.
Oil Charge - The system is charged with a R-134a compatible oil.
Compressor Oil Level - It is not necessary to frequently check or change the compressor oil. However,
it may be necessary to replenish or replace the compressor oil in the following cases:
1.
Whenever the compressor, evaporator, condenser or receiver-drier is replaced.
2.
Whenever the refrigerant has leaked from the system.
3.
Whenever the refrigerant is suddenly released from the cooling cycle.
4.
Whenever any oil-related problems occur in the cooling cycle.
Follow the component manufacturer's recommended procedures for repairs or replacements to

the system.
Operator Controls
3-25
Air Conditioner
Servicing (cont.)
Changing Compressor:
1.
Connect pressure gauge to suction gauge port on suction service valve stem one to two turns
clockwise. If gauge shows a pressure above zero gauge pressure and compressor can be operated, close suction service valve and operate compressor until compressor suction pressure is
reduced to approximately 2 psig.
2.
Stop compressor and immediately close discharge service valve by turning clockwise.
3.
Remove suction and discharge service valves from compressor.
4.
Remove mounting bolts from compressor and remove compressor from engine.
5.
Remove clutch.
6.
Check to see that new replacement compressor:

a. Is of the same model and bill of material or an approved replacement for the one being removed.
b. Oil level meets compressor manufacturer's specifications.
7.
Install clutch removed from defective compressor with "non-Rok" key in place after checking to see
that the clutch has no objectionable imperfections in it. Tighten hexhead bolt in end of shaft.
NOTE
Carefully lower, do not drop, clutch or compressor shaft. In most instances it is a

good idea to replace clutch assembly as well.
8.
Mount compressor using specified torque for mounting bolts, making sure that belts are properly
aligned and tightened to recommend belt tension (120 pounds for new belts, 100 pounds for used
belts).
9.
Securing service valves to compressor:

a. If valves are of the flat pad type, check to see that valve mounting surfaces on both valves and
cylinder head are clean, free of nicks, gaskets and foreign material. Using new mounting gasket
mount valves to compressor and tighten mounting bolts.
b. If valves are of the Rotalock type, check to see that valve mounting surfaces on both valves
and compressor are clean and that o-ring valve mounting gasket is properly positioned and in good
condition. If deformed, broken or split, replace with new gasket. Properly align valve to cylinder
head and tighten Rotalock nuts.
c. Special care should be used so that no dirt or foreign material enters compressor during installation. The new replacement compressor should not be left unsealed to the atmosphere longer
than is absolutely necessary for preparation and actual installation. In no case should compressor
be open to atmosphere for more than five minutes.
3-26
Operator Controls
Air Conditioner
Servicing (cont.)
Changing Compressor (continued):
10.
With service valves in closed position, connect vacuum pump to discharge and suction gauge
ports of service valves and evacuate to 500 microns Hg. Stop vacuum pump and close lines to
compressor.
11.
Open suction service valve until a minimum pressure of 50 psig in crankshaft is reached. Close
service valve, purge pump until a vacuum of 500 microns Hg is again reached. Open and backside
discharge service valve by turning counterclockwise, which closes discharge gauge port.
12.
Open suction service valve. Charge system with refrigerant to specified limits through suction
service valve gauge port. Operate system for 5 minutes at fast idle, check for leaks. No leaks are
permissible.
13.
Seal off discharge and suction connection ports of defective compressor.
Seal Assembly Replacement Procedure (Optional, HG 1000 Only):

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

NOTE
If the compressor being repaired has a dust shield, carefully remove it to avoid
marring the shaft and discard.
5.
Remove seal plate assembly by removing the six bolts in plate and gently pry plate loose, being
careful not to scratch, mar, or nick crankcase mating surface or edges.
6.
Remove carbon nose and spring assembly from shaft by a seal puller. When pulling the seal assembly
from the shaft, do not scratch crankshaft. If rubber seal around shaft does not come out with carbon
nose and spring assembly, remove same with long nose pliers, pulling on edge of grommet.
7.
Remove all gasket material, dirt and foreign material from crankcase mating surface to seal plate,
exposed crankshaft, and adjacent surfaces.
8.
Coat exposed surface of crankshaft with clean refrigeration oil. Dip bellows seal assembly and shaft
seal washer in clean refrigeration oil. Place bellows seal assembly over shaft with end for holding
shaft seal washer going on last. With hand, push bellows seal assembly on shaft to a position beyond
taper of shaft. Do not push into seal cavity.
Operator Controls
3-27
Air Conditioner
Servicing (cont.)
Seal Assembly Replacement Procedure (continued):
9.
Assemble shaft seal washer in bellows seal assembly, assuring before doing so to see that bellow
seal assembly and notches in washer line up with the tabs in bellow seal assembly. Cover exposed
surface of shaft seal washer with clean refrigeration oil.
10.
Insert new o-ring in crankcase groove on mating surface for seal plate.
11.
Place new front seal plate or seal plate and retainer over the shaft. Properly line up mounting holes
with seal and seal plate. When aligned, place plate and seal assembly up against crankcase. Insert
the six capscrews and screw in squarely and evenly. Tighten capscrews in a circular sequence to a
torque of 67.5 ft-lb.
12.
Rotate shaft by hand 15 to 20 revolutions to seat seal. Clean off excess oil.
13.
Install the key. Replace the clutch and tighten the clutch mounting bolt.
NOTE
In general, it is more cost effective to replace the compressor.
Liquid Receiver/Drier - In the event that the system is contaminated, or has lost all its charge, or is
down for extensive maintenance, the receiver/drier should be replaced. It is a low cost item and
provides a great deal of protection. If the system has lost its charge completely, replacement should
be effected immediately prior to final leak testing and charging. This prevents contaminants being
drawn into the desiccant and thereby decreasing its capacity.
NOTE
If the system is charged, the refrigerant MUST be recovered into a refrigerant

recovery device.
High Pressure and Low Pressure Controls - Follow Maintenance Schedule. If found faulty, replace
completely. Do not attempt to repair any part. Connection is via access ports so minimal refrigerant
is lost.
Filters - Clean regularly as per Maintenance Schedule with low pressure water or clean compressed air.
Replace if found that they cannot be cleaned.
3-28
Operator Controls
Air Conditioner
Servicing (Cont.)
DO NOT brush fins of coil with wire brush or irreparable damage will occur. If fins are
bent, use a correct coil fin comb to realign them.
Evaporator Coil - Follow Maintenance Schedule. If found that the coil needs cleaning, wash with low
pressure, ambient temperature water. Ensure that a baffle is used to prevent any water from being
washed into the cabin through the return air plenum. Some detergent may be misted on to assist
cleaning.
Setting of TX Valve Superheat & Evaporator Pressure Regulators - The purpose of these devices in
the air conditioning unit are as follows:
TX Valve - Thermostatic Expansion (TX) Valve - This device has high pressure liquid refrigerant entering and passing through a very small orifice thereby causing a drop in pressure. This lower pressure refrigerant has some 'flash gas' in it, therefore its volume for a given mass increases, and as
the same amount of mass is being fed to the evaporator its velocity through the distributor increases, which causes a further pressure drop and more liquid 'evaporation'. This refrigerant then enters
the evaporator coil at a much lower pressure and as heat is taken up through the heat exchange
surface, evaporation continues, thereby cooling the air and changing the state of the refrigerant
from a high density liquid to a low density gas.
Complete evaporation of the liquid must take place prior to the refrigerant leaving the heat exchange coil, as liquid refrigerant at the compressor will cause damage. Refrigerant is incompressible and flushes out bearings. Refrigerant vapor leaving the evaporator coil should be 'superheated'. At the point where the temperature of the refrigerant corresponds to the saturated pressure,
the condition is said to be saturated. If the temperature is higher than saturated pressure, the
condition is said to be superheated.
Normally around 10 - 11oF (6oC) is considered favorable.
If it is too high, as is the case in an undercharged system, the system loses capacity as the amount
of energy to superheat gas is no where near as much as to change the state of the refrigerant from
a liquid to a gas. Suction pressures will be low, suction line warmer than normal.
If it is too low, suction pressures will be higher, but coil temperature will also be high, so heat
transfer will not be as effective. If it is 'flooding back', the line will be sweaty all the way back to the
compressor and the compressor could be noisy.
Operator Controls
3-29
Air Conditioner
Servicing (Cont.)
Setting of TX Valve Superheat & Evaporator Pressure Regulators (continued)
The following table has been provided for your convenience:
SATURATED
10oF
TEMPERATURE
SUPERHEAT
SUCTION PRESSURE
psi
kPa
oF
oC
oF
oC
28.4
196
30
-1
40
30.0
207
32
42
31.7
219
34
44
33.4
230
36
46
35.1
242
38
48
36.9
254
40
50
11
How to set - Ensure that coils and filters are clean and system fully charged. Run through normal
checks and ensure pressures, etc., are within expected levels and no blockages in supply line to
TX valve.
Check that the bulb or coil is securely and cleanly clamped to the suction line.
Fit a thermometer probe to the suction line adjacent to the bulb or coil.
Connect up pressure gauge at the EPR port.
Operate the unit under a stable load and calculate the superheat, then adjust the TX valve slowly.
After adjustment, please allow time for the system to stabilize as 'hunting' will occur for some time.
Evaporator Pressure Regulator - This device modulates according to pressure in the evaporator. Its
purpose is to keep pressure, and therefore temperature, above a set figure to prevent ice building-up on the coil, and water in the heating circuit from freezing and possible rupture of the water
pipes.
If the pressure falls, it will restrict the flow, therefore the evaporator pressure and temperature rise,
but the suction pressure to the compressor falls. Operation is reversed if pressure rises.
In normal air conditioning applications, it should be set at 28-30 psi.
How to Set - Once the TX valve has been adjusted to correct superheat the EPR valve can be adjusted
by screwing the adjusting screw beneath the knurled cap. The Lp gauge line is left in position.
3-30
Operator Controls
Air Conditioner
Troubleshooting
I. System Produces No Cooling
CAUSE
INDICATIONS
REMEDY
Fuse blown or circuit breaker tripped
Electrical components will not operate.
Replace fuse or reset circuit breaker.
Broken or disconnected electrical wire
Check all terminals for loose connections; check wiring for hidden breaks.
Broken or disconnected ground wire
Check ground wire to see if loose, broken, or disconnected.
Clutch coil burned out or disconnected
Compressor clutch inoperative.
Check current flow to clutch; replace if

inoperative.
Electric switch contacts in pressure

switches burned excessively, or clutch
relay not working
Compressor clutch inoperative.
Replace low pressure or high pressure

switches or clutch relay.
Blower motor disconnected or burned

out
Blower motor inoperative.
Check current flow to blower motor;

repair or replace if inoperative.
Loose or broken drive belt
Visual inspection.
Replace drive belts and/or tighten to

specifications.
Compressor partially or completely

frozen
Compressor pulley slips on belt or will

not turn when clutch is engaged.
Remove compressor for service or

replacement.
Compressor reed valves inoperative
Only slight variations of both gauge

readings at any engine speed.
Service or replace compressor reed

valves.
Expansion valve stuck in open position
Head pressure normal, suction pressure

high evaporator flooding.
Replace expansion valve.
Broken refrigeration line
Complete loss of refrigerant.
Examine all lines for evidence of breakage by stress or rubbing wear.
Safety valve
Complete or partial refrigerant loss.
Examine valve on drier.
Leak in system
No pressure on high and low gauges

(applies to any system having complete
loss of refrigerant).
Evacuate system, apply static charge

leak test system, & repair leak as necessary.
Compressor shaft seal leaking
Clutch and front of compressor oily;

system low or out of refrigerant.
Replace compressor shaft seal.
Clogged screen or screens in receiver

dehydrator or expansion valve; plugged
hose or coil
High gauge normal or may read high.

Low gauge usually shows vacuum or
very low pressure reading. Frosting usually occurs at point of blockage.
Repair as necessary.
Mechanical:
Refrigeration:
Operator Controls
3-31
Air Conditioner
Troubleshooting
II. System Will Not Produce Sufficient Cooling
CAUSE
INDICATIONS
REMEDY
Electrical:
Blower motor sluggish in operation
Small displacement of air from discharge duct; blower motor possibly

noisy.
Remove blower motor for service or

replacement.
Compressor clutch slipping
Visual inspection.
Remove clutch assembly for service or

replacement.
Obstructed blower discharge passage
Blower operates at high speed but air

displacement very small.
Examine entire discharge passage

for kinks, waddings or failure to open
passage during installation. Correct as
necessary.
Clogged air intake filter
Insufficient air displacement by blower.
Replace air filter screens and service, or

replace if necessary.
Insufficient air circulation over condenser coils; fins clogged with dirt or bugs.
Insufficient cooling at discharge outlet;

excessive high pressure gauge reading.
Clean condenser.
Evaporator clogged
Fins clogged with lint, dust, or coated

with cigarette tars.
Remove cover and clean with

compressed air. Use cleaning solvent to
remove cigarette tars.
Evaporator pressure regulator defective

or improperly adjusted
High pressure gauge readings normal;

low gauge usually reads too high.
Repair or adjust as necessary.
Insufficient refrigerant in system
Bubbles in sight glass; high gauge readings excessively low.
Test for leaks. Repair as necessary.

Recharge system until bubbles
disappear and gauge readings stabilize
to specifications.
Clogged screen in expansion valve
Gauge pressures may be normal or may Purge system, remove screen, clean
show slightly increased head pressure
and replace.
and low suction pressure; discharge output temperature higher than specified.
Expansion valve thermal bulb has lost

charge
Excessively high or low gauge readings;

may cool in excess or not enough.
Clogged screen in receiver
High pressure gauge usually higher than Purge system; replace receiver.
normal; receiver cold to touch and may
frost.
Excessive moisture in system
Excessive high and low gauge reading.

Lack of cooling.
Mechanical:
Refrigeration:
NOTE
3-32
Purge system; replace expansion valve.
Inspect system for refrigerant

overcharge. Correct.
If gauges still read high, inspect condenser for oil clogging.
After completing repairs above, system MUST have dehydrator replaced purged, evacuated and charged.
Operator Controls
Air Conditioner
Troubleshooting
II. System Will Not Produce Sufficient Cooling (cont.)
CAUSE
INDICATIONS
REMEDY
Refrigeration (cont.):
Air in system
Excessive high and low gauge reading.

Sight glass shows bubbles or is cloudy.
System contaminated.
Purge system, replace filter/drier,

evacuate and charge system with new
refrigerant.
Evaporator pressure control valve improperly set
High air temperature off of evaporator

coil, high evaporator coil temperature.
Adjust pressure setting on valve to

2830 psi. (1.92.1 bar).
NOTE
When a unit must be removed from the system for service or replacement, the system must
have the dehydrator replaced also, and the system must be purged, evacuated and recharged
to remove excess moisture.
III. System Cools Intermittently

CAUSE
INDICATIONS
REMEDY
Electrical:
Defective fuse or circuit breaker, blower
switch, or blower motor
Electrical units operate intermittently.
Remove defective part for service or

replacement.
Partially open, improper ground or loose

connections in compressor clutch coil
Clutch disengages prematurely during

operation.
Check connections or remove clutch coil

for service or replacement.
Visual inspection operates until head

pressure builds up (as viewed on high
pressure gauge) at which time clutch
begins slipping, may or may not be
noisy.
Slippage over a prolonged period will

require that clutch be removed for
service; may require readjustment for
proper spacing.
Mechanical:
Compressor clutch slipping
Refrigeration:
Unit icing up may be caused by excesUnit ices up intermittently.
sive moisture in system, incorrect superheat adjustment in expansion valve or
thermostat adjusted too low
Replace expansion valve if excess

moisture present, adjust thermostat.
Purge system, evacuate, recharge.
Thermostat defective
Low side pressure may be low or excessively high; adjustments will not correct.
Replace thermostat.
Stuck regulator valve
Both head and suction pressures low;

moisture in system usually indicated.
Purge system and evacuate and replace

dehydrator to remove moisture; if still
stuck, replace regulator valve.
Operator Controls
3-33
Air Conditioner
Troubleshooting
IV. Excessively Noisy System
CAUSE
INDICATIONS
REMEDY
Electrical:
Effective winding or improper connection in compressor clutch coil
Visual inspection; clutch vibrates.
Replace or repair as necessary.
Loose or excessively worn drive belts
Belts slip and are noisy.
Tighten or replace as required.
Noisy clutch
May or may not slip; noisy when engaged
Remove clutch for service or replacement as necessary.
Compressor noisy
Loose mounting, worn part inside compressor.
Check mountings and repair; remove

compressor for service or replacement.
Loose panels
Excessive rattles during operations.
Check and tighten all panels; hose hold

down clamps, or rubbing or vibrations of
hoses or pipes.
Compressor oil level low
Compressor noisy and lower portion hot

to touch.
If oil level low, determine cause of loss.

If correction made, fill with specified oil.
Blower fan noisy; excessive wear in

blower motor.
Blower motor noisy.
Remove blower motor for service or

replacement as necessary.
Mechanical:
Refrigeration:
Excessive charge in system
Rumbling noise or vibration in high pres- Discharge excess freon until high pressure line; thumping noise in compressor; sure gauge drops within specifications.
excessive head pressure and suction
pressure; bubbles in sight glass.
Low charge in system
Hissing in evaporator case at expansion

valve; bubbles or cloudiness in sight
glass, low head pressure.
Check system leaks, charge system.
Excessive moisture in system
Expansion valve noisy; suction pressure

low.
Replace dehydrator, purge system,

evacuate and charge system.
High pressure service valve closed
Compressor has excessive knocking

noise; high pressure gauge reads above
normal.
Open valve immediately.
3-34
Operator Controls
Operator's Seat
Operator Controls
3-35
Operator's Seat
3-36
Operator Controls
Section 4
Operating Instructions
4-1
Notes
4-2
Pre-Start Checks
Commissioning A New Machine
The rotary blasthole drill will (in most cases) arrive on two trucks. The mast is shipped separate (in
most cases) from the drill rig itself. With the drill rig unloaded from the truck and on level and stable ground,
the mast will need to be installed. A manufacturer representative will be on hand to make adjustments and
settings on a new machine.
Load drill pipe using a crane whenever possible, this is the best and safest method. If a crane is not available when drill pipe is being loaded, follow the procedure
in this section titled "Loading Drill Pipe".
Walk Around Checks:

It is the responsibility of the operator to report any damage or service problems to the supervisor.
You may wish to develop your own checklist and standard operating procedure, such as starting point,
what to look for, etc. Generally, you should check the following areas before start-up, this applies to new
and used machines:
Check around and under machine for leaks. Determine source of leak and have repairs made.
Check crawler belts for broken or cracked pads, missing lock pins or bolts, loose track pins and
crawler belt tension. Check track rollers for proper lubrication and wear. Check crawler frames for
cracks or damage.
Check dust curtains for wear and tear.
Check for loose or missing bolts. Report any damage and have repairs made.
Check connections to air filters, make sure they are tight. Check to see that filter elements are in
place.
Check radiator and oil cooler hoses for cracks and loose clamps.
Check engine vee belts for cracks or other damage.
Check engine fuel/water separator if so equipped and drain water.
Check all pivot points to be sure they are receiving adequate lubrication.
Check fire suppression equipment to be sure they are adequately charged.
Check to see that all alarm systems and EMERGENCY STOPS are functioning properly.
Check to be sure all safety guards are in place and not damaged.
Check engine/pump driveshaft. Check for loose or missing bolts and adequate lubrication.
Check all cables for damage or fraying, loose or missing clamps.
Check drill bit for wear, broken or missing carbides.
Check that all decals and nameplates are in place and are not damaged.
Check wiring for damage and loose connections.
4-3
Pre-Start Checks
Pre-Start Checklist
Fluid Levels:
A.
Radiator Coolant
B.
Batteries
C.
Engine Oil
D.
Fuel
E.
Pump Drive Gearcase
F.
Water Tank
G.
Hydraulic Tank
H.
Compressor Oil Separator Tank
I.
Rotary Drive Gearcase (check with mast vertical)
J.
Winch Gearcase
K.
Track Drive Gearcases
Operator Controls:
Safety first! Become familiar with all the controls and their functions.
Take it slow at first, as the drilling cycle and controls become more familiar, you can gradually
increase your speed to the full operating capability of the machine.
Accidents happen quickly, which is why you should operate the machine slowly at first, until you
are satisfied that you comfortable with all the control functions.
Check that all system gauges are operating properly after start-up.
Be alert for any unusual noises or smells.
Know the location of EMERGENCY STOP devices and fire extinguishers and how they operate
(refer to machine locator drawing in introduction of manual).
Fire Extinguisher Specifications:

Fire extinguishers shall comply with EN791:1995 paragraph 5.12.2 and EN 3:1975. Each fire extinguisher shall have an agent with a mass of not less than 13.2 lbs. (6 kg). Fire extinguishers shall be suitable
for extinguishing both oil and electrical fires.
4-4
Fire Suppression System (optional)

Description
The drill can be equipped with an optional fire suppression system.
The system is manually activated by pushing a remote actuator.
There are two actuators, one located in the operator's cab and one outside the machine. Make yourself
familiar with the location of the actuators. Location varies on different machines.
In addition there is a battery cut-off switch, which automatically cuts the power to the machine off when
the fire suppression system is activated.
Fig. 4-0 Fire Suppression System - 30 lb. Tanks with Actuators (3)
Fig. 4-0a Relief Valve
Operation
When the system is activated, the fire suppression agent in the three (3) tanks is released and discharged through a series of nozzles, located in critical areas around the machine. At the same time the
pneumatic battery cutoff switch cuts off the battery voltage to the machine.
Maintenance
Make sure the system is in good operating condition. A fire suppression system does little good if it
does not work when you need it. Make it a habit of daily inspection of hoses, fittings, and discharge nozzles.
The nozzles should have plastic caps in place to keep out dirt and debris. Make sure the actuators are not
damaged and not covered up with clutter. Take care of your system, and it will take care of you.
NOTE
At any time if any part of the fire suppression system is suspected of not being fully operational or has suffered damage, it shall only be serviced by a professional fire protection service.
4-5
Fire Suppression System (optional)

In Case of Fire
Locate nearest remote actuator.
1.
Turn ignition switch off if possible
2.
Pull Ring Pin on actuator.
3.
Push Red Button on actuator.
4.
Get away from machine and call for help.
Fig. 4-0b Pneumatic Battery Cutoff Valve
Fig. 4-0c Remote Actuator in Operator's Cab
After System Has Been Discharged

After a fire, or accidental discharge, the system must be checked and serviced by a professional fire
protection service.
Be sure the fire is completely out and there are no "hot spots" before getting near the machine.
It's good idea to keep a portable fire extinguisher on hand ( see fire extinguisher specifications on
previous page). When approaching the machine, have a fire extinguisher with you.
Determine the cause of the fire and make necessary repairs, before putting machine back into service.
After discharge, and when it is safe to return to the machine, the battery cutoff valve needs to be
reset. This is done by first pulling the ring on the pressure relief valve to relieve all pressure in the
system. When all pressure is relieved, push the reset button on the battery cutoff valve IN. You will
not be able to push the reset button in with pressure still in the system.
4-6
Normal Start-Up Procedure

Before starting the engine, warn nearby members of the work crew that you are starting
the machine.
DO NOT USE ETHER on engines equipped with an Air Inlet Heater (electrically or fuel
ignited manifold heater).
To Start Engine:
1.
Be sure all controls are in the Off or Neutral position.
2.
Place the compressor Start-Run valve (10) in the start position or low position on high pressure
machines.
NOTE
DO NOT start the engine if there is pressure in the compressor receiver tank. If the
engine has recently been running, this may require an approximate 10 minute wait to
allow complete receiver tank bleed down. Starting the engine while there is residual
pressure in the receiver tank will result in a significantly reduced life of the diesel engine starter.
3.
Place throttle lever (2) at about 1/3 speed.
4.
Turn the ignition switch (15) On.
NOTE
The engine diagnostic lamp (8) will flash while the engine is cranking. The lamp
should turn off after proper oil pressure is reached. If lamp continues to flash after
engine is running, the ECM has detected a problem in the system. Refer to engine
manual for diagnostic codes.
5.
Push the engine start button (16) until the engine starts, when engine is started, release start
button. Do not crank engine for more than 30 seconds, then allow starter to cool for two minutes
before attempting to start again.
6.
If temperature is below 32o F (0o C) use the optional ether injection (17) for starting, use caution
not to use too much as engine damage can occur. Press button for 3 seconds and release, then
allow 3 seconds before starting engine.
Fig. 4-1 Instrument Panel - Right Side

15. Ignition Switch
16. Engine Start Button
17. Ether Injection (optional)
18. Drill Hourmeter
19. Engine Hourmeter
20. Engine Oil Pressure
4-7
Normal Start-Up Procedure
Fig. 4-1a Control Panel - Right Side

1. Level
2. Engine Throttle Lever
8. ECM Diagnostic Lamp
10. Compressor Start-Run Valve*
(*not shown)
After Start Checks:

After start checks are carried out to ensure that the machine is in a safe working condition before the
operator commences drilling procedures.
1.
Check to ensure engine oil pressure is in normal operating range (consult engine manual).
2.
Check to ensure compressor air pressure is at least 100 PSI (6.9 bar) for low pressure machines
or 300 PSI (20.7 bar) for high pressure machines.
Compressor air pressure must not exceed 125 PSI (8.6 bar) for low pressure machines
or 350 PSI (24.1 bar) for high pressure machines.
3.
Check entire machine for oil leaks.
Normal Shut Down:

1.
Allow engine to idle for a minimum of five (5) minutes before stopping.
2.
Turn the ignition key to OFF position.
3.
Check machine for any unusual conditions.
4.
Report any defects to your immediate supervisor.
4-8
Ground Level Engine Stop (optional)

DO NOT use the ENGINE STOP switch to stop the machine, except in an emergency.
Shutting the engine down without the proper idle down period can cause engine damage.
Be sure you know where the ENGINE STOP device(s) are located. These devices are optional, therefore not all machines will be equipped with them.
In the event of emergency shutdown, the operator should notify the supervisor and be sure corrective
action is taken to remedy the fault that caused the emergency shutdown, before restarting the machine.
1.
Take necessary corrective action to correct the fault.
2.
Make a walk around inspection of the machine to be sure no additional damage has been done or
could occur. Pay particular attention to the engine and compressor systems.
3.
Check circuit breakers and reset the engine stop device.
Fig. 4-2 Ground Level Engine Stop Button
P61 PLUG
REF
CAB JUNCTION
BOX TERMINAL
E-STOP
ENGINE KILL
SWITCH
BLU 16
NC
+BAT (UNSWITCHED)
56
+BAT (UNSWITCHED)
55
REMOTE SHUTDOWN SW
101
BLU 16
+BAT (SWITCHED)
31
27
26
DIAGNOSTIC LAMP
24
THROTTLE POSITION SENSOR
10
8
71
32
54
+BAT (UNSWITCHED)
ELECTRICAL SCHEMATIC
Fig. 4-3 Electrical Circuit (ref. 426571)
4-9
Cold Weather Operation

Hydraulic System Warm-Up
BE SURE machine does not overheat. Observe hydraulic and water temperature gauges.
When pump drive gearbox is disconnected all hydraulic functions are inoperative, including the cooler fan.
1.
For cold weather start, disengage the pump drive gearbox using the lever on the gearbox (if so
equipped). Start the engine and warm up for at least five (5) minutes (refer to "Engine Start-Up
Procedure" on preceding page).
2.
Stop the engine, engage the pump drive gearbox and restart the engine.
3.
Level the machine.

NEVER ATTEMPT to commence drilling unless the machine has been leveled and is
located on stable ground conditions. Machine can turn over, causing serious injury or
death.
DO NOT position jacks on cribbing or timber bridging.
DO NOT position machine close to a highwall.
a. Set the throttle at approximately 1600 RPM and lower all jack pads to the ground by operating
the rear and front jack control levers to the down position.
b. Operate rear right and rear left jack controls to down position until rear of machine track is
clear of the ground and approximately level by watching level indicator (refer to "Leveling Machine").
c. Operate the front jack control to down position, until front of machine track is clear of the
ground, approximately level.
4. Raising the Mast.
a. Be sure the machine is level and solidly stabilized with the leveling jacks before attempting to
raise the mast.
b. Be absolutely sure that the mast will not come in contact with power lines, telephone lines or
any other obstructions.
LOOK UP before raising or lowering mast. Operating near, or coming in contact with
electrical power lines will result in serious personal injury or death. Machine is not
insulated.
See Section 2 for Clearances from High Voltage Lines chart.
ALWAYS level machine before raising or lowering mast and before drilling.
4-10

5.
Hold Rotation Lever to one-quarter speed and operate rotation in forward position.
DO NOT engage or disengage track drive while engine is running and tracks are in contact with ground. Immediate machine damage could result.
Verify right and left tracks are a minimum of 3 in. (76.2 mm) off the ground.
6.
Set Drill/Propel switch to Propel position.
7.
Hold Propel Levers at 1/4 position and operate tracks alternately in both directions.
8.
Work all hydraulic controls to distribute warming oil and to help elevate oil temperature. Pay particular attention to winch warm-up by cycling several times without load.
9.
When hydraulic oil temperature reaches 1000 F (37.80 C) the system is operational.
Compressor Warm-Up (Low Pressure)

1.
Run machine with Compressor Start-Run Valve in the Start position until temperature reaches
160o F (71.1o C). After warm-up, turn selector to Run position.
2.
Gradually load compressor by opening air service valve, using the Drilling Air switch until pressure drops to 70 - 80 PSI (4.8 - 5.5 bar). If temperature rises above 210o F (99o C), close air service valve and continue warm-up.
3.
Partially open air service valve, using the Drilling Air switch. If compressor has stabilized at 160oF
(71.1oC) it is now operational.
4.
Gradually increase engine speed to 2100 RPM. Compressor pressure should read 100 PSI (7 bar)
and temperature should be 160 - 200o F (71.1 - 93.3o C). Temperature should be monitored and
maintained by the air flow direction through the cooler.
4-11

Compressor Warm-Up (High Pressure)
1.
Run machine with Compressor Start-Run Valve (10) Low until compressor temperature reaches
180oF (82.2oC). After warm-up turn selector valve to High position.
2.
Gradually load compressor by opening air service valve, using the Drilling Air switch (43) until
pressure drops to 140 PSI (9.7 bar). If temperature rises above 210oF (98.9oC), close air service
valve and continue warm-up.
3.
Partially open air service valve, using the Drilling Air switch (43). If compressor has stabilized at
180oF (82.2oC) it is now operational.
4.
Gradually increase engine speed to 2100 RPM. Compressor pressure should read 350 PSI (24.1
bar) and temperature should be 210oF (99oC). Temperature should be monitored and maintained by
the air flow direction through the cooler.
Fig. 4-3a Operator Control Panel - left side

10. Compressor START/RUN (low pressure) or LOW/HIGH (high pressure) Valve
43. Drilling Air ON/OFF Switch
4-12
Propelling Machine
ALWAYS propel the machine in reverse (towards operator's cab) where possible to provide maximum visibility. Propel the machine slowly when working on slopes, ramps, or
rough terrain. Be extremely careful when working around trenches or banks.
DO NOT travel on steep slopes or crosswise to grades.
DO NOT propel machine with mast up other than from hole to hole as this causes machine to become unstable.
Failure to follow these recommendations could result in a machine roll over.
NOTE
When propelling this machine, forward is towards the radiator end of the machine, and
reverse is towards the operator's cab.

5a. Right Track Lever
5b. Left Track Lever
48. Drill/Propel Switch
4-13
Propelling Machine
1.
Select Propel mode with the Drill/Propel switch (48).
2.
Engage right and left track propel levers (5a, 5b) together slowly in the required direction of travel.
Propel speed is varied by the degree of travel, forwards or backwards of the propel levers. To propel in a straight line, the propel levers must be operated equally from the neutral positions.
3.
To turn the machine left or right, one propel lever may be engaged more than the other to make the
machine turn. For very tight turns one propel lever may be engaged to the full forward position and
the opposite lever engaged to the full reverse position.
Both tracks must be operated when propelling the machine. Never allow either track to
drag while propelling in a straight line or turning.
4.
To stop propelling machine once at destination, move the propel levers back to the neutral position.
5.
Select Drill mode with the Drill/Propel switch (48).

ALWAYS select Drill mode once propelling functions are finished as Drill mode engages
the brakes. Never leave the machine unattended unless Drill/Propel switch is in the Drill
mode. Failure to follow these procedures could result in personal injury or property damage.
Propelling Up, Down and Across Grades:

1.
The mast should always be lowered before propelling the machine up, down or across grades.
2.
When propelling up or down a grade, index the pipe loader to a mid position, so drill pipes cannot
slide forward out of the carousel.
3.
When propelling up or down a steep grade, the operator's cab should be facing downhill. With the
mast down, the front end of the machine is heavier than the rear (cab end). This makes the machine more stable.
4.
When propelling up a steep grade, a spotter should be used to guide you, as visibility is restricted
to the operator.
5.
Always be careful when propelling machine across grades, as the machine is more unstable
sideways than it is lengthways. Propel with the operator's cab facing uphill when crossing grades
whenever possible.
4-14
Propelling Machine
Propelling Over Electrical Cables:
1.
Always use an approved crossing point, if one has been constructed. Always cross at right angles
and do not turn machine while crossing.
NEVER propel machine across electric cables. Severe personal injury or death could occur, as well as property damage.
2.
If no approved crossing point exists, then the following procedure should be used to cross electric
cables:
a. Use a spotter to help guide you. Approach the cable at 90o and stop machine when cable is
between the jack pads and the tracks.
b. Carefully lower jacks, making sure the jack pads will not rest on the cable. Raise machine
upon the jacks until tracks are clear of the ground.
c. Move cable under tracks until it is between the opposite end of the tracks and jack pads at the
other end of machine.
d. Carefully lower machine, making sure cable is not under tracks and retract jacks fully before
continuing to propel machine.

5a. Right Track Lever
5b. Left Track Lever
48. Drill/Propel Switch
4-15
Leveling Machine
Leveling Machine
NEVER ATTEMPT to commence drilling unless the machine has been leveled and is
located on stable ground conditions. Machine can turn over, causing serious injury or
death.
DO NOT position jacks on cribbing or timber bridging.
DO NOT position machine close to a highwall.
If machine needs to be re-leveled after it is already on all four jacks:
FIRST level rear (cab end) of machine.
ALWAYS extend front (radiator end) jacks to equalize pressure in both front jacks after
re-leveling machine.
Raising Machine (lowering jacks)

When raising machine, level the rear (cab end) of the machine first, then level the front (radiator end).
Refer to leveling procedure on following page.
Lowering Machine (raising jacks)

When lowering machine, lower the front (radiator end) of the machine first, keeping jack pads close
to the ground. When tracks are on the ground and machine is stable, jacks may be raised fully. Refer to
leveling procedure on following page.
Fig. 4-5 Control Console - Right Side

1. Level
3c. Left Rear Jack
3a. Right Rear Jack
4. Mast Lever
3b. Front Jacks
4-16
Re-Leveling Machine
Leveling Procedure
1.
Using the Rear Jack levers (3a & 3c), extend the jacks to contact the ground. Level the rear (cab
end) of the machine using the Level Indicator (1) as your guide.
NOTE
Front jacks must be lowered AFTER using rear jacks to level machine. This is to ensure equal hydraulic pressure in both front jacks.
2.
Using the Front Jack Lever (3b), lower the jacks until they contact the ground. Level the front (radiator end) of the machine.
3.
Level machine as near to level as possible.

ALWAYS keep the machine as low to the ground as possible when leveling the machine.
This machine has safety check valves in the leveling system to prevent the jacks from
moving in the case of a power failure. Should it be noticed that the jacks are creeping,
the machine should not be operated and repairs completed immediately. Failure to follow these instructions could lead to serious personal injury or equipment damage.
4.
To raise the jacks (lower machine), move Jack Lever (3b) to the raise position to lower the front
(radiator end) of the machine. Move Jack Levers (3a & 3b) to the raise position to lower the rear
(cab end) of the machine. Rear jacks may be raised individually or together.
If machine needs to be re-leveled after it is already on all four jacks:
FIRST level rear (cab end) of machine.
ALWAYS extend front (radiator end) jacks to equalize pressure in both front jacks
after re-leveling machine.
Re-Leveling Procedure
If machine has been leveled and is up on all four jacks and you need to re-level the machine, use the
following procedure (refer to fig. 4-5 for leveling jack controls):
1.
Level the rear (cab end) of the machine first using levers 3a and 3c.
2.
Level the front (radiator end) of the machine using lever 3b even if it appears level. This MUST be
done to equalize the hydraulic pressure to the front jacks.
4-17
Raising Mast
electrical power lines will result in serious personal injury or death. Machine is not insulated.
Refer to Clearances from High Voltage Lines chart below.
BE SURE to visually check to see that mast lock pins are fully engaged in the holes in the
mast lock brackets before drilling. Also be sure pins are fully retracted before lowering mast.
Clearances from High Voltage Lines

Voltage
Minimum Clearance
up to 50 kv
10 ft. (3 m)
over 50 to 75 kv
11 ft. (3.4 m)
over 75 to 125 kv
13 ft. (4 m)
over 125 to 175 kv
15 ft. (4.6 m)
over 175 to 250 kv
17 ft. (5.2 m)
over 250 to 370 kv
21 ft. (6.4 m)
over 370 to 550 kv
27 ft. (8.2 m)
over 550 to 1000 kv
42 ft. (12.8 m)
1.
Level the machine.
2.
Check mast for loose drilling tools or parts.
3.
Be sure mast lock pins are retracted and drill bit will clear work deck area.
4.
Raise mast by engaging the Mast Lever (4) to the raise position. The mast should start to lift; if
not, check the auxiliary hydraulic pressure gauge to see if any other functions are engaged.
5.
As the mast approaches the vertical position, the mast raising speed will tend to increase, so it will
become necessary to slow the speed to stop the mast from hitting into the base of the machine too
hard.
6.
The mast angle may be set from 70 degrees to the vertical depending on drilling applications.
7.
Once the mast has been set at the desired angle, lock the mast into position by pushing the Mast
Lock/Unlock Switch to the Lock position. Always visually check to be sure the mast lock pins are
fully engaged into the mast lock brackets.
4-18
Lowering Mast
electrical power lines will result in serious personal injury or death. Machine is not insulated.
Refer to Clearances from High Voltage Lines chart below.
BE SURE to visually check to see that mast lock pins are fully engaged in the holes in the
mast lock brackets before drilling. Also be sure pins are fully retracted before lowering mast.
1.
Retract the drill string from the hole, ensuring that the drill bit will clear the work deck area.
2.
Rotate the drill pipe loader to the stored position and swing the loader into the center of the mast.
3.
Unlock the mast by pushing the Mast Lock/Unlock Switch (fig. 4-6) to the Unlock position.
4.
Lower the mast by engaging the Mast Lever (4) to the Lower position, controlling the lowering
speed with the mast lever.
MAST LOCK
Fig. 4-6
Drill Function Panel - Mast Lock Switch
Fig. 4-5 Control Console - Right Side

1. Level
3c. Left Rear Jack
3a. Right Rear Jack
4. Mast Lever
3b. Front Jacks
4-19
Loading Drill Pipe

Load drill pipe using a crane whenever possible, this is the best and safest method. If
a crane is not available when drill pipe is being loaded, follow the procedure outlined
below.
Equipment Required:
1.
Service truck with service winch capable of lifting male end of pipe above the drilling platform of the
machine.
2.
Adequate lifting straps.
Procedure:
1.
Be sure machine is on level and solid ground.
2.
Check all pipe rack control functions to be sure they operate according to labels on control panel.
Switch hoses if necessary. Check fluid level in rotary gearbox.
3.
Lift the male end of the pipe to approximately the height of the middle railing around the drilling platform. Be sure pipe is secure and won't slip.
4.
Raise mast to the same angle as pipe and back machine up to the pipe.
5.
Apply grease to drill pipe threads and lower the rotary head until the top sub-adapter engages the
threads of the pipe. Thread the pipe all the way to the shoulder of the pipe and top sub-adapter.
6.
Stabilize machine by lowering all four jacks to the ground. Machine does not have to be lifted off the
ground, but jack pads should be in solid contact with ground.
7.
Raise the rotary head up the mast with the pipe, but do not let the pipe go above the deck bushing
in the mast base. It is also a good idea to use the pipe support if you have an angle hole machine.
8.
When the lower end of the drill pipe approaches the deck bushing, stop the rotary head and raise
the mast to the vertical position. Use the pipe rack controls to rack the pipe (refer to instructions on
"Retracting Drill Pipe" in this section).
9.
Repeat steps 3-8 for the remaining pipe sections.
Installing and Removing Drill Bit

Before drilling can commence, you must first install the drill bit sub and the drill bit.
1.
Remove the rotary deck bushing from the work deck and insert the drill bit breakout basket into the
work deck.
2.
Place the drill bit into the bit basket.
3.
Place the bit sub onto the drill bit and make-up thread joint "hand" tight.
4.
Engage the drill pipe to the bit sub and rotate drill pipe clockwise slowly until the thread joint becomes tight. Tighten thread joint to 3000 PSI (207 bar) on the rotation pressure gauge.
5.
For removal of drill bit, place bit breakout basket into the work deck.
6.
Lower drill bit into the breakout basket and use the breakout wrench to break the thread joint.
7.
Once thread joint is loose, simultaneously rotate drill pipe counterclockwise and slowly raise drill
pipe until the drill bit is unscrewed.
4-20
Drilling Procedures
LOOK UP before raising or lowering mast. Operating near, or coming in contact with electrical power lines will result in serious personal injury or death. Machine is not insulated.
Refer to Clearances from High Voltage Lines chart in Section 2.
DO NOT operate machine when wind speed is above 75 MPH (120.8 Km/h).
Fig.4-7 Drilling Controls

C. Rotary Torque Control
6. Rotation Lever
7. Hoist/Pulldown Lever
9. Pulldown System Pressure Control
9a. Holdback System Pressure Control
14a. Water Injection Flow Control
26. Rotation/Left Track Pressure Gauge
27.
28.
29.
35.
43.
44.
Pulldown Pressure Gauge

Hydraulic System Pressure Gauge
Drilling Air Pressure Gauge
Water Injection/Dust Collector Switch
Drilling Air Switch
Pulldown System (Auto Feed) Switch
4-21
Drilling Procedures
Drilling with Standard Bit (refer to fig. 4-7)
The machine MUST be level and up on all four jacks BEFORE the mast is raised. Once the drill pipe,
bit sub, and drill bit have been coupled up, drilling operations are ready to commence.
1.
Lower the drill bit until it comes in contact with the ground.
2.
Zero the drill monitor, if equipped.
3.
Turn on the drilling air by switching the Drilling Air switch (43) to the ON position. Note the air
pressure on the Drilling Air Pressure Gauge (29).
4.
Start rotating the drill string forward slowly (30-40 RPM) using Rotation Lever (6). Forward rotation is clockwise.
5.
Slowly lower the drill string using Pulldown Lever (7) until the drill bit is firmly collared in the drill
hole (about 2 - 3 ft.[0.6 - 0.9 m]). Collaring of the hole should be done slowly and carefully to ensure that the hole will be straight.
6.
Once the hole is collared, engage the Auto Feed (44) by pushing the switch down to the engage
position, then start increasing the Pulldown Pressure (9) and rotation speed until a satisfactory
rate of penetration is achieved. Pulldown pressure and rotation speed will be dictated by the type
of ground being drilled. Refer to Section 5 - Drilling Practices for more information. Adjust Rotary
Torque Control (C) as needed.
NOTE
Applying excessive weight or using too fast of rotation speed will result in damage to
the drill bit.
7.
Watch the air and rotation pressure gauges while drilling. If a rise in pressure is noted, gently push
the Hoist/Pulldown Lever (7) back towards the hoist position just enough to take weight off the bit,
then move back to original position. Repeat as necessary until drill string "sounds right" for normal
drilling.
8.
If dust suppression is required, either the dust collector or water injection systems may be used.
Switch Water Injection/Dust Collector Switch (35) Down for dust collector, Up for water injection.
Adjust water flow for water injection with Flow Control Valve (14a).
NOTE
9.
Drill down until the desired depth of the hole is reached, then disengage the Auto Feed Switch
(44) and start raising the drill string out of the hole using the Hoist/Pulldown Lever (7). As the drill
bit approaches the top of the hole, turn off the air and stop rotating the pipe. Lift the drill bit clear of
the ground, high enough to allow good clearance when moving to the next hole.
NOTE
4-22
Do not use the dust collector if ground water is encountered. Excessive water injection will reduce drill bit service life.
If depths of more than one drill pipe are required, follow the operating procedures for
multiple pass drilling.
Drilling Procedures
Drilling with a Down-the-Hole Hammer (refer to fig. 4-7)
ALWAYS check bit manufacturer's literature for proper bit size, safety, operation and
maintenance information.
It is the responsibility of the operator to be sure they understand the proper operating
procedures supplied by the bit manufacturer.
The manufacturer will not be responsible for equipment damage due to improper use or
misapplication of down-the-hole hammer equipment.
The following is a general guideline for drilling with down-the-hole hammers. Always refer to manufacturer's specifications for correct application and specific drilling procedures.
Preparation
1.
Tighten all joints to recommended torque by bit supplier.
2.
Use proper size choke in the rigid valve (according to manufacturer's specifications) before tool is
operated.
3.
Always use the largest diameter bit first, and if necessary, follow with the next smaller diameter bit.
Never use the bit to ream; this will damage the carbides.
4.
Place driver sub over bit, followed by o ring and bit retainer ring. Screw the driver sub/bit assembly into the piston case hand tight before using power make-up. Use slow rotation to tighten to the
recommended torque provided by the bit supplier.
Start Up
1.
Be sure the lubricator is working properly and oil has fully coated the drill pipe inside diameter.
2.
Turn on Drilling Air switch (43) and rotate slowly.
3.
Lower the tool slowly into the hole until the bit contacts the bottom and the piston starts operating.
Add just enough pressure to start breaking rock.
ALWAYS apply air and start rotation before putting weight on bit to avoid damage to bit.
4.
As the bit starts breaking rock, apply minimum total weight on bit (refer to manufacturer's specifications).
5.
After drilling a few feet, increase weight on bit until the tool runs smoothly. The air pressure will rise
slowly and then stabilize.
NOTE
Additional weight on bit will not increase penetration rate appreciably.
4-23
Drilling Procedures
Drilling with a Down-the-Hole Hammer (cont.)
Total Weight On Bit
It is important that the minimum weight on the bit be maintained throughout the hole depth. As the
hole gets deeper and pipe sections are added the holdback pressure control (9a) must be turned IN
(clockwise) to decrease pressure on the bit to compensate for the added weight of the drill pipe.
NOTE
When reading the pulldown pressure gauge (27), remember this is hydraulic pressure
and not weight in actual pounds (see bit manufacturer's specifications for minimum
total weight on bit).
Fig. 4-7 Drilling Controls

C. Rotary Torque Control
6. Rotation Lever
7. Hoist/Pulldown Lever
9. Pulldown System Pressure Control
9a. Holdback System Pressure Control
14a. Water Injection Flow Control
26. Rotation/Left Track Pressure Gauge
4-24
27.
28.
29.
35.
43.
44.
Pulldown Pressure Gauge

Hydraulic System Pressure Gauge
Drilling Air Pressure Gauge
Water Injection/Dust Collector Switch
Drilling Air Switch
Pulldown System (Auto Feed) Switch
Drilling Procedures
Back Pressure
When a pneumatic tool is operating near the surface, it is exhausting directly to atmosphere and is
producing the maximum horsepower for a given inlet pressure. If any positive pressure above atmospheric
pressure (back pressure) is encountered at the exhaust, the tool's efficiency will be reduced.
As the hole is drilled deeper, back pressure is constantly increasing, therefore blow energy will be
reduced.
To compensate for this reduced efficiency, it is necessary to increase air pressure at the inlet. Increase
the inlet pressure until normal drilling rate is obtained.
Rotation Speed
Proper rotation speed is important for long bit life and good penetration.
Refer to manufacturer's bit size vs. rotation speed specifications.
Recommended Rotation Speed Range:
Use slower rotation for hard abrasive formations.
Use faster rotation for softer, less abrasive formations.
The bit should penetrate about 3/8 in. (9.7 mm) per tool revolution (except for bits 10 in. (254 mm)
diameter and larger).
560 RPM
For example:
If the rate of penetration is 50 ft. (15.25 m) per hour, the RPM should be about 25. RPM is about
one-half of the penetration rate in feet per hour.
Adjust the rotation to obtain the best drilling rate and to minimize wear on the bit.
Water or Foam Injection

During drilling operations, water or foam injection can be beneficial in some applications.
Reduces dust damage to drilling equipment on the surface.
Reduces dust inhalation of the drilling personnel.
Reduces temperature of the compressed air, preventing close fitting parts from seizing or galling.
Helps clean the drilled hole when the formation is producing small amounts water.
The following are helpful hints when using water or foam injection:
1.
Increase the oil injection rate when water or foam is being used.
2.
Test water periodically to assure the proper pH factor. Water with a pH of less than 10 will cause
corrosion on steel parts.
3.
Insure that water being used is free from solids contamination.
4.
Upon completion of each hole or any time tool is not being used for three or more hours, clean the
tool and the drill pipe by blowing lubricated air through the system.
5.
Water or foam injection will cause the tool to corrode if the tool is not properly maintained. Follow
bit manufacturer's maintenance procedures to assure long bit life.
4-25
Drilling Procedures
Drilling with a Down-the-Hole Hammer (cont.)
Suggested Operating Procedures
1.
Maintain good pulldown pressure on the tool and insure that the hole is being cleaned.
2.
Small amounts of water may form mud and partially block the hole. Inject about 1-4 GPM (3.8 - 15
l/min) of water into the air stream during drilling (see manufacturer's specifications for tool size vs.
water injection rate).
If the tool starts drilling extremely fast, the pulldown system may not be capable of
maintaining the recommended weight required on the bit. The piston will strike the bit
when it is not against the rock face, causing severe damage to the bit. Every effort must
be made to avoid this condition.
3.
If there is a drop off in the size and volume of cuttings or an air pressure build-up while the tool is
operating at a normal rate, raise the tool without turning off the rotation. Work the tool up and down
to assure that the tool and pipe are free and the hole is clean before continuing to drill.
4.
Cracks in the formation may cause the tool to bind in the hole. Raise the tool, clear the hole with
air and work the tool up and down to assure the tool and pipe are free, before continuing to drill.
Rotate slowly and feed the tool down the hole slowly to resume drilling.
5.
If the top of the hole craters and cuttings and debris fall into the hole, install a short length of casing
into the hole. Allow the casing to extend about 6 in. (152.4 mm) above the surface and pack rags,
clay or dirt around the outside of the casing.
6.
When rotation stops, the tool will continue hammering until it is raised up off the bottom. If the tool
is not raised up off the bottom, the bit carbides will become buried in the formation. Severe damage
to the bit can occur if rotation is resumed without first raising the tool up off the rock surface.
7.
Very rough rotation can be caused by a dull bit or in certain rock formations.
8.
If tool fails to function properly, refer to manufacturer's service and troubleshooting information.
4-26
Multiple Pass Drilling

Adding Drill Pipe (refer to fig. 4-7)
1.
Drill down until the rotary head stops at the bottom of the mast.
2.
Disengage the pulldown system by switching Auto Feed Switch OFF. Stop rotation with Rotation
Lever (6).
3.
Lift the drill string and align the flats on the drill pipe with the deck wrench. Turn Dust Suppression
Switch OFF, engage Deck Wrench with switch onto pipe, and turn Drilling Air Switch OFF.
4.
Using reverse rotation, break the thread joint and undo the threads slowly, simultaneously raising
the rotary head clear of the bottom threads.
DO NOT allow drill pipe to drop in deep holes, pipe thread damage and bit damage will
occur.
5.
Apply thread grease to the drill pipe threads by pressing Drill Stem Thread Lube Switch.
6.
Raise the rotary head to the top of the mast with Hoist/Pulldown Lever (7).
7.
Swing the drill pipe loader into position using the Pipe Loader Swing Switch. A drill pipe should
now be located under the rotary head. If not, you will need to rotate the loader to align the next
pipe.
To Rotate Drill Pipe Loader
a.
Unlock the pipe loader by switching the Drill Pipe Loader Lock Switch to UNLOCK.
b. Index the pipe loader to the next position by using the Pipe Loader Rotate Switch. Once in
position, lock the loader by switching the Drill Pipe Loader Lock Switch to LOCK.
8.
Lower the rotary head slowly onto the drill pipe, once the head engages the drill pipe thread, stop
lowering the head. Slowly engage forward rotation, keep rotating until the thread joint becomes
tight, which is indicated by an increase in rotation pressure as seen on the Rotation Pressure
Gauge (26).
ALWAYS tighten the drill pipe joints in the pipe loader.
9.
Lift the drill pipe clear of the holder on the pipe loader and swing the loader out to the drilling position using the Drill Pipe Loader Swing Switch.
10.
Lower the drill pipe until it engages with the pipe in the deck wrench. Slowly rotate the drill pipe in
the forward direction until the joint becomes tight, which is indicated by an increase in rotation pressure as seen on the Rotation Pressure Gauge.
11.
Retract the deck wrench, using the Deck Wrench switch. You are now ready to resume drilling.
4-27
Multiple Pass Drilling

Retracting Drill Pipe (refer to fig. 4-7)
1.
Once the desired hole depth is reached, turn the Auto Feed switch OFF and raise the rotary head
with the Hoist/Pulldown lever (7) until the drill pipe thread joint is above the deck wrench.
2.
Turn the Water Injection/Dust Collector Switch and Drilling Air switch OFF.
3.
Align the flats on the lower drill pipe with the deck wrench, the flats should be approximately 2
inches above the deck wrench. Engage the deck wrench on the flats of the drill pipe using Deck
Wrench switch.
4.
Slowly place the Rotation lever (6) into reverse and allow the rotation pressure to increase until
the drill pipe joint breaks loose.
If the upper thread joint becomes loose before the lower joint, retighten the upper joint
and use the breakout wrench to loosen the lower joint.
DO NOT allow the upper drill pipe joint to unscrew unless positioned in the drill pipe
loader.
5.
Once the pipe joint is broken loose, continue reverse rotation and simultaneously raise the rotary
head with the Hoist/Pulldown lever (7) until the threads are disengaged. Stop rotation.
6.
Raise the drill pipe until the bottom of the drill pipe will clear the drill pipe holder when the loader is
swung into the center of the mast.
7.
Align the flats on the drill pipe to the same position that would be required to engage the deck
wrench.
8.
Swing the pipe loader into the center of the mast with the Drill Pipe Loader Swing switch, ensuring that the drill pipe goes into the pipe loader easily. Do not force the drill pipe into the pipe loader.
9.
Once the loader is in position, lower the drill pipe into the holder, stop the pipe approximately 2 in.
(50.8 mm) from the bottom of the holder.
10.
Slowly place the Rotation lever (6) in reverse, allowing the rotation pressure to increase until the
top joint breaks, which can be identified by a decrease in rotation pressure. Once the joint breaks,
continue reverse rotation until the drill pipe drops into the holder.
NEVER use excessive force when breaking joints. Make sure loader locking pin is locked
before attempting to break joints. Make sure drill pipe is properly secured in loader.
11.
Once the rotary head is disengaged from the drill pipe, raise the rotary head at least 8 in. so it will
clear the top of the drill pipe.
12.
Swing pipe loader to the drilling position. Use Drill Pipe Loader Rotate switch to rotate carousel
to the next position if required.
13.
Lower rotary head to the drill pipe in the deck wrench using the Hoist/Pulldown lever (7). Use
the Fast Down switch to increase the lowering speed of the rotary head. Use forward rotation to
engage and tighten to full rotation pressure to ensure joint will remain tight.
14.
Repeat items 3-13 until all pipes have been removed.
4-28
Section 5
Drilling Practices
Drilling Practices
5-1
Drilling Terminology
A.P.I. Thread
American Petroleum Industry Standard type thread. Pulldown
The amount of weight that is being applied to the
bit.
Beco Thread
A heavy duty thread type used on Blast Hole drill
Stabilizers
pipe.
Stabilizers are used to reduce possible hole deflection.
Bit Basket
Used to hold the drill bit when adding or removing
Substitutes (Subs)
the bit.
Subs or adapters are used where different thread
sizes or types are required to be joined together.
Blade Bit
A drill bit with three or four fixed cutting edges.
T.C.I.
Bootleg
Tungsten Carbide Inserts, used on Tri-Cone roller
The portion of the borehole remaining after the blast.
bits.
Carousel
The carousel or drill pipe loader is used to hold
spare drill pipe in the mast for deeper drilling
requirements.
Compressed Air
Used to blow drilled cuttings from the hole and to
cool the bit bearings.
Down-The-Hole Hammer
A pneumatically operated bottom-hole percussion
drill that is rotated mechanically by the drill rig.
Thread Grease
Thread Grease is used to lubricate the threads on
the pipe.
Tri-Cone Roller Bit
A drill bit with three rolling cones, inserted with
tungsten carbide buttons or milled teeth.
U.H.V.
Up Hole Velocity, is the speed at which the drill cuttings are being blown out of the hole,
this speed is usually referred to in feet per minute.
Drill Bit
Water Injection
Drill bits are used to break the rock by a chipping or Used to help with dust suppression and aid hole
cutting action
cleaning.
Drill Pipe
Drill pipe is used as a modem to rotate the drill bit,
transfer force to the drill bit and to pass air or water
to the bit to aid in hole cleaning.
Dust Collector
Used to control dust exiting the drill hole.
Nozzles
Orifices in the bit used to control air flow and pressure.
Penetration Rate
The speed at which the drill bit is cutting.
5-2
Drilling Practices
Bit Weight & Rotary Speeds

Many variations in formation characteristics can affect the weight on bit and rotary speed requirements.
Your own field experience is the best guideline for determining the appropriate weight on bit and rotation
speed combination for your particular drilling operation. However, bit force and rotation speeds must be
kept within the safe and economic limits of the drill rig and drill string.
When calculating the pulldown force on the drill bit, you must include the weights of the rotary head
and drill string into your calculation, because when more drill pipes are added, the weight on the bit will
increase and in some cases it may be necessary to reduce the hydraulic pulldown force being supplied to
avoid blocking or damaging the drill bit.
Drill bit manufacturers suggest that a pulldown force of 3500-7000 pounds per inch of drill bit diameter
can be exerted to the drill bit in the right drilling conditions, however this is only a guideline and ground
conditions will dictate how much weight can be applied.
PULLDOWN FORCE CALCULATION
Bit Diameter = 7- 7/8"
7.875 x 3500 = 27,562.5 Pounds Force
7.875 x 7000 = 55,125 Pounds Force
The rotary blasthole drills utilize hydraulic pressure to exert pulldown force on the drill bit; this pressure is indicated on the pulldown system pressure gauge. However, the pressure readings on this gauge
indicate hydraulic pressure only and must be converted into actual Weight on Bit (pounds force) per square
inch of drill bit diameter.
Check with your bit supplier for optimum drilling efficiency operation.
Laboratory experiments have shown that uniform rock formations, when drilled with rotary drill bits
react as follows:
1. Penetration rate is at least directly proportional to the weight on bit.
2. Penetration rate is directly proportional to the rotary speed.
In principal, the faster that we could rotate and the more weight we put on the drill bit, the higher the
rate of penetration. Although in actual drilling practices it is important to note that the many variations in
formation characteristics, drill bit condition and chip removal affect the rate of penetration, therefore statements 1 and 2 must only serve as a guideline.
In soft, easily drilled formations, the use of high pulldown pressures are restricted due to the drill bit's
tendency to "Ball Up" thereby reducing its efficiency. However, it is usually possible to offset the reduction
in pulldown force by increasing the rotary speed. The danger of bit damage is reduced in low strength
formations.
The extent to which you can increase the rotary speed is limited by the presence of abrasive properties and the ability to clear the cuttings immediately from the bit face, which would prematurely erode the
cutting structure or bit bearings under excessive rotary speeds.
Drilling Practices
5-3
Bit Weight & Rotary Speeds

(cont.)
In hard formations, it is necessary to use higher pulldown pressures to overcome the compressive
strength of the rock formation. The operation of tri-cone roller bits in hard rock is complicated by the sliding
and skipping of the bit cutters as the rock breaks away unevenly. Failure to get complete clearing of the
drill cuttings becomes a larger problem when high rotation speeds are used.
The use of excessive rotation speeds can cause increased abrasive wear and create shock loads too
great for the drill bit, pipe and drill rig. Therefore, there may be little advantage in increasing rotary speeds
above recommended levels. Smooth vibration free drilling produces holes most efficiently and possible
gains from high rotation speeds may need to be sacrificed to get a constant rate of penetration and economical bit life.
5-4
Drilling Practices
Rotary Drill Bits

The two main bit types available for rotary blast hole drilling are:
1.
Drag or Blade Bits
2.
Tri-Cone Roller Bits
Rotary drill bits operate using a combination of two forces:

1.
Thrust "Weight on Bit"
2.
Torque "Rotation"
Drill bits must make chips or cuttings and combined with air pressure and volume contribute to the
clearing of the drilled cuttings.
Drag Bits
Drag bits are used in soft formations like clay, shale, and soft overburden materials. These bits make
maximum use of rotary torque for chip making.
Drag bits generally have 3 or 4 cutting wings which are tipped with tungsten carbide inserts to resist
heat during drilling.
Advantages of Drag Bits
1.
Relatively low in cost compared to tri-cone roller bits.
2.
High penetration rates in soft formations.
3.
Good penetration of difficult formations such as clay.
Disadvantages of Drag Bits

1.
Shorter service life than tri-cone bits.
2.
Not good for drilling hard formations.
3.
Unstabilized drag bits are prone to drill crooked holes.
Drilling Practices
5-5
Rotary Drill Bits

Tri-Cone Roller Bits
Tri-Cone roller bits are made for four general types of drilling conditions, these are soft, medium, hard
and very hard ground formations.
Roller bits consist of a bit body with three cones equipped with steel teeth or tungsten carbide buttons.
The teeth or buttons are distributed over the three roller cones in such a manner that the entire bottom of
the hole is worked when the bit is rotated.
General characteristics for soft formation bits are that the bits have larger, more widely spaced teeth
or buttons and differing cone centering geometry, while hard formation bits have smaller tungsten carbide
inserts for cutting teeth which are closely spaced to reduce torque and the size of the chips in hard material.
The cones of the drill bit are mounted on bearings which are designed to withstand the thrust and
rotation forces exerted on the bit. The gauge or size for the bit is protected by hard facing or tungsten
compacts on the outer surface of the cones and the shirt tails of the bit body.
Tri-cone bits are fitted with air tubes and nozzles which allow air to pass through the bit. The air tubes
are designed to allow air to pass through the bit. The air tubes are designed to allow air to flow through to
the bit bearings, the air then aids in cooling and cleaning the bearings.
The bit nozzles allow the main volume of air to flow through the bit for cleaning the cuttings from the hole.
These nozzles are designed so that different sized orifices can be installed for different drilling conditions.
To make sure air gets down to the bearing air tubes, ensure a certain amount of working air pressure
at the bit face. Change this pressure by changing the size of the nozzles, which might be needed if the
drilling conditions get softer. The orifice size would probably need to be increased to allow more air to pass
through the bit for better hole cleaning.
Advantages of Tungsten Carbide, Tri-Cone Roller Bits
1.
Four to Ten times more footage per bit than conventional hard formation steel tooth bits.
2.
The penetration rate will usually equal or exceed that of conventional hard formation bits.
3.
Higher feed pressures can be used in hard formations.
4.
Bits can be used in both soft and hard formations.
Disadvantages of Tungsten Carbide, Tri-Cone Roller Bits

1.
More expensive than conventional bits.
2.
Generally not good for drilling clay formations.
5-6
Drilling Practices
Rotary Drill Bits

Tri-Cone Roller Bits (cont.)
Tungsten carbide bits may cost more than steel tooth bits and economics must be considered when
choosing the correct bits for each application and should enter into your decision when to use them.
All tungsten carbide bit designs incorporated the use of compacts in the gauge surface or the cones,
and varying combinations of compacts and hard facing on the gauge surface of the bit leg to provide increased resistance to abrasive wear.
When the formation is relatively uniform, these bits characteristically drill at a constant penetration
rate throughout their life.
Sufficient weight must be applied to the bit to produce an effective chipping-crushing action of the formation. However, you should be aware that weights in excess of "sufficient" are not necessarily economical,
as they may result in breakage of the compacts as well as reducing the life of the bearings.
Normally the weights used on tri-cone roller bits range from 3,500 to 7,000 pounds per inch of bit
diameter with rotary speeds varying up to 200 revolutions per minute.
Drilling Practices
5-7
Rotary Blast Hole Drill Strings

Drill Pipe
Drill pipe is used as a modem to transfer rotation to the drill bit and to convey air to clean the cuttings
from the hole.
Blast hole drill pipe is selected to suit the diameter of the hole being drilled, the pulldown and hoisting
capacity of the machine, and up-hole velocity requirements to clean the hole.
Standard drill pipe is designed to be run in tension. Drill pipe run in tension is held relatively straight,
bending and wear are therefore kept to a minimum. However, Blast Hole rigs apply pressure to the bit
through the pull-down system on the machine.
Since blast hole pipe is run in compression it must be made from heavy wall tubing to resist forces
which not only may be high, but are also changing rapidly. The pipe must continue to do this in spite of
abrasive wear and continual bending stresses. Drilling operations often place great stresses on the drill
string, therefore the drill pipe must be manufactured to the highest degree to achieve the ultimate service life.
Periodic inspections should be made of the condition of your drill pipe and should include the following items:
1.
Outside diameter measurement of pipe.
2.
Check welded joints for cracks or excess wear.
3.
Check threads for excessive wear or galling.
4.
Check pipe for bends or eccentric joints.
Fabricated Drill Pipe

Blast hole drill pipe design features tool joints made from steels selected specifically for the application
and heat treated to obtain optimum strength and toughness.
The tool joints are designed with long tangs that are internally tapered, which enables them to be
forced or shrink fitted to the tubing and then welded. Wrench slots or flats are milled to suit the break-out
requirements of the drill.
5-8
Drilling Practices

Pipe Threads
There are many different types of threads available for drill pipe connections most of which are not
acceptable for blast hole drilling because of their vulnerability to damage from excessive forces to the drill
string in blast hole drilling.
The two most commonly used threads are:
1.
A.P.I. Regular (American Petroleum Industry Standard)
2.
BECO style thread
With the increase in demand for efficient, economical blast hole drilling, it was observed that several
factors caused greater thread wear on blast hole drills.
1.
The drilling of multiple pass holes demands frequent pipe changes. This increased frequency
greatly contributes to thread wear.
2.
The coupling of the rotary head to a drill pipe in the pipe loader often occurs at an elevation high in
the mast, affording very poor visibility to the operator. This operation is often done by feel and cross
threading is not an uncommon result.
3.
Thread loading during joint make-up should be instrument controlled. The rotary head used on
blast hole drills can generate very high torque and the skills of the operator usually determines the
actual magnitude of the axial forces used. A careless operator can destroy the threads if care is not
exercised.
4.
All drill pipe that operates in compression has the tendency to bend and rub on the walls of the
hole. These bending forces also act on the threads which increases the possibility of cracks,
breaks and tool joint failures.
A.P.I. Regular Threads

Field experiences have shown that the normal A.P.I. Regular threads have displayed less than satisfactory life under the above conditions. The majority of drill bits are provided with A.P.I. Regular pins, but since
bit changes are less frequent than pipe changes, thread wear is less, making the A.P.I. Regular threads
acceptable for bit connections.
BECO Threads
The primary feature of the BECO thread series is that 2 threads per inch pitch is utilized. This coarser
thread survives much better under adverse conditions. The coarse threads are stronger, less susceptible
to damage, more tolerant of wear and easier to loosen from a tight condition. Since the incorporation of
the BECO thread system in the early 1960's, the thread has become an unofficial world wide standard for
drill pipe used in rotary blast hole drilling operations.
Drilling Practices
5-9
1
API Box Thread
API Thread
BECO Thread
3
Sub Length Measured
Shoulder to Shoulder
4
5
Pipe Length Measured

Bit Sub Length Measured

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Rotary Head
Spindle
Shock Sub
Crossover Sub
Top Sub
Drill Pipe (Rod)
Bit Sub
Bit Basket
Deck Bushing
Tri-Cone Drill Bit
10
Basic DrillBasic Design Features and Make-up
5-10
Drilling Practices

Thread Grease
Precision machined threads and shoulders must be protected from damage. Threads are subjected
to a lot of abuse, therefore it is imperative that they are inspected and greased regularly. Prior to each use,
clean and visually inspect each pin and box for thread and shoulder damage. Check carefully for galls,
burrs, scratches and particularly for cracks. Clean or repair if necessary. Use a zinc, lead or copper based
lubricant that is recommended for rotary connections and apply thoroughly to all thread and shoulder surfaces. Ensure grease is clean and free of dust and debris.
Substitutes
Substitutes (subs) or adapters are used where threads of one size or type must be coupled with threads
of another size or type. They are also used at points of heat wear to provide readily replaceable threads.
Changes in drill pipe diameter must occur gradually. Subs should be gently tapered.
Drill Bit Stabilizers

Drill bit stabilizers are used to reduce possible hole deflection and to ensure that the drill bit runs concentrically (evenly in the center of the hole) about its axis and thereby optimizes bit life and penetration rates.
There are two main types of stabilizers available, blade and roller. Blade stabilizers have fixed wings
that have been either hard faced or mounted with tungsten carbide inserts. Roller stabilizers are mounted
with replaceable rollers which are built up with a special tungsten carbide weld and held in place by long
lasting non grease bearings.
Advantages of Blade Type Stabilizers
1.
Generally cheaper.
2.
May use replaceable wear bars for rapid rebuilding.
3.
Can use replaceable sleeves.
Disadvantages of Blade Type Stabilizers

1.
Require rebuilding for each new drill bit.
2.
Have relatively high torque requirements.
3.
In hard ground they may provide little stabilization after the first couple of holes.
Advantages of Roller Type Stabilizers

1.
Lower torque requirements than blades.
2.
Better stabilization.
3.
Generally give more economical life.
4.
Throw away or replaceable rollers.
Disadvantages of Roller Type Stabilizers

1.
High purchase cost.
2.
Expensive replacement of parts
Drilling Practices
5-11
Compressed Air
Compressed air is the most common method used with blast hole drills for clearing chips from the
hole. The advantages of drilling blast holes with compressed air are fast chip removal, and that holes are
normally left dry.
In some circumstances a controlled amount of water or foam can be injected into the air stream to aid
chip removal, enhance hole stability and control dust problems.
Chips not cleared immediately will be broken into smaller pieces. Secondary breaking wastes energy
and increases bit wear.
Air Requirements
In rotary blast hole drilling we must always be concerned with delivery of air in sufficient volume and
at the proper pressure to assure optimum bit life when drilling with recommended bit weight and RPM.
Sufficient air volume should be provided to produce an up-hole velocity of 4,000 to 6,000 feet per minute
( 1220 to 1830 meters per minute).
Up-Hole Velocity Calculations

Cubic Feet Per Minute:
Velocity =
Free Air CFM x 183.4

(D - d2) .7854 in inches
2
D = Bit Diameter
5-12
d = Drill Pipe Diameter
Drilling Practices
Drilling Related Problems

The majority of drilling problems originate from errors in judgement or simply from making a bad decision. Drilling problems generally offer several courses or action to overcome the drilling problem, therefore
we must make a decision to try another method of operation to rectify the problem. Drilling decisions often
avert or accelerate the complex drilling difficulties which we refer to as drilling problems.
EXAMPLE:
a.
A decision may be made a long time before the problem is evident, like deciding to use inadequate
up hole air velocity. This may lead to slow, inefficient drilling or stuck drill strings.
b.
Or the decision can bring immediate problems, like a decision to increase the pulldown pressure
may result in premature failure of the drill bit.
During drilling operations every action taken may have consequences. Operators must recognize that
their job involves a continuous sequence of making decisions and the quality of these decisions determines
the quality of the operator's performance.
Drilling consists of a continuing sequence of:
1.
Being aware
2.
Interpreting indicators or messages
3.
Making decisions
4.
Monitoring results
Many drilling problems are revealed to the operator by an indicator. This indicator can take almost any
form (e.g.: a reduction in the volume of drill cuttings being cleared from the hole). This may not be a problem
in itself, but it could be an indicator of a problem developing down the hole, therefore if the operator knows
the indicators, they are then made aware of the pending problem.
Human Error Problems

These problems have a direct and usually short term connection with a decision (e.g.: The operator
decides to try and drill one more hole with a badly worn bit before changing the bit).
Operational Related Problems

These problems are connected with the failure of the drilling equipment (e.g.: Engine fails while drill
string is in the hole, possibly leading to the drill string becoming stuck while engine is repaired).
Formation Related Problems

Some formations present problems that are not readily solved using the available drilling equipment
or skills (e.g.: Swelling ground formations due to high levels of ground water). These situations should be
viewed as a challenge rather than a problem.
Drilling Practices
5-13
Operating Problems and Indicators

1.
Drill Bit Penetration Slows or Stops

This is a statement of an indicator rather than a problem. The solution depends on the correct diagnosis of the problem, which could be:
2.
a.
Formation Change
b.
Drill Bit Blocked Up
c.
Incorrect Bit Type
d.
Dull Drill Bit
e.
Incorrect Pulldown Pressure or Rotary Speed
f.
Inadequate Hole Cleaning
High Drill String Torque

Excessive drill string torque is also an indicator of a pending problem, some of which might be:
3.
a.
Excessive Pulldown Pressure
b.
c.
Crooked Hole
d.
Damaged or Badly Worn Drill Bit
Drill String Vibration

This itself often seems like a problem, but the true problem usually lies in the reason for the vibration, some of which are:
4.
5-14
a.
Incorrect Rotary Speed
b.
Bent Drill Pipe
c.
Eccentric Drill Pipe Joints
d.
Incorrect Drill Pipe to Hole Size
e.
Crooked Hole
f.
Worn Deck Bushing or Stabilizer
Stuck Drill Pipe

a.
b.
Crooked Hole
c.
Faulty Formations
Drilling Practices
Solving Drilling Problems

1.
Recognize the problem. The operator must be aware of the small problems before they develop
into bigger ones.
2.
Analyze the problem. Determine exactly what the problem is, what caused it and what is involved
to rectify the problem.
3.
Compare the current problem with others previously encountered to assist in finding the most likely
solution. Decide on a solution.
Experienced operators make decisions almost automatically, they are immediately aware of the significance of an indicator. They react spontaneously because their experience tells them the appropriate
action to take. By correctly selecting the desirable action in each situation, an operator will:
1. Maximize the quality of the products of drilling
2. Maximize drilling production
Drilling Practices
5-15
Notes
5-16
Drilling Practices
Section 6
Machine Transport
Machine Transport
6-1
Machine SpecificationsShipping
MD6290 Basic Shipping Weights and Dimensions
Quantity
Description of Goods
Approximate Dimensions
Truck one (1)
MD6290 Rotary Blasthole drill c/w 1 each Owner/Operator manual

and warranty packet stowed within cab
10.82 m (35 ft 5 in) L x

4.06 m (13 ft 3 in) W x
3.96 m (13 ft) H
41,050 kg (90,500 lb)
Truck two (2)
Mast assembly for MD6290 Rotary Blasthole drill

(mast for 35 ft pipe)
14.81 m (48 ft 7 in) L x

1.91 m (6 ft 3 in) W x
1.91 m (6 ft 3 in) H
14,514.96 kg (32,000 lb)
Truck two (1)
Cab half for MD6290 Rotary Blasthole drill c/w 1 ea. Ship out filter kit,
2 ea. tubes superflex, 2 ea. brackets, 1 ea. bag of nuts & bolts, 2 ea. mast
bushings, 1 ea. horseshoe bushing, 1 ea. bit basket & 1 ea. lifting bale
2.286 m (7 ft 5 in) L x
0.81 m (2 ft 8 in) W x
2.51 m (8 ft 3 in) H
635 kg (1,400 lb)
Truck two (2)
Walkway for MD6290 Rotary Blasthole drill c/w toolbox stowed within
2.74 m (9 ft) L x
0.86 m (2 ft 9 in) W x
1.30 m (4 ft 3 in) H
589.7 kg (1,300 lb)
Note: final dimensions and GVW and corresponding load-out vary based on options selected and final configuration.
MD6240 Basic Shipping Weights and Dimensions

Truck one (1)
(12 m), Rotary Blasthole drill c/w Owner/Operators manual stowed in cab
Truck two (2)
Mast assembly for (12 m), Rotary Blasthole drill
Truck three (3)
Cab half assembly for (12 m), Rotary Blasthole drill c/w 1ea. #89044 lter kit,
2 ea. Superex, 2 ea. brackets, 2 ea. mast bushings, 2 ea. dust chute c/w curtain,
2 ea. clamps, 1 ea. horseshoe bushing, 1 ea. bit basket, 1 ea. lifting bale, 2 ea. portable
re suppression w/brackets, 3 ea. bag of nuts, bolts, 6 ea. handrails, 1 ea. table bushing
and cab supports
2 each walkways bundled together with 2 each ladders, toolbox, c/w with accessories
stowed within, bit sub, dust chute hose and 2 each chutes for hose for (12 m)
Truck three (3)
Truck three (3)
Mast support rack (mounted off front end) for (12 m)
Truck three (3)
1 each walkway
10.82 m (35 ft 6 in) L x

4.0 m (13 ft 2 in) W x
3.9 m (12 ft 7 in) H
44,678.5 kg (98,500 lb)
17.7 m (58 ft) L x
1.9 m (6 ft 4 in) W x
1.8 m (6 ft 2 in) H
16,329.3 kg (36,000 lb)
2.29 m (7 ft 6 in) L x
0.81 m (32 in) W x
2.51 m (8 ft 2 in) H
635 kg (1,400 lb)
5.1 m (16 ft 7 in) L x
0.9 m (3 ft 2 in) W x
1.5 m (5 ft) H
2,948.3 kg (6,500 lb)
2.9 m (9 ft 6 in) L x
2.2 m (7 ft 2 in) W x
0.4 m (15 in) H
548.8 kg (1,210 lb)
2.87 m (9 ft 4 in) L x
0.61 m (2 ft) W x
1.20 m (4 ft 3 in) H
544.81 kg (1,200 lb)
Note: Final dimensions and GVW and corresponding load-out vary based on options selected and final configuration.
6-2
Machine Transport
Transporting Machine
Mast Removal and Installation
Generally, when transporting the machine, it will be necessary to remove the mast and ship it on a
separate truck, due to weight and height restrictions. Follow the steps outlined below for removal and installation of the mast.
BE SURE machine is on level and solid ground before performing any service procedures.
BE SURE hydraulic and pneumatic systems are not pressurized before removing any fittings or connections.
Mast Removal:
1.
Remove drill pipe from mast (refer to "loading and unloading drill pipe" in Section 3) and swing
carousel all the way in.
2.
Lower mast to horizontal position, so that mast is resting on mast support.
3.
Shut down the machine and be sure pressure has been relieved before removing any connections
or fittings. Tag and remove all hydraulic, pneumatic and grease lines to the mast. Use numbered or
lettered caps and plugs to aid in reassembly. Disconnect electrical plug from mast valve bank.
NOTE
If using one crane for lifting the mast, the lifting slings should be positioned at about a
45o angle from the mast.
4.
Attach four steel cable lifting slings to the mast at the lifting points. Two are located at the mast
crown and two are located at the mast base. Use a crane capable of supporting the weight of the
mast and able to lift the mast high enough to clear the height of the machine (refer to machine
specifications). Attach two guide ropes to mast to control swinging of mast.
5.
Remove the two capscrews that secure the mast pivot lug cap and remove cap from each side of
mast (fig. 6-1).
6.
Support the mast cylinders to prevent movement after the cylinder pins are removed. Raise the
mast slightly to take weight off the mast cylinder pins and remove the cotter pins and cylinder pins
from mast.
Keep all personnel clear of mast when lifting. Do not allow anyone under mast when lifting.
7.
Lift mast clear of machine and tram machine out from under mast. Position trailer under mast and
lower mast onto trailer and secure for transport (refer to loading and unloading procedures).
8.
Using a suitable lifting device lean the mast cylinders forward and secure to the "A" Frame if the
machine is being transported.
Machine Transport
6-3
Fig. 6-1 Mast Assembly (lower end)

1. Pivot Lug (2)
2. Capscrew (4), Torque per Note below
Mast Installation
Keep all personnel clear of mast when lifting. Do not allow anyone under mast
when lifting.
NOTE
1.
Attach four steel cable lifting slings to the mast at the lifting points. Two are located at the mast
crown and two are located at the mast base . Use a crane capable of supporting the weight of the
mast and able to lift the mast high enough to clear the height of the machine (refer to machine
specifications on previous pages). Attach two guide ropes to mast to control swinging of mast.
2.
Be sure area of mast installation is level and ground is solid. Apply a coat of grease to the mast
pivot bushings. Position machine under mast and carefully lower mast, aligning the mast pivot lugs
with the pivot bushings on the "A" Frame. Mast should be resting on the pivot bushings and the
mast rest at the front of the machine.
3.
Position the mast lift cylinders to line up with the holes in the mast. The mast may have to be lifted
slightly to align the holes. Install pins, washers and cotter pins.
4.
Install the pivot lug caps with capscrews and washers and torque per note below.
5.
Connect all hoses, by matching the numbered or lettered caps and plugs. Be sure all grease lines
are installed (if used). Connect electrical connection to mast valve bank. Be sure all connections
are tight. Start machine and check for any leaks.
Mast Pivot Bolt Torque

NOTE
6-4
MD6290
Dry = 1820 Ft. Lbs. (2468 Nm)

Lube = 1360 Ft. Lbs. (1844 Nm)
MD6240
Dry = 3160 Ft. Lbs. (4284 Nm)

Lube = 2360 Ft. Lbs. (3200 Nm)
Machine Transport
Loading and Unloading of Machine
Fig. 6-2 Machine ready for transport

1. Tiedown points (4 per side)
Loading Machine
This machine is to be operated only by trained personnel, or a copy of the Operator
Manual must be provided to personnel involved with loading and unloading of machine. Operator must read and understand the safety, start-up, shutdown and operation
sections of the manual.
1.
Raise dust curtains and secure with rope to prevent interference with trailer wheels (fig. 6-3).
2.
Place any loose items into tool box, such as brass bushings from mast pivot, bit sub, etc.
3.
Place mast raise cylinders against mast "A" frame and secure with rope to keep them from moving.
4.
Remove walkway from cab. Support walkway with forklift or overhead lifting device and remove the
four bolts that secure walkway to frame. Load walkway onto trailer with mast. Install the four bolts
back on the frame, so they do not get lost.
5.
Cross tape all windows with duct tape.
6.
Be sure jacks are raised all the way up and secure jack pads with chain and nut (provided on each
pad). Tram machine onto trailer in reverse for greater visibility.
7.
If lifting machine onto trailer or ship, use the lifting lugs welded to the jack housings. If unit is not
equipped with lifting lugs, contact the manufacturer for lifting information for your machine.
8.
Tape exhaust(s) closed, clip all chains on handrail openings, check to see that all doors are closed
tight and ignition is turned off. If unit is equipped with a battery disconnect switch, this should be turned
off.
9.
Machine should be secured to trailer at four places on each side (fig. 6-2). Secure frame to trailer at
front and rear and secure track to trailer at front and rear.
Machine Transport
6-5
Fig. 6-3 Dust Curtain - tied up
Unloading Machine
This machine is to be operated only by trained personnel, or a copy of the Operator
Manual must be provided to personnel involved with loading and unloading of machine.
Operator must read and understand the safety, start-up, shutdown and operation sections of the manual.
1.
Inspect machine for damage before unloading.
2.
Remove tape from exhaust(s) and switch battery disconnect switch on (if so equipped).
3.
With all tie-downs removed, propel machine off trailer and position on solid level ground.
4.
Install cab walkway and mast (refer to mast installation on previous page).
5.
Complete checklist on "Commissioning a New Machine" in Section 4 of this manual or complete

the "Pre-Start" checklist also in Section 4 of this manual.
6-6
Machine Transport
Loading and Unloading of Mast
Fig. 6-4 Mast ready for transport

1. Tiedown points - mast crown lifting lug, middle and mast base lifting lug
Loading Mast
Keep all personnel clear of mast when lifting. Do not allow anyone under mast
when lifting.
NOTE
1.
Attach four (4) steel cable lifting slings to the mast at the lifting points. Two are located at the mast
crown and two are located at the mast base. Use a crane capable of supporting the weight of the mast
and able to lift the mast high enough to clear the height of the machine (refer to machine specifications on previous pages). Attach two guide ropes to mast to control swinging of mast.
2.
Load mast on trailer with mast crown (top) at rear of trailer. Secure mast to trailer using the lifting lugs
(two at mast crown and two at mast base) as tiedown points. Secure mast to trailer at midpoint also.
Unloading Mast
1.
For unloading of mast, refer to "Mast Installation" on page 4 of this section.
Fig. 6-5 Mast Tie Down Detail
Machine Transport
6-7
Notes
6-8
Machine Transport
Section 7
Options and Accessories
7-1

Description
For machines operating in arctic type conditions an optional cold weather package can be installed to
pre-heat fluids and lubricants. With the cold weather option, the machine can operate down to temperatures
of -40oF (-40oC).
The cold weather option includes the appropriate lubricants (listed in this section) in the compressor,
engine, hydraulic system and gearboxes.
An optional diesel fired heater/pump unit, using fuel from the machine's diesel tank, circulates a water/anti-freeze mixture through heat exchanger tubes located in the hydraulic tank, fuel tank, water tank,
radiator and engine block ( see fig. 7-5).
The heating system can also be powered by a generator (GenSet) mounted on the machine, or an external power source, to provide 120 or 240 VAC to the system to thermostatically control heating elements
and silicone heating pads (see fig. 7-6). A heater/controller (fig. 7-2) supplies power to a distribution breaker
box and pumps heated water/anti-freeze through the engine block.
The heating elements for this type of system are installed in the hydraulic tank, fuel tank and engine while
the heating pads are installed in the compressor control box, receiver tank, auto lube grease container and
under the batteries in the battery tray.
Additional measures included for extreme cold protection are:
Thermo-glass cab windows
Additional heater in cab
Spray-on insulating material under the cab, water and fuel tanks
Cold weather wiring for AC/DC systems including low temperature conduit
Ether injection for engine starting, if desired (cat engines only)
There are no additional fluid additives required for cold weather operation.
NOTE
When cold weather operation is specified, the options discussed above may be used
separately or in combination to suit a specific operating environment.
Heater/Pump Unit
The heater/pump unit heats and circulates water
and anti-freeze through the engine, radiator, hydraulic tank and fuel tank. Fig. 7-1 shows a typical installation. A 24VDC motor operates the water pump.
Diesel fuel is used to fuel the heating system.
Fig. 7-1 Heater/Pump Installation

1. Heater/Pump Unit
2. Manifold
7-2

Relieve pressure on hydraulic and pneumatic systems before loosening connections or
parts.
Operation
The pre-heat system is energized prior to starting the machine in temperatures less than 32oF. (0oC)
by a switch located on the front of the operator console. Warm up periods are in relation to outside temperatures, but normally sufficient warm up can be accomplished in approximately one hour prior to starting
machine.
If the machine is supplied by a GenSet, the GenSet is switched on to provide power for preheating. After
the GenSet warms up to operating temperature, the heater/controller is switched on and the Operator can
then select which system is to be energized via the distribution breaker box (see fig. 7-6).
If the heater/controller is supplied power from an external source, the Operator plugs in the system and
then switches on the heater/controller.
ON/OFF Switch
Heater
Pump
Fig. 7-3 Heat Exchanger

Element in Hydraulic Tank
Fig. 7-2 Heater/Controller Installation
Fig. 7-4 Heating Pad on Auto

Lube Grease Container
7-3

Maintenance
BE SURE there are no fuel leaks near the burner unit.
DISCONNECT BATTERY or unplug cable to heater controller before doing any welding
on machine. Damage to controller unit will result.
Allow time for burner unit to cool before doing any repair work.
Heater/Pump UnitMaintenance and Repair

Refer to the Espar repair manual for the Hydronic 30 compact heater in Section 10 of the Service Manual.
Order repair parts from Parts Manual for your specific machine.
Cooling System Freeze Protection

In the late fall, before temperatures drop below 32oF. (0oC), the complete cooling system should be
drained and flushed. The thermostat should be removed during flushing. Check for proper operation or
replace before reinstalling. When refilling, add a sufficient amount of anti-freeze for your climate. A 50/50
mixture is recommended for maximum protection
Water Injection System Freeze Protection

To blow water out of the lines and pump before shutting machine down, the following steps need to be
done with the machine in idle mode.
1.
Turn the optional handle on the cab side crawler frame to open ball valve to drain water tank. After
water tank is drained, leave ball valve on bottom of water tank open until time to add water to tank,
then close valve.
2.
After water tank is drained, open shut off valve on top of air receiver to release air into water
system. With the water injection switch in the cab in OFF position, this will blow water through the
pump and back to the tank. After 5 seconds, switch the water injection switch to ON. This will blow
water into the main air line.
3.
Turn main air ON to blow water out of standpipe and drill pipe. Let run for about 15 seconds. At this
time all water is out of lines and pump.
4.
Shut machine down. While the machine's air receiver is in blowdown mode, leave shut off valve on
top of air receiver open to blow into water injection system.
5.
After air receiver has blown down, close shut off valve on top of air receiver to close line.
6.
Before starting machine, prime the water pump by pouring water into the pipe nipple on suction
side of pump inlet.
Receiver Tank
Drain water from the receiver tank daily or whenever the machine is shut down for more than one
hour.
NOTE
7-4
BE SURE to evacuate all the remaining water from the water injection pump to prevent the pump from freezing.
1" HOSE
1" HOSE
1" HOSE
HYD RESERVOIR
1" HOSE
1" HOSE
1" HOSE
WATER TANK
1" HOSE
1" HOSE
1" HOSE
1" HOSE
1" HOSE
FUEL TANK
RETURN
SUPPLY
FUEL SUPPLY HOSE

(5 MM. I.D.)
SUPPLIED WITH HEATER
(403352)
SUPPLY
RETURN
FUEL FILTER
1 1/2" HOSE
SUPPLY
SUPPLY
RETURN

3/4" HOSE
1 1/2" HOSE
1 1/2" HOSE
REAR VIEW
1 1/2" HOSE
ENGINE
SIDE VIEW
Fig. 7-5 Cold Weather Plumbing

Using Diesel Fired Heater
7-5
1 1/2" HOSE
3/4" HOSE
3/4" HOSE
3/4" HOSE
RETURN
7-6
Fig. 7-6 Heater Control Schematic Using

120/240 VAC System
LOAD
LINE
V5
6
100
100
AMP
AMP
380V
220V
380V
12GA
EARTH NEUTRAL
380V
12GA
CUSTOMER SUPPLIED EXTERNAL POWER

SOURCE 380V Y3/220V 1}
CUSTOMER SUPPLIED
CIRCUIT PROJECTION
V2
U2
7
W5
U5
W2
THREAD
GREASE
DRUM
HEATER
650W
TCR
C1
12GA
12GA
COOLANT
PUMP 10GPM
HI LIMIT
THERMOSTAT
THERMISTOR
N/C
OFF
ON
FUEL TANK HEATERS

2@2KW
10GA GND
L1 10GA
L3 10GA
HEATING
ELEMENT
2KW
HEATING
ELEMENT
9KW
CONTACTOR
MAGNETIC
15 AMP
GFI
15 AMP
GFI
50 AMP
15 AMP
GFI
25 AMP
GFI
50 AMP
GFI
15 AMP
GND
HEATING
ELEMENT
9KW
12GA
GND
TEMP
CONTROL
10GA
HEATING
ELEMENT
9KW
10GA
TEMP
CONTROL
12GA
GND
12GA
12GA
HEATING
ELEMENT
2KW
12GA
12GA
HEATING
ELEMENT
1.35KW
12GA
GND
HEATING
ELEMENT
1.35KW
HEATING
ELEMENT
.338KW
NOTE: 120 VOLTS

APPLIED TO STANDARD
240 VOLT HEATER
NOTE:
HEATER NEUTRAL WIRE
NOT CONNECTED
12GA
GND
12GA
ADJ
TEMP
CONTROL
25F-330F
COMPRESSOR CONTROL BOX HEATER

338W
SUCTION MANIFOLD OR HYD TANK COMPRESSOR RECEIVER TANK HEATERS
WATER TANK HEATER
2@1.35KW
HEATER
9KW
2KW
12GA
10GA
TEMP
CONTROL
10GA
10GA
12GA
650W
12GA
GND
750W
12GA
GND
75W
75W
GND
HEATER
HEATER
AUTO LUBE GREASE

DRUM HEATER
750W
FIXED TEMP
CONTR0L
60F
12GA
12GA
TEMP
CONTROL
12GA
12GA
GND
TEMP
CONTROL
12GA
HEATER
75W
HEATER
ENGINE OIL HEATER

(PAN)
500W
GND
75W
HEATER
HEATING
ELEMENT
2KW
HEATING
ELEMENT
2KW
GND
TEMP
CONTROL
HEATING
ELEMENT
2KW
HYD. TANK HEATERS 2@2KW
TEMP
CONTROL
BATTERY HEATERS
4@75W
GND
WATER TANK HEATER

9KW
AUXILIARY POWER SUPPLY 220VAC

1}
GENERATOR
W1
U6
W6
V1
12GA
GND
H4
BUS BAR
NO BUS BAR
GFI
H3
H1
2GA
2GA
U1
V6
9KW
TEMP
CONTROL
10GA
H2
AMP
100
200 AMP RECEPTACLE AND

PLUG
AMP
100
ENGINE COOLANT FORCED CIRCULATION HEATER
TEMP
CONTROL
X4
120V
SECONDARY
X3
X2
120V
SECONDARY
X1
TRANSFORMER
50KVA
AMP
100
MAIN BREAKER
ON BOARD GENERATOR SET
25 AMP
GFI
50 AMP
DISTRIBUTION BREAKER
BOX
4GA
4GA
4GA
ISOLATION SAFETY SWITCH
Kim Hotstart
CSS
Coolant Small System
Installation & Operation Manual
216211-000 rev-2
7-7
Notes
7-8
Kim Hotstart
The Kim Hotstart System
System Overview
Shown on the next page is the basic layout of the CSS Heating System. This circulating
heating system consists of a coolant heating chamber, heating element, adjustable
thermostatic control, a centrifugal pump, a control box with electro-mechanical controls
and a mounting plate.
Basic System Operation

Upon energizing the system, engine coolant which is taken from the coolant drain area in
the lower section of the engine is circulated via a centrifugal pump, pulled through the
heating chamber and back to a location on the engine furthest from the coolant suction
line. The pump stays on and continues this circulation process even when the heating
elements are off to provide an accurate, uniform heat to the engine. In the element
enclosure is a thermister. This device senses the temperature of the engine coolant and
sends a signal to a solid-state temperature controller in the control box that turns the
element on and off as needed.
The front panel on/off switch or a 24 VDC input for automatic operation can control
system operation manually.
7-9
Kim Hotstart
7-10
Kim Hotstart
Coolant return line to rear of engine.
Engine
Optional Shut-Off Valve

Optional Check Valve
Coolant
Inlet
Coolant
Outlet
CSS System
engcool.eps
7-11
Kim Hotstart
Coolant Requirements
Upon an initial coolant fill and each subsequent replacement, check the quality of the source
water. Proper coolant management procedures can eliminate engine and heating system
problems. Use these guidelines:
Basic Water Quality

Chlorides
Sulfates
Total Hardness
Total Solids
pH
50 PPM Max
50 PPM Max
100 PPM Max
250 PPM Max
7,5 to 10.5
To achieve the level of quality required, it may be necessary to use distilled water (not
deionized). Distilled water is corrosive without proper inhibitors. Kim Hotstart Manufacturing
also recommends use of a well-inhibited ethylene glycol cooling solution at 30% to 60% ratio.
Glycol based inhibitors provide superior corrosion protection, inhibition, a lower freeze point
and an increased boiling point.
For heavy duty engines, use a low silicate coolant formula inhibitor composition with a silicate
level of no more than 230 PPM. This coolant fill is supplemented with an inhibitor additive
package to provide specific inhibition for wet sleeve cylinder liners, cavitation, pitting and
erosion.
NOTE: The use of glycol still requires non-corrosive water, periodic reinhibition and inhibitor monitoring.
Kim Hotstart Manufacturing recommends use of "Fleetguard DCA4" (or equivalent), a high
quality inhibitor package that provides excellent steel, aluminum, copper and other cooling
system metals protection for the pre-heating system and engine. DCA4 formula consists of a
balanced combination of phosphate, molybdate and nitrite inhibitor, and is packaged in units for
easy calculation of coolant amounts.
7-12
Kim Hotstart
System Start-Up
After system installation has been completed, follow these steps for proper Coolant Heating
System start-up.
Coolant Heating System Start-Up

CAUTION:
DO NOT START THE PUMP BEFORE FILLING THE SYSTEM WITH

COOLANT AND NEVER OPERATE THE PUMP DRY.
Step 1
Check and tighten all electrical and plumbing connections.
Step 2
Ensure isolation valves are open before starting system.
Step 3
Once the heating system is installed and the engine is filled, run the engine for
a short period before energizing the heater. This will purge any air from the
pump and heating tank. Loosen outlet flange at pump to bleed air.
Step 4
The thermostat is set at 65 from the factory for initial start-up. Energize the
coolant heating system by turning the coolant switch on the control box to the
ON position. After flow is verified through the tank and any trapped air is
expelled, adjust thermostat to the desired temperature.
NOTE:
On initial startup, it may take several attempts to achieve proper flow.
7-13
Kim Hotstart
24 VDC Connection
A terminal block, labeled A and B , for the 24 VDC input signal is supplied inside the control
box of the Kim Hotstart heating system. The signal source for this connection is usually the fuel
pump or alternator. Once the signal is detected at the control circuit, the heating system will
automatically shut down during engine operation and re-energize upon engine shutdown.
CAUTION
THE HEATING SYSTEM MUST NOT BE OPERATED WHILE THE ENGINE IS
RUNNING. IF OPERATED, PREMATURE ELEMENT FAILURE MAY RESULT.
7-14
Kim Hotstart
System Components
This section describes the control box and heating tank components of the CSS Heating System.
Control Box
The control box used in the Kim Hotstart Heating System is shown. The control box contains the
electrical control components of the heating system. Parts in the control box may vary,
depending on the particular system configuration you purchased.
7-15
Kim Hotstart
Fuses
There are one or two different types of fuses located in the control box depending on the heating
system:
Transformer Primary Fuses
These fuses, located in the control box, protect the power transformer from overloading.
Transformer Secondary Fuse
This fuse, located in the control box, protects the control circuit components of the
control box and the pump.
Transformer
The transformer steps down the source primary voltage to 120 volts. Wiring information is listed
on the top of the transformer. This transformer is overload protected with fuses.
NOTE:
7-16
When ordering replacement parts, be sure to reference your heating system's

model and serial numbers found on the identification plate.
Kim Hotstart
Coolant Heating Tank Assembly
The Kim Hotstart coolant heating tank assembly is shown below.
Following is an overview of operation and replacement instructions for the CSS heating tank
assembly and components, including the coolant heating element.
7-17
Kim Hotstart
Heating Element Replacement
The heating element heats the engine coolant. To replace the heating element, follow the steps on
the following page. Be sure to allow at least 12" of space for element removal. The wattage and
phase of the heating element are listed on the identification label found on the base of the heating
element assembly.
WARNING
DISCONNECT ALL POWER AT THE SOURCE LEADING TO THE KIM HOTSTART
HEATING SYSTEM PRIOR TO PERFORMING ANY MAINTENANCE ON THE
HEATING SYSTEM.
7-18
Kim Hotstart
Step 1
Turn the Kim Hotstart Heating

system OFF.
Cover
Step 2
Drain the fluid from the heating tank.
Step 3
Open the element enclosure and

disconnect the following wires to the
heating element assembly:
Enclosure
L1, L2, L3 (L1 & L3 on single

phase units)
Conduit
The 2 wires from the thermister.

The 2 wires from the hi-limit
thermostat.
Thermistor
Probe
Heating
Element
The heating element ground wire.

Step 4
Remove the conduit connector and

electrical wires from the element
enclosure.
Step 5
Remove the heating element by

loosening the clamp from the heating
tank as shown.
Step 6
Replace the heating element or

perform the necessary cleaning
procedure.
V-Clamp
O-Ring
Inlet
Tank
elemdis.eps
NOTE:
Orientation of element thermister probe must be kept away from inlet opening
plumbing. It must be re-installed in the same orientation to the tank as it originally
came from the factory.
To re-assemble the heating element and tank, follow the steps listed above in reverse order.
Make sure the green ground and black power electrical wires are properly reconnected. To order
a new heating element, refer to part number on the label of the element, or the assembly drawing
included with this manual.
7-19
Kim Hotstart
High-Limit Thermostat Replacement
The High-Limit Thermostat Sensing Unit is a safety device designed to prevent over heating of
the coolant in the event that the heating systems System Main Thermostat fails. The sensing
unit is located inside the element housing and is fixed at 140F (ON)/160F (OFF). To replace
the high-limit thermostat sensing unit, follow these steps.
WARNING
DISCONNECT ALL POWER AT THE SOURCE PRIOR TO PERFORMING ANY
MAINTENANCE TO THIS HEATING SYSTEM.
Step 1
Remove the enclosure cover

of the element housing.
Step 2
For 3-phase applications

only, remove the element
jumper strap which crosses
over the top of the high-limit
sensing unit (red wires).
Step 3
Using a small screw driver,

remove the toothed lock ring
that holds the high-limit
sensor and seat in place.
Step 4
Pull the sensor and seat

straight out and disconnect
the sensor from its seat.
Step 5
Reconnect the new sensor.
Lock Ring
Sensor Seat
Thermostat Sensor
hisenr.eps
Reassemble in reverse order.

High-Limit Sensing Unit Replacement Parts
Sensing Unit
Temp. On
Temp. Off
Part Number
LSU 4
40F (5C)
60F (15C)
HLC 4*
LSU 6
60F (15C)
80F (27C)
HLC 6*
LSU 8
80F (27C)
100F (38C)
HLC 8*
LSU 10
100F (38C)
120F (49C)
HLC 10*
LSU 12
120F (49C)
140F (60C)
HLC 12*
LSU 14
140F (60C)
160F (71C)
HLC 14*
* Replacement stats will come with lock ring and sensor seat.
7-20
Kim Hotstart
Coolant System Temperature Setting Adjustments
The system temperature setting adjustment is located inside the control box. The solid-state
adjustable thermostat provides 5 incremental settings between 65 and 140. To adjust the
heating system's temperature, follow these steps.
CAUTION
DISCONNECT ALL POWER AT THE SOURCE PRIOR TO PERFORMING ANY
MAINTENANCE TO THIS HEATING SYSTEM.
Step 1
Open the control box.
Step 2
Inside the control box, locate the thermostat control with four dip switches.
Step 3
The system's temperature setting is factory preset at 65F for initial start-up.
After flow is achieved a setting of 100 under normal conditions is sufficient for
normal operation. If a higher or lower temperature is required, reset the dip
switches to desired temperature.
CAUTION
SEE SET-TEMPERATURE TABLE FOR ORIENTATION OF THE COMBINED
SWITCHES THAT ARE NUMBERED 1, 2, 4 AND 8 LOCATED ON TOP
OF THE SOLID-STATE CONTROL.
After the desired temperature is achieved, close the control box and re-energize the heating
system. A few seconds will pass before the thermostat control begins to energize the element.
7-21
Kim Hotstart
Set Temperature Table
7-22
Kim Hotstart
System Maintenance & Troubleshooting
This section describes maintenance procedures for the Kim Hotstart Small Capacity Heating
System and provides tips for troubleshooting.
System Maintenance
The following maintenance procedures are provided to ensure trouble-free operation of your
heating system:
Control Box
Plumbing Connections
Electrical Connections
Heating Tank
System Mounting
WARNING
DISCONNECT ALL POWER PRIOR TO PERFORMING ANY SYSTEM
MAINTENANCE.
Control Box
Y Periodically check O-rings and gaskets for proper seals.
YCheck the control box for moisture (if necessary spray with moisture repellent or add
desiccant packets).
Plumbing Connections
YPeriodically check plumbing connections for leaks and, if necessary, tighten
connections. A loose connection on the suction side will cause a loss of flow.
Electrical Connections
YExcessive vibration will eventually cause terminals to loosen. Periodically tighten all
electrical connections. Ensure that all connectors to the circuit board are firmly seated.
Y At least once every six months, spray the inside of the main control box with a moisture
repellent for electrical connections.
7-23
Kim Hotstart
Heating Tank
YAt least once per year, clean the interior of the heating tank and the heating element
with a wire brush and/or damp cloth. Periodically check the element for sediment
build-up around the hairpins. Any scaling or build-up will shorten element life.
Maintenance and replacement procedures for the heating element are described in
Section 3.
System Mounting
Y Excessive vibration may cause mounting bolts to loosen. Periodically check and
tighten all mounting bolts.
Troubleshooting
Symptoms
Coolant is not heating
7-24
Possible Causes
Solutions
Air leaks in suction lines
Tighten suction line connections
No power
Energize main power supply
Blown fuses
Replace primary and/or

secondary fuses
Isolation valves are closed

(user supplied)
Open isolation valves
Thermostat is not set properly
Adjust thermostat dip switches

inside control box
Kim Hotstart
Wiring Diagram
7-25
Murphy PowerView
Description
The Cummins QST30 engine operation can be monitored by the optional Murphy PowerView display, located on the engine instrument panel (fig. 7-7). The PowerView is a multifunction gauge, that
allows the operator to monitor several engine functions. It also displays fault codes, if there is an engine
malfunction. There are four touch sensitive buttons that allows the operator easy access to the displays.
Refer the following PowerView Installation and Operations Manual for complete instructions.
Fig. 7-7 Murphy PowerView Display
7-26
Murphy PowerView
PV-02124N
Revised 05/04
Section 78
00-02-0528
Installation and Operations Manual

Please read the following information before installing. A visual inspection of this product for damage during shipping is
recommended before mounting. It is your responsibility to have a qualified person install this unit.
GENERAL INFORMATION
Display Parameters
WARNING
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
Disconnect all electrical power to the machine.

Make sure the machine cannot operate during installation.
Follow all safety warnings of the machine manufacturer.
Read and follow all installation instructions.
Description
The PowerView is a powerful new display in a line of components manufactured
by FWMurphy as part of its J1939 MurphyLink Family. The J1939
MurphyLink Family of products have been developed to meet the needs for
instrumentation and control on electronically controlled engines communicating
using the SAE J1939 Controller Area Network (CAN).
The PowerView System is comprised of the PowerView and the Mlink
PowerView Gages. The PowerView is a multifunction tool that enables equipment
operators to view many different engine or transmission parameters and service
codes. The system provides a window into modern electronic engines and transmissions. The PowerView includes a graphical backlit LCD screen. It has excellent
contrast and viewing from all angles. Back lighting can be controlled via menu or
external dimmer potentiometer. The display can show either a single parameter or a
quadrant display showing four parameters simultaneously. Diagnostic capabilities
include fault codes with text translation for the most common fault conditions.
The PowerView has four buttons using self-calibrating charge transfer activation
technology, which eliminates the concern for pushbutton wear and failure. In addition, operators can navigate the display with ease.
The enhanced alarm indication has ultra bright alarm and shutdown LEDs (amber
& red). It has a wide operating temperature range of -40 to +85 C (-40 to185 F),
display viewing -40 to +75 C (-40 to 167 F), and increased environmental sealing
to +/- 5 PSI ( 34kPa). It also features Deutsch DT style connectors molded into
the case and fits quickly and easily into existing 2-1/16 in. (52 mm) gage opening
with little effort.
Other components in the system are microprocessor-based Mlink
PowerView Gages for displaying critical engine data broadcast by an electronic engine or transmissions Engine Control Unit (ECU): engine RPM, oil
pressure, coolant temperature, system voltage, etc. and a combination audible alarm and relay unit for warning and shutdown annunciation. Up to 32
components may be linked to the PowerView using a simple daisy chain
wire connection scheme using RS485. The PowerView and all connected
components can be powered by 12- or 24-volt systems.
Warranty
A limited warranty on materials and workmanship is given with this
FWMurphy product. A copy of the warranty may be viewed or printed by
going to www.fwmurphy.com/warranty.html
MurphyLinkTM is a registered trademark of FWMurphy. All other trademarks and
service marks used in this document are the property of their respective owners.
The following are some of the engine and transmission parameters displayed
by the PowerView in English or Metric units as well as in Spanish, French,
or German (when applicable, consult engine or transmission manufacturer
for SAE J1939 supported parameters):
Engine RPM
Engine Hours
Machine Hours
System Voltage
% Engine Load at the current RPM
Coolant Temperature
Oil Pressure
Fuel Economy
Throttle Position
Engine Manifold Air Temperature
Current Fuel Consumption
Transmission Oil Pressure
Transmission Oil Temperature
Transmission Gear Position
Active Service Codes
Stored Service Codes (when supported)
Set Units for display (English or Metric)
Engine Configuration Parameters
Specifications
Display: 1.3 x 2.6 in. (33 x 66 mm), 64 x 128 pixels.
Operating Voltage: 8 VDC minimum to 32 VDC max.
Reversed Polarity: Withstands reversed battery terminal polarity indefinitely within operating temperatures.
Operating Temperature: -40 to +85C (-40 to185F).
Display Viewing Temperature: -40 to +75C (-40 to 167F).
Storage Temperature: -40 to +85C (-40 to185F).
Environmental Sealing: IP68, +/- 5 PSI (+/- 34.4 kPa).
Power Supply Operating Current: (@ 14 VDC)=
52 mA minimum; 268 mA maximum (LCD heater on).
CAN BUS: SAE J1939 Compliant.
Case: Polycarbonate / Polyester.
Clamp: Polyester (PBT).
Connectors: 6-Pin Deutsch DTO6 Series.
Maximum Panel Thickness: 3/8 in. (9.6 mm).
Mounting Hole: 2.062 inch (52 mm) in diameter.
Auxiliary Communications: Either:
Gages: One (1) RS485 port, MODBUS RTU master.
MODBUS: One (1) RS485 port, MODBUS RTU slave, selectable
baud rate; 9600; 19.2K; 38.4K.
Potentiometer (External Dimmer)Input: 1K ohm, 1/4 W
Shipping Weights (all models): 1/2 lb. (225 g.)
Shipping Dimensions (all models): 6 x 6 x 6 in. (152 x 152 x 152 mm).
7-27
Murphy PowerView
GENERAL INFORMATION continued
Table of Contents
Faceplate Features
General Information
page #
Description................................................. 1
Display Parameters.................................... 1
Specifications............................................. 1
Key Pad Functions..................................... 2
Mechanical Installation
Typical Mounting Dimensions................... 2
Typical Quick-connect Diagram................ 3
Electrical Installation
PIN Connectors Nomenclature.................. 3
Typical Wiring Diagrams........................... 4
Operations
First Time Start Up................................... 5
Main Menu Navigation............................. 5
Selecting a Language................................. 5
Stored Fault Codes.................................... 6
Engine Configuration Data....................... 6
Faults and Warnings............................... .7
Active Fault Codes................................... 8
Shutdown Codes...................................... 8
Back Light Adjustment............................ 9
Contrast Adjustment.............................. 10
Select Units............................................... 10
Setup 1-Up Display................................... 11
Setup 4-Up Display.................................. 14
Utilities.....................................................15
MODBUS Setup....................................... 15
J1939 Parameters....................................17
Glossary...................................................18
Amber
Warning LED
Red Shutdown
Derate LED
Display
Bezel
Menu Key
Enter Key
Left Arrow Key (Scroll Up)
Right Arrow Key (Scroll Down)
Keypad Functions
The keypad on the PowerView is a capacitive touch sensing system.
There are no mechanical switches to wear or stick, and the technology
has been time proven in many applications. It operates in extreme temperatures, with gloves, through ice, snow, mud, grease, etc., and it allows
complete sealing of the front of the PowerView. The key is touched
feedback is provided by flashing the screen. The keys on the keypad perform the following functions:
Menu Key - The Menu Key is touched to either
enter or exit the menu screens.
Left Arrow - The Left Arrow Key is touched
to scroll through the screen either moving the parameter selection toward the left or upward.
Right Arrow - The Right Arrow Key is touched
to scroll through the screen either moving the parameter
selection toward the right or downward.
Enter Key - The Enter Key (also known as Enter
Button) is touched to select the parameter that is highlighted on the screen.
Typical Mounting Dimensions

HOLE CUTOUT
SIDE
3.489 in.
(89 mm)
1.94 in.
(50 mm)
FRONT
2.070 in.
(53 mm)
2.41 in.
(61 mm)
2.062 in.
(52 mm)
diameter
1.972 in.
(50 mm)
.953 in.
(24 mm)
0.125 in.
(3 mm)
R 0.063 in.
(1.6 mm)
0.78 in. (20 mm)
4.25 in.
(108 mm)
7-28
3.18 in. (81 mm)
Murphy PowerView
MECHANICAL INSTALLATION
Typical Quick-Connect Diagram

Last PVA Gage or
PVAA Audible Alarm
To Engine
ECU
A
To optional
external device
To PVAA
Audible Alarm
Terminating
Resistor PVJR
To Battery
Power
PVW-CH
POWERVIEW
PV100
Relay N.O.
Relay N.C.
OR
Ext.
Sonalert
PVW-PH
Relay Comm.
Optional PVW-A wire harness
Customer provided wire

harness or CAN extension
harnesses or power
extension harnesses.
(includes terminating resistor)

A
PVA Gage
Next PVA Gage
Wire harness
PVW-J
External Dimmer
Wire 24 inch.
A
External
Dimmer
B+
GRND
CANSHLD
CANLO
CANHI
Wire harness PVW-P
Wire harness PVW-J
Wire harness PVW-J
ELECTRICAL INSTALLATION
PowerView Unit Back View

Deutsch DT06-6S Style Connections
Plug A
Plug B
PIN 3 CAN LO
PIN 4 CAN SHLD
PIN 2 CAN HI
PIN 5 Dimmer
Potentiometer
PIN 1 V+
PIN 6 GRND
PIN 3 RS485+
PIN 4 RS485
B
PIN 1 V+
PIN 6 GRND
Recommended Connectors:
Body: Deustch DT06-6S
Wedge Lock: W6S
Terminals: 0462-201-16141
Sealing Plug: 114017
7-29
Murphy PowerView
TYPICAL WIRING DIAGRAMS
IMPORTANT: To eliminate external interference: RS485(+) and RS485(-) should be twisted pair cable or twist wires together, one twist per
inch minimum. CANL, CANH and CAN Shield should be approved J1939 CAN bus cable (CAN wire for example: RADOX plug and play cable,
from Champlain cable). (RS485 wire for example: BELDEN 9841 or 3105A).
PowerView Deutsch DT06-6S Style Unit to PVA Gage

NOTE 5
Green-CAN_L
Yellow-CAN_H
NOTE 4
RS485 (-) Data
See
NOTE 6
Pin 3
120
See Note
Pin 2
PVA Gage
Pin 1
NOTE 1
V+
Pin 1
Pin 5
Red-V+
Ignition
Switch
120 ohms
Pin 4
Pin 4
Pin 6
ENGINE
CONTROL
MODULE
(SAE J1939
Compliant)
NOTE 2
Gray-CAN_SHLD
RS485 (+) Data
Pin 3
Back View
GRND
Pin 6
Gray-Ground
Note 1: Place Resistor between
CANH and CANL Line near
PowerView (included in PVW-P or
factory purchased panels).
Blue-Back Light
NOTE 7
Battery
Note 2: Use SAE J1939 compliant
Illumination
Control*(optional)
NOTE 3
wiring or equipment.
Note 3: Electronic dimmer switch
recommended with 4A, capacity
or heavy duty rheostat switch,
1000 ohm, 0.25 watt.
Note 4: Only use 120 ohm

characteristic impedance cable,
ex Belden 9841.
Note 5: RS485 shield connected
to PowerView end only.
Note 6: Place Resistor at End of
Line on last PVA gage. (Included
for factory purchased panels.)
Note 7: If a backlight dimmer is not
used, connect the blue backlight wire
to ground. Do not leave the blue
backlight wire unconnected.
PowerView Deutsch DT06-6S Style Unit to MODBUS Output

NOTE 5
RS485 (+) Data
Pin 3
Green-CAN_L
Yellow-CAN_H
120
See Note
Pin 3
Pin 2
Gray-Ground
Blue-Back Light
NOTE 7
Battery
NOTE 3
Illumination Control*(optional)
For a complete listing of MODBUS Registers

visit our website at www.fwmurphy.com
7-30
Note 4: Only use 120 ohm

characteristic impedance cable,
ex Belden 9841.
Pin 5
Red-V+
Pin 6
NOTE 1
Ignition
Switch
to MODBUS Output
See NOTES 6 and 8
Pin 4
Pin 4
Pin 1
ENGINE
CONTROL
MODULE
(SAE J1939
Compliant)
NOTE 4
RS485 (-) Data
NOTE 2
Gray-CAN_SHLD
Note 1: Place Resistor between
Note 5: RS485 shield connected

to PowerView end only.
CANH and CANL Line near

PowerView (included in PVW-P
or factory purchased panels).
Note 6: Place Resistor at End of Line.

(Included for factory purchased panels.)
Note 2: Use SAE J1939 compliant

wiring or equipment.
Note 3: Electronic dimmer switch
recommended with 4A, capacity
or heavy duty rheostat switch,
1000 ohm, 0.25 watt.
Note 7: If a backlight dimmer is not

used, connect the blue backlight wire
to ground. Do not leave the blue
backlight wire unconnected.
Note 8: PVA gages cannot be used
with the MODBUS feature.
Murphy PowerView
POWERVIEW OPERATION
PowerView Menus (First Time Start Up)

1. When power is first applied to the PowerView, the "Logo" is displayed.
3. Touching the right arrow button will scroll down to reveal the last
items of Main Menu screen highlighting the next item down.
ADJUST BACKLIGHT
ADJUST CONTRAST
UTILITIES
2. The "Wait to Start" message will be displayed for engines with a

pre-startup sequence. Once the "Wait to Start" message is no longer displayed the operator may start the engine. Note: Displays only when SAE
J1939 message is supported by engine manufacturer.
GO TO 1-UP DISPLAY
LANGUAGES
STORED CODES
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
WAIT TO
START
PREHEAT
3. Once the engine has started the single engine parameter is displayed.
0
4. Touch the "Arrows" to scroll to the desired menu item or touch "Menu"
to exit the Main menu and return to the engine parameter display.
1500
98%
1000 RPM
LOAD@RPM
ENG RPM
57 PSI
14.2
OIL PRES
BAT VOLT
Selecting a Language
1. Starting at the main menu display use the "Arrows" to scroll to the
"Language" menu and once highlighted touch the "Enter" button.
3000
1800 RPM
GO TO 1-UP DISPLAY
LANGUAGES
LANGUAGES
STORED CODES
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ENG RPM COOL TEMP
Main Menu Navigation

1. Starting at the single or four engine parameter display, touch "Menu".
98%
0
1500
3000
1800 RPM
ENG RPM
COOL TEMP
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
2. The language choices will be displayed. Use the "Arrow" buttons to

scroll through the selections and touch "Enter" to make a selection.
ENGLISH
ESPAOL
FRANAIS
DEUTSCH
2. The first seven items of the Main Menu will be displayed.

Touching the "Arrow Buttons" will scroll through the menu selection.
GO TO 1-UP DISPLAY
LANGUAGES
STORED CODES
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
3. Now that you have selected the language, touch the "Menu" button to
return to the main menu display.
7-31
Murphy PowerView
POWERVIEW OPERATION continued
Stored Fault Codes
5. Touch the "Menu Button" to return to the main menu.
1. Starting at the single or the four engine parameter display touch the
"Menu button".
1500
3000
LOAD@RPM
ENG RPM
ENG RPM
1800 RPM
SPN110 FMI10
HIGH COOLANT TEMP
1000 RPM
14.2
COOL TEMP
BAT VOLT
MORE
98%
1 of x
HIDE
57 PSI
OIL PRES
2. The main menu will pop up on the display. Use the "Arrow Buttons" to
scroll through the menu until the Stored Fault Codes is highlighted.
GO TO 1-UP DISPLAY
STORED
CODES
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
6. Touch the "Menu Button" to exit the Main menu and return to the
engine parameter display.
GO TO 1-UP DISPLAY
98%
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
Engine Configuration Data

1. Starting at the single or four engine parameter display touch the
"Menu Button".
3 Once the "Stored Fault Codes" menu item has been highlighted touch
the "Enter Button" to view the "Stored Fault Codes" (when applicable,
consult engine or transmission manufacturer for SAE J1939 supported
parameters).
GO TO 1-UP DISPLAY
STORED
CODES
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
98%
0
1500
3000
1800 RPM
ENG RPM
COOL TEMP
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
2. The main menu will pop up on the display. Use the "Arrow Buttons"
to scroll through the menu until the "Engine Configuration" is highlighted.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE
ENGINE CONFG
CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
4. If the word "MORE" appears above the "Arrow Buttons" there are
more stored fault codes that may be viewed. Use the "Arrow Buttons" to
scroll to the next Stored Diagnostic Code.
3. Once the "Engine Configuration" menu item has been highlighted
touch the "Enter Button" to view the engine configuration data.
1 of x
7-32
MORE
SPN110 FMI10
HIGH COOLANT TEMP
HIDE
GO TO 1-UP DISPLAY
STORED CODES
ENGINE
ENGINE CONFG
CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
Murphy PowerView
4. Use the "Arrow Buttons" to scroll through the engine configuration data.
ENGINE SPEED PT 1
or normal operation an auxiliary gage should fail, the single or four parameter screen will be replaced with the "MLink Gage Fault" message.
1000 RPM
1 of x
ENGINE OIL PRESSURE

GAGE NOT RESPONDING
MORE
HIDE

3. To acknowledge and "Hide" the fault and return to the single or
four parameter display, touch the "Enter Button".
ENGINE SPEED PT 1
1000 RPM
1 of x
ENGINE OIL PRESSURE

GAGE NOT RESPONDING
MORE
HIDE
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
98%
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
4. The display will return to the single or four parameter screen.

!
57 PSI
OIL PRES
1500
3000
1800 RPM
ENG RPM COOL TEMP !
Faults and Warnings

Auxiliary Gage Fault
1. During normal operation the single or four parameter screen will be
displayed.
98%
0
1500
3000
1800 RPM
ENG RPM
COOL TEMP
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
98%
1000 RPM
LOAD@RPM
ENG RPM
!
14.2
BAT VOLT
Indicates Auxiliary Gage Fault
.!
Indicates Fault Warning
Indicates Derate or Shutdown Condition Fault
57 PSI
OIL PRES
5. Touching the "Enter Button" will redisplay the hidden fault.

Touching the "Enter Button" once again will hide the fault and return the
screen to the single or four parameter display. NOTE: The fault can only
be cleared by correcting the cause of the fault condition.
1 of x
ENGINE OIL PRESSURE

GAGE NOT RESPONDING
HIDE
2. The PVA Series of auxiliary gages can be attached to the PowerView.

These auxiliary gages communicate with the Modbus master PowerView
via a daisy-chained RS-485 port. If at any time during system initialization
7-33
Murphy PowerView
Active Fault Codes

1. During normal operation the single or four parameter screen will be
displayed.
98%
0
1500
LOAD@RPM
3000
1800 RPM
ENG RPM
14.2
COOL TEMP
BAT VOLT
1000 RPM
ENG RPM
57 PSI
1500
ENG RPM
COOL TEMP
ENG RPM
14.2
57 PSI
OIL PRES
BAT VOLT
6. Touching the "Enter Button" once again will hide the fault and
return the screen to the single or four parameter display.
WARNING
1 of x
SPN110 FMI0
HIGH COOLANT TEMP
SPN110 FMI0
HIGH COOLANT TEMP
1000 RPM
LOAD@RPM
1800 RPM
WARNING
MORE
98%
3000
OIL PRES
2. When the PowerView receives a fault code from an engine control

unit the single or four parameter screen will be replaced with the "Active
Fault Codes" message.
1 of x
5. The display will return to the single or four parameter display, but the
display will contain the "Active Fault"warning icon. Touching the "Enter
Button" will redisplay the hidden fault.
MORE
HIDE
HIDE
3. If the word "MORE" appears above the "Arrow Buttons" there are
more active fault codes that may be viewed.
Use the "Arrow Buttons" to scroll to the next "Active Fault Code"
7. The Single or Four parameter screen will display the fault icon until
the fault condition is corrected. NOTE: Ignoring active fault codes could
result in severe engine damage.
GO TO 1-UP DISPLAY
98%
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
1 of x
SPN110 FMI0
1000 RPM
LOAD@RPM
ENG RPM
!
14.2
BAT VOLT
57 PSI
OIL PRES
MORE
HIGH COOLANT TEMP

HIDE
Shutdown Codes
1. During normal operation the single or four parameter screen will be displayed.
98%
4. To acknowledge and "Hide" the fault and return to the single or four
parameter display touch the "Enter Button".
1500
3000
1800 RPM
ENG RPM
1000 RPM
LOAD@RPM
ENG RPM
57 PSI
14.2
COOL TEMP
OIL PRES
BAT VOLT
1 of x
SPN110 FMI0
HIGH COOLANT TEMP
MORE
HIDE
2. When the PowerView receives a severe fault code from an engine control unit the single or four parameter screen will be replaced with the
"Shutdown!" message.
1 of x
SHUTDOWN
SPN110 FMI0
HIGH COOLANT TEMP
MORE
7-34
HIDE
Murphy PowerView
3. To acknowledge and "Hide" the fault and return to the single or
four parameter display touch the "Enter Button".
SHUTDOWN
1 of x
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
ADJUST
BACKLIGHT
SPN110 FM10
HIGH COOLANT TEMP
MORE
HIDE
4. The display will return to the single or four parameter display, but
the display will contain the "Shut Down" icon. Touching the "Enter
Button" will redisplay the hidden fault.
!
0
1500
98%
1000 RPM
LOAD & RPM
3000
1800 RPM
ENG RPM
!
57 PSI
14.2
ENG RPM COOL TEMP!
OIL PRES
BAT VOLT
to scroll through the menu until the "Adjust Backlight" is highlighted.
3. Once the "Adjust Backlight" menu item has been highlighted touch
the "Enter Button" to activate the "Adjust Backlight" function.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
5. Touching the "Enter Button" once again will hide the fault and return
the screen to the single or four parameter display.
1 of x
4. Use the "Arrow Buttons" to select the desired backlight intensity.
SHUTDOWN
SPN110 FM10
HIGH COOLANT TEMP
MORE
ADJUST BACKLIGHT
HIDE
6. The Single or Four parameter screen will display the fault icon until
the fault condition is corrected. NOTE: Ignoring active fault codes could
result in severe engine damage.
!
0
1500
3000
98%
ADJUST BACKLIGHT
1000 RPM
LOAD & RPM
ENG RPM
1800 RPM
ENG RPM
14.2
COOL TEMP !
BAT VOLT
57 PSI
OIL PRES
Back Light Adjustment

"Menu Button".
GO TO 1-UP DISPLAY
98%
0
1500
3000
1800 RPM
ENG RPM
COOL TEMP
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
98%
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
OIL PRES
7-35
Murphy PowerView
Contrast Adjustment
1. Starting at the single or four engine parameter display, touch the
"Menu Button".
98%
0
1500
3000
1800 RPM
ENG RPM
COOL TEMP
LOAD@RPM
14.2
BAT VOLT
ENG RPM
57 PSI
98%
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
OIL PRES
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
3. Once the "Adjust Contrast" menu item has been highlighted touch
the "Enter Button" to activate the "Adjust Contrast" function.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
ADJUST CONTRAST
4. Use the "Arrow Buttons" to select the desired contrast intensity.

ADJUST CONTRAST
7-36
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
1000 RPM
to scroll through the menu until "Adjust Contrast" is highlighted.
ADJUST CONTRAST
Select Units
"Menu Button".
98%
0
1500
3000
1800 RPM
ENG RPM
COOL TEMP
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
2. The main menu will pop up on the display. Use the arrow buttons to
scroll through the menu until the "Select Units" is highlighted.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT
SELECTUNITSD
UNITS
ADJUST BACKLIGHT
3. Once the "Select Units" menu item has been highlighted touch the
"Enter Button" to access the "Select Units" function.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT
SELECTUNITSD
UNITS
ADJUST BACKLIGHT
4. Use the arrows to highlight the desired units. "English" for Imperial
units i.e. PSI, F or Metric kPa, Metric Bar for IS units i.e. kPa, Bar, C.
ENGLISH
METRIC KPA
METRIC BAR
Murphy PowerView
5. Touch the "Enter Button" to select the highlighted units.
3. Once the "Setup 1-up Display" menu item has been highlighted
touch the "Enter Button" to access the "Setup 1-up Display" function.
ENGLISH
METRIC KPA
METRIC BAR
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP1-UP
1-UPDISPLAY
DISPLAY
SETUP
SETUP 4-UP DISPLAY
SELECT UNITSD
ADJUST BACKLIGHT
6. Touch the "Menu Button" to return to the "Main Menu".

ENGLISH
METRIC KPA
METRIC BAR
GO TO 1-UP DISPLAY
98%
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
LOAD@RPM
14.2
BAT VOLT
1000 RPM
4. Three options are available for modification of the 1-Up display.

a). Use Defaults This option contains a set of engine parameters:
Engine Hours, Engine RPM, System Voltage, Battery Voltage, %
Engine Load at Current RPM, Coolant Temperature, Oil Pressure.
b). Custom Setup This option allows for the modification of what
parameter, the number of parameters, and the order in which the
parameters are being displayed.
c). Automatic Scan Selecting the scan function will cause the
1-Up Display to scroll through the selected set of parameters
one at a time, momentarily pausing at each.
5. Use Defaults - To select "Use Defaults" use the arrow buttons to
scroll to and highlight "Use Defaults" in the menu display.
USE DEFAULTS
DEFAULTS
USE
CUSTOM SETUP
AUTOMATIC SCAN OFF
ENG RPM
57 PSI
OIL PRES
6. Touch the "Enter Button" to activate the "Use Defaults" function.
Setup 1-Up Display

1. Starting at the single engine parameter display, touch the "Menu
Button".
98%
0
1500
3000
1800 RPM
ENG RPM
COOL TEMP
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
scroll through the menu until the "Setup 1-up Display" is highlighted.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP1-UP
1-UPDISPLAY
DISPLAY
SETUP
SETUP 4-UP DISPLAY
SELECT UNITSD
ADJUST BACKLIGHT
USE
USEDEFAULTS
DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
7. A message indicating the Single Engine parameter display parameters are reset to the factory defaults will be displayed, then the display
will return to the Custom Setup menu.
RESTORED TO
DEFAULTS
7-37
Murphy PowerView
8. Custom Setup - To perform a custom setup of the 1-Up Display, use
the arrow buttons to scroll to and highlight "Custom Setup" on the display.
USE DEFAULTS
CUSTOM
CUSTOMSETUP
SETUP
AUTOMATIC SCAN OFF
13. Touch the "Enter button" to select the highlighted parameter for inclusion in the Single Engine Parameter Display.
ENGINE SPEED
PERCENT LOAD AT CURRENT RPM 2
ENGINE OIL PRESSURE
1
ENGINE COOLANT TEMP
3
9. Touching the "Enter Button" will display a list of engine parameters.

USE DEFAULTS
CUSTOM
CUSTOMSETUP
SETUP
AUTOMATIC SCAN OFF
14. Continue to scroll and select additional parameters for the custom
1-Up Display. Touch the "Menu button" at any time to return to the
"Custom Setup" menu.
15. Automatic Scan - Selecting the scan function will cause the 1Up Display to scroll through the selected set of parameters one at a time.
Use the "Arrow Buttons" to scroll to the "Automatic Scan" function.
10. Use the "Arrow Buttons" to scroll to and highlight a selected parameter (parameter with a # symbol to right of it).
USE
DEFAULTS
ENGINE
SPEED
1
ENGINE OIL PRESSURE
2
ENGINE COOLANT TEMPERATURE
This number indicates

the order of display for
the parameters and
that the parameter is
selected for display.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC
OFF
AUTOMATICSCAN
SCAN
OFF
16. Touching the "Enter Button" toggles the "Automatic Scan" function on.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC
OFF
AUTOMATICSCAN
SCAN
ON
11. Touch the "Enter Button" to deselect the selected parameter removing it from the list of parameters being displayed on the 1-up display.
USE
DEFAULTS
ENGINE
SPEED
1
ENGINE OIL PRESSURE
2
17. Touching the "Enter Button" again toggles the "Automatic Scan"
function off.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC
OFF
AUTOMATICSCAN
SCAN
OFF
12. Use the "Arrow Buttons" to scroll and highlight the desired parameter
that has not been selected for display.
ENGINE SPEED
ENGINE OIL PRESSURE
1
ENGINE COOLANT TEMP
7-38
Note that the numbers

now indicate the new
order of display for
the parameters.
Murphy PowerView
18. Once the "Use Defaults", "Custom Setup" and "Automatic Scan" functions have been set touch the "Menu Button" to return to the main menu.
4. Touch the "Enter Button" to activate the "Use Defaults" function.

This action will reset the unit to the factory default.
USE
USE DEFAULTS
DEFAULTS
CUSTOM SETUP
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC
OFF
AUTOMATICSCAN
SCAN
ON
5. The "Use Defaults"screen will be displayed during the reseting period then will automatically return to the "Setup 4-Up Display" menu.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
1500
3000
1800 RPM
ENG RPM
RESTORED TO
DEFAULTS
COOL TEMP
6. Select the "4-Up Custom Setup" from the "4-Up Setup" menu.
Setup 4-Up Display

1. From the single or four engine parameter display touch the "Menu Button".
98%
0
1500
3000
1800 RPM
ENG RPM
COOL TEMP
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
scroll through the menu until the "Setup 4-Up Display" is highlighted.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
3. Once the "Setup 4-Up Display" menu item has been highlighted
touch the "Enter Button" to activate the "Setup 4-Up Display" menu.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP
SETUP 4-UP
4-UP DISPLAY
DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
USE DEFAULTS
CUSTOM
CUSTOM SETUP
SETUP
7. The quadrent with the backlit parameter value is the current selected
parameter. Use the "Arrow Buttons" to highlight the parameter value in
the quadrant you wish to place a new parameter.
125F
COOL TEMP
1000 RPM
ENG RPM
14.2
14.2
BAT VOLT
57 PSI
OIL PRESP
8. Touch the "Enter Button" and a list of parameters will appear.

125F
COOL TEMP
1000 RPM
ENG RPM
14.2
14.2
BAT VOLT
57 PSI
OIL PRESP
7-39
Murphy PowerView
9. The parameter that is highlighted is the selected parameter for the
screen. Use the "Arrow Buttons" to highlight the new parameter to be
placed in the quadrent selected in the previous screen.
ENGINE SPEED
ENGINE HOURS
BATTERY POTENTIAL
ENGINE OIL TEMPERATURE
TEMPERATURE
ENGINE OIL PRESSURE
3
1
2
4
The number to the right of the

parameter indicates the quadrant
in which it is displayed.
1. = Upper Left Quadrent
2. = Lower Left Quadrent
3. = Upper Right Quadrent
4.= Lower Right Quadrent
10. Touch the "Enter Button" to change the selected parameter in the
quadrant to the new parameter.
ENGINE SPEED
ENGINE HOURS
BATTERY POTENTIAL
TEMPERATURE
ENGINE OIL PRESSURE
1
Note the number to the right of
the selected parameter indicating
that the parameter is now
assigned to that display location.
12. The parameter in the selected quadrent has changed to the parameter selected in the previous screen.
125F
COOL TEMP
143F
OIL TEMP
RPM
1000
RPM
ENG RPM
57 PSI
OIL PRESP
13. Repeat the parameter selection process until all spaces are filled.
125F
COOL TEMP
143F
OIL TEMP
7-40
125%
COOL TEMP
143F
OIL TEMP
1000 RPM
ENG RPM
57 PSI
OIL PRES
Utilities (Information and troubleshooting)

1. Starting at the single or four engine parameter display, touch the Menu button.
125%
1
2
2
4
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
11. Use the "Menu Button" to return to the 4-UP Custom Setup screen.
ENGINE SPEED
ENGINE HOURS
BATTERY POTENTIAL
TEMPERATURE
2
ENGINE OIL PRESSURE
RPM
1000
RPM
ENG RPM
57 PSI
OIL PRESP
1500
3000
COOL TEMP
1800 RPM
ENG RPM
143F
COOL TEMP
OIL TEMP
1000 RPM
ENG RPM
57 PSI
OIL PRES
2. The main menu will be displayed. Use the Arrow buttons to scroll
through the menu until the Utilities is highlighted.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
UTILITIES
3. Once the Utilities menu item has been highlighted, touch the
Enter Button to activate the Utilities functions.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
UTILITIES
4. Touch "Select" to enter the Gage Data display. When Gage Data is
selected the PowerView will communicate with the analog gages at a fixed
rate of 38.4 k Baud, 8 data bits, no parity check, 1 stop bits, half duplex.
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
MODBUS SETUP
FAULT CONVERSION
DEMO MODE ON
Murphy PowerView
5. Use the Arrow buttons to scroll through the items or touch Menu
to return to the Utilities menu.
1 of x
ENGINE OIL PRESSURE

ADDRESS: 20
SOFTWARE REVISION #:
ERRORS: NONE
11. Use the Arrows to scroll and highlight the version then touch Select
and an asterisks appears to the right of the selection.
NOTE: There are four (4) different methods for converting fault codes. The
PowerView always looks for J1939 Version 4 and can be set to use one of the
3 other J1939 versions. Most engine ECUs use Version 4, therefore in most
cases adjustment of this menu option will not be required.
Upon receiving an unrecognizable fault, change to a different J1939
Version. If the fault SPN does not change when the version is changed, the
ECU generating the fault is using Fault Conversion method 4. If the SPN
number does change but is still unrecognizable, try changing to another
J1939 Version not yet used and continue to check the SPN number.
6. Touch Menu Button to return to the Utilities menu.
J1939 VERSION
VERSION 11
J1939 VERSION 2
J1939 VERSION 3
J1939 VERSION 4
1 of x
ENGINE OIL PRESSURE

ADDRESS: 20
SOFTWARE REVISION #:
ERRORS: NONE
7. Use the Arrows to highlight Remove All Gages. Touch Select to

clear gage data from memory. It takes a moment to clear all gages.
12. Touch the Menu button to return to Utilities menu. Touch the
Menu button again to to return to the Main menu.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
UTILITIES
CLEARING GAGES
PLEASE WAIT
8. When the gage data has cleared, the display automatically returns to
the Utilities menu. Scroll to Software Version. Touch Select to
view the software version currently in the PowerView.
SOFTWARE
VERSION
MURPHY: X.XX
MODBUS Setup
1. Starting at the single or four engine parameter display, touch the Menu
button.
1500
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
FAULT
FAULTCONVERSION
CONVERSION
3000
98%
LOAD@RPM
1800 RPM
ENG RPM
9. Touch Menu to return to Utilities. Highlight Fault Conversion

using the Arrows. Touch Select to enter the Fault convertion menu.
COOL TEMP
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
2. The main menu will be displayed. Use the Arrow buttons to scroll
through the menu until the Utilities is highlighted, then touch Enter.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
UTILITIES
7-41
Murphy PowerView
3. Once in the Utilities menu use the Arrows to scroll through the menu
until the Modbus Setup menu is highlighted, then touch Enter.
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
MODBUS
SETUP
MODBUS SETUP
FAULT CONVERSION
4. Use the Arrows to scroll down to and highlight either the Slave
Active or Master Active modes. Touch the Enter button to toggle
between master and slave.
USE FACTORY DEFAULT
SERIAL PORT SETUP
SOFTWARE VERSION
SLAVE ADDRESS SETUP
MASTER ACTIVE
MASTER
ACTIVE
5. Use the Arrows to scroll to the Serial Port menu to highlight it,
then touch Enter.
USE FACTORY DEFAULT
SERIAL
PORT SETUP
SETUP
SERIAL PORT
SOFTWARE VERSION
SLAVE ADDRESS SETUP
MASTER ACTIVE
6. Use the Arrow button to scroll to each selection to configure the

MODBUS values for your application.
BAUD RATE
PARITY
PARITY
DATA BITS
STOP BITS
7. When finished, touch Menu to return to the previous screen.
7-42
Murphy PowerView
SAE J1939 MurphyLink System Implementation of J1939 Parameters
Source: SAEJ1939-71 Surface Vehicle Recommended Practice
SAE J1939 Section
Description
PGN
Parameter
Display Value
5.3.6
Elec Eng Cont #2 - EEC2
61443
Accelerator Pedal Position

Percent Load at Current RPM
THROTTLE
LOAD@RPM
5.3.7
Elec Eng Cont #1 - EEC1
61444
Actual engine % torque

Engine Speed
ENG TORQ
ENG RPM
5.3.14
Vehicle Distance
65248
Trip Distance
Total Vehicle Distance
TRIP DIST
VEH DIST
5.3.19
Engine hours, Revolutions
65253
Total Engine Hours
ENG HRS
5.3.23
Fuel Consumption
65257
Trip Fuel
Total Fuel Used
TRIP FUEL
FUEL USED
5.3.28
Engine Temperature
65262
Engine Coolant Temp

Fuel Temperature
Engine Oil Temperature
Engine Intercooler Temperature
COOL TEMP
FUEL TEMP
OIL TEMP
INTC TEMP
5.3.29
Engine Fluid Level/Pressure
65263
Fuel Delivery Pressure

Engine Oil Level
Engine Oil Pressure
Coolant Pressure
Coolant Level
FUEL PRES
OIL LVL
OIL PRES
COOL PRES
COOL LVL
5.3.31
Cruise Control /Vehicle Speed
65265
Wheel Based Vehicle Speed
VEH SPD
5.3.32
Fuel Economy
65266
Fuel Rate
Instantaneous Fuel Economy
Average Fuel Economy
FUEL RATE
FUEL ECON
AVG ECON
5.3.35
Ambient Conditions
65269
Barometric Pressure
Air Inlet Temperature
BARO PRES
AIR IN TP
5.3.36
Inlet/Exhaust Conditions
65270
Boost Pressure
Intake Manifold Temp
Air Filter Differential Pressure
Exhaust Gas Temperature
BST PRES
MANI TEMP
AIR DIF PR
EXH TEMP
5.3.37
Vehicle Electrical Power
65271
Alternator Voltage
Electrical Potential (Voltage)
Battery Pot. Voltage (Switched)
ALT VOLT
SYS VOLT
BAT VOLT
5.3.8
Electronic Transmission Controller #2
61445
61445
Selected Gear
Current Gear
SLECT GEAR
CURNT GEAR
5.3.38
Transmission Fluids
65272
Transmission Oil Pressure
TRAN PRES
Transmission Oil Temperature
TRAN TEMP
5.3.46
Engine Fluid Level/Pressure #2
65243
Injector Metering Rail 1 Pres

Injector Metering Rail 2 Pres
INJ PRES1
INJ PRES2
5.3.58
Fan Drive
65213
5.3.111
Auxiliary Pressures & Temperatures
65164
FAN SPD
Auxiliary Temperature
AUX TEMP
Auxiliary Pressure
AUX PRES
Diagnostic Messages
65226
65227
65228
DM1 - Active Diagnostic

DM2 - Previously Act Diag Codes
DM3 - Diagnostic Clear
SRVCCODE
STORCODE
J1939 N/A
Machine Hours (PowerView Calculated)
N/A
Machine Hours
MACH HRS
5.3.17
Engine Conf.
65251
Engine Configuration
ENG CONF
61442
Output Shaft Speed
OUT SFT SP
61442
Input Shaft Speed
IN SFT SPD
61442
Torque Converter Lockup Engaged
TORQ LOCK
5.3.5
7-43
Murphy PowerView
GLOSSARY (Troubleshooting information)
CANBUS FAILURE
PowerView has not received any CAN messages for at least 30 seconds.
NO DATA
PowerView has not received the particular message being displayed for
at least 5 seconds.
NOT SUPPORTED
PowerView has received a message from the ECU stating the displayed
message is not supperted.
DATA ERROR
PowerView has received an error message from the ECU for the displayed message.
EMPTY
No parameter selected for this 4-UP quadrant.
WAIT TO START PREHEATING
This is a message from the engine indicating it is in a preheating cycle.
Wait until this message clears before starting the engine.
TIMEOUT ECU NOT RESPONDING
The ECU did not respond to the PowerView request.
NO GAGE DATA
The PowerView has no record of connected gages to the RS485 bus.
7-44
Foremost Shock Sub
7-45
Foremost Shock Sub
7-46
Foremost Shock Sub
7-47
Foremost Shock Sub
7-48
Foremost Shock Sub
7-49
Foremost Shock Sub
7-50
Foremost Shock Sub
7-51
Foremost Shock Sub
7-52
Section 8
Lubrication and Preventative Maintenance

NOTE
This section contains recommended procedures and instructions which personnel

will need in order to properly perform necessary lubrication and preventive maintenance. This information should be considered as the manufacturer's recommendations only and are based upon normal operation. For severe or unusual conditions
the recommended lubrication instructions should be varied in accordance with extended hours of operation, climate and drilling conditions.
8-1
Notes
8-2
Service PointsMainframe
In most cases lubrication points on the drill will be connected to the auto lube system (if used), or will
be connected to lubrication lines from a remote lube bulkhead (manual lube system).
Auto Lube System

The auto lube system consists of an air powered pump assembly which is fitted to 120 lb. (54 kg.)
grease container (Fig. 8-1). The pump supplies grease under pressure (2500 PSI [172 bar]) to manifolds
containing injectors which supply grease to points required. A filter/regulator/lubricator supplies 90100
PSI (6.27 bar) to the pump.
The system is controlled by a lube & sensor controller mounted in the operator's cab. The controller
controls the lubrication system and also will verify delivery of lubricant into a bearing. See Section 10 in the
Service Manual for component service information.
Auto Lube System
Description
Fig. 8-1 Auto Lube Pump and Grease

Container
No. of Lube Points
Mast Crown Sheaves
Mast Lower Sheaves
Pipe Rack BearingUpper
Pipe Rack BearingLower
CarouselUpper
CarouselLower
Pipe Rack Roller
Mast Pivot Pins
Mast Elevating Cylinders
Rear Axle
Front AxleCenter
Front AxleEnds
JacksRear
JacksFront
Regulator
Lubricator
Water
Trap
Fig. 8-2 Auto Lube Pump

Controller in Cab
Fig. 8-3 Auto Lube Regulation
8-3
Central Lube System
Fig. 8-4 Lube Point Locations
NOTE
8-4
Lubrication points may vary by location and/or quantity based upon drill model.
Manual Lube System

Manual Lube System
R.H. Pump Drive Mount (11) Points
Description
No. of Lube Points
JacksFront
JacksRear
Front Axle
Rear Axle
Lower Mast Raise Cylinder
Mast (16) Points

Description
No. of Lube Points
Upper Mast Raise Cylinder
Mast Pivot
Pulldown Sheaves
Pipe Rack Bearings
Pipe Rack Roller
Rotary Air Swivel
Mast Lock
PUMP DRIVE MOUNT-DUST COLLECTOR SIDE

LOWER LEFT ELEV.
LEFT REAR JACK
LEFT REAR AXLE
LOWER RIGHT ELEV.
RIGHT REAR JACK
RIGHT REAR AXLE
LEFT FRONT JACK
LEFT FRONT AXLE
RIGHT FRONT JACK
RIGHT FRONT AXLE
FRONT AXLE CENTER
UPPER LEFT ELEV.

UPPER LEFT SHEAVE
UPPER RIGHT SHEAVE
UPPER CAROUSEL
UPPER PIPE RACK
UPPER RIGHT ELEV.
RIGHT MAST PIVOT
LOWER RIGHT SHEAVE
RIGHT MAST LOCK
CAROUSEL ROLLER
ROTARY AIR SWIVEL
CAROUSEL LOCK
LOWER PIPE RACK
LOWER LEFT SHEAVE
LEFT MAST LOCK
LEFT MAST PIVOT
BOTTOM PLATE
NOTE: ROTATED 90 FOR CLARITY
Fig. 8-4a Manual Lube Bulkhead Locations
8-5
Service Points
ENGINE AIR FILTER
ENGINE COOLANT
FAN DRIVE
COMPRESSOR
AIR CLEANER
COMPRESSOR
OIL FILTER
COMPRESSOR AIR/OIL
SEPARATOR TANK
DRIVE SHAFT
ENCLOSURE
DIESEL ENGINE
FUEL FILL
PUMP DRIVE
CHARGE FILTER
DUST COLLECTOR
FILTERS
CHARGE FILTER
RETURN FILTERS
HYDRAULIC
OIL TANK
PRESSURE/VACUUM
FILTER
PIPE
CAROUSEL
WINDOW
WASHER
BOTTLE
Fig. 8-5 Service Points
8-6
Fig. 8-6 Service Points
A/C UNIT
HYDRAULIC OIL
FILLER PUMP
TRACK FINAL DRIVE
BATTERY BOX
ROTARY DRIVE
Service Points
8-7
LubricationGeneral
Recommended lubrication instructions provided herein are based upon normal operation, and should be varied in accordance with other than normal operating conditions.
After lubrication and filling, remove excess spills. Always keep fittings, caps and fill
plugs clean of foreign matter.
Equipment Lubrication
Determination of when oil changes are made, filters and filter elements are to be cleaned and/or replaced,
and lubrication of equipment is required, should be based on the severity of operation.
Equipment photo's and drawings have been included to show the general location of points and equipment which require scheduled and periodic lubrication. The lubrication charts list the various lube and check
points, filters and filter elements, and provides data such as quantities, types of lubricants recommended,
and the recommended frequency of lubrication.
Care of Lubrication Points

Before lubricating, or filling hydraulic fluids, the fittings, caps, and filler plugs should be thoroughly
cleaned to prevent contamination.
NOTE
8-8
For additional lubrication information, refer to vendor manuals provided with the drill.
Lubrication and Maintenance Chart

C/A = Check/Add if required
Interval
Service Point
Service Required
Lubricant Required 5
Capacity
Engine Oil
C/A (Cummins QST30)

C/A (Cummins QSK19)
C/A (Cat C27)
C/A (Cat C15)
C/A
Drain water
C/A (QST30 engine only)
C/A (QSK19 engine only)
C/A (C27 engine only)
C/A (C15 engine only)
C/A
C/A
15W-40 (factory fill)

Diesel Fuel 1
50/50 Anti-freeze/Water
Chevron AW MV ISO 32 3
Dexron III ATF (factory fill)
35 gal. (133 L)
16 gal. (60.6 L)
19 gal. (72 L)
10 gal. (38 L)
varies by model
23 gal. (85 L)
11.1 gal (42.2 L)
14.5 gal (55 L)
5.4 gal. (20.8 L)
223.5 gal. (846 L)
58 gal. (220 L)
C/A
C/A
C/A
Check Service Indicators
Check Service Indicators 4
Check/Clean
Lubricate
Check/Clean
Inspect Integrity/Damage
Check for leaks & loose bolts
Inspect
Check they are getting grease
Top Up
Top Up
Top Up
Dexron III ATF (factory fill)

Water/Anti-freeze
80W-90 Gear Oil
NLGI No. 2 Grease
NLGI No. 1 Grease

NLGI No. 2 Grease 9
Fuel Tank
Fuel/Water Separator
Engine Coolant 2
Daily
or
Each
Shift
Weekly
or
50 Hrs
Hydraulic Oil Tank

Separator Tank (low press)
Separator Tank (high press)
Water Tank (optional)
Pump Drive Gearcase
Air Cleaners
Oil Filters
Radiator & Coolers
Shock Sub & Air Swivel
Tracks, Rollers, Sprockets
Track Frames, Axles, Mounts
Mast & A-Frame
Cab Mountings
Deck & Surrounds
Rotary Head & Motor(s)
Pulldown/Hoist Ropes
Pulldown Sheaves
Grease Pump Lubricator
Pipe Thread Lubricator
DTH Hammer Reservoir 7
Fire Suppression System
Fire Extinguisher
Operating Controls
Walk Around Inspection
Cooler Fan
Hydraulic Filters
Coolant Filter (if equipped)
Separator Tank (low press)
Separator Tank (high press)
Compressor Oil Filter
Rotary Drive Gearbox
Water Pump (vertical)
Water Pump (horizontal)
Track Final Drive Gearbox 6
Charged
Charged/Secure
Check for correct function
Check for leaks, damage, etc
Rock Drill Oil - Grade 30
35 gal. (132.5 L)
varies by model
6.75 qt. (6.4 L)
as required
15 gal. (57 L)
Check/Torque mounting bolts

Initial Change, then every 500 hrs
C/A
Initial Change, then every 3 mnths
Dexron III ATF

Dexron III ATF
80W-90 Gear Oil

80W-90 Gear Oil
ISO 68
80W-90 Gear Oil
58 gal. (220 L)
35 gal. (132.5 L)
20 gal. (75.5 L)
1 qt. (.95 L)
42 oz. (1.26 L)
2.1 gal. (8 L)
PLUS ALL ITEMS LISTED IN DAILY SERVICE
8-9

Interval
Service Point
IInitial Change at 24 hours of winch

operation
Change
Change at 250 hours
Engine Oil & Filter
Replace
Engine Fuel Filter(s)
Replace
Engine Air Filter (primary)
Check
Engine Air Filter (safety)
Check/Refill/Test
Engine Coolant
Replace
Engine Coolant Filter
Check Condition/Test
Radiator Cap
Clean/Top Up
Batteries
Drain Water
Fuel Tank
Replace
Comp. Air Filter (primary)
Check
Comp. Air Filter (safety)
Drain Water
Comp. Receiver Tank
C/A Oil
Receiver Tank
Replace
Comp. Main Oil Filter
Comp. Control Cyl. Orifice (HP) Clean
Comp. Control Regulator (HP) Check/Adjust
Press. Control Regulators (HP) Check/Adjust
C/A
Pump Drive Gearbox (Cotta)
Drain & Replace Oil
Rotary Drive Gearbox
Check Pre-Load (0.0020.004 in.)
Rotary Drive Spindle
Check/Replace (shim as required)
Rotary Head Wearpads
Check, LP=150 PSI (10 bar)
Water Pump Pressure
HP=375400 PSI (2628 bar)
C/A
Water Pump Oil Level
Clean
Water Pump Strainer
Check
Water Pump Coupling
Check/Adjust
Air Conditioner Belt
Check/Adjust
Alternator Belt
10
Inspect/Lube
Mast Pivot Pins/Bushings
Hoist/Pulldown Ropes
Check/Adjust per Service Manual
Track Chains
Winch
150 to
250
Hrs
Service Required
Capacity
80W-90 Gear Oil
1/2 to 2 pints
(.24 to .95 L)

see daily
Water/Anti-Freeze 50/50 see daily
Distilled Water
Dexron III
80W-90 Gear Oil

6.75 qt. (6.4 L)
80W-90 Gear Oil
20 gal. (75.5 L)
see 50 hrs
NLGI No. 2 Grease
NLGI No. 2 Grease
see 50 hrs
ISO 68
42 oz. (1.26 L)
Dexron III ATF
see daily
PLUS ALL ITEMS LISTED IN DAILY & 50 HRS SERVICE

Water Pump (horizontal)
300
Hrs
Separator Tank8
Change Oil
(500 hrs if using special Cat oil)
Change Oil
PLUS ALL ITEMS LISTED IN DAILY/50/150250 HRS SERVICE
8-10

Interval Service Point
Hydraulic Fluid
Hydraulic Filters
Engine Air Filter (safety)
Engine Crankcase Breather
Comp. Control Air Filter
Comp. Air Filter (safety)
Air Filter Housings
Pump Drive Gearbox
Water Pump (vertical)
Water Injection Pump Strainer
Dust Collector
500
Hrs
Air Conditioner Filter

Winch
Rotary Drive Spindle
1000
Hrs or
Yearly
2000
Hrs
or
Two
Years
Service Required
Capacity
3
Initial Change, then every 1000 hrs Chevron AW MV ISO 32
223.5 gal. (846 L)
Replace
Replace
Check/Clean
Replace
Replace
Clean
Drain/Replace Oil
80W-90 Gear Oil
6.75 gal. (6.4 L)
Change Oil (every 3 months)
80W-90 Gear Oil
1 qt. (.95 L)
Replace
Check Timer Cycle
(3.2 sec. between pulses)

Check air pressure
(approx. 40 psi [2.8 bar])

Replace
Drain Gear Oil/Replace

4 pints (1.9 L)
80W-90 Gear Oil
Checkadjust as necessary
PLUS ALL ITEMS LISTED IN DAILY/150250/300 HRS

Track Final Drive Gearbox 6
Drain/Replace
Hydraulic Tank
Drain, Clean, Replace Oil
80W-90 Gear Oil

Chevron AW MV ISO 32
see daily
223.5 gal. (846 L)
Water/Anti-freeze 50/50
see daily
PLUS ALL ITEMS LISTED IN DAILY/150250/300/500 HRS

Comp. T-Tank Separator
Comp. Return Strainer
Engine Coolant
All Pump Pressure Settings
All Valve/Other Settings
Replace
Replace
Drain/Flush/Replace
PLUS ALL ITEMS IN DAILY/150250/300/500/1000 HRS
NOTES:
1.
No. 1-D or No. 2-D diesel fuels as listed in ASTM D975 are acceptable fuels.
2.
Distilled water or deionized water is recommended for use in engine cooling systems. Do not use hard water,
softened water that has been conditioned with salt or sea water. Use a 1:1 mixture of water/glycol for optimum performance.
3.
Chevron AW MV ISO 32 is the standard factory fill for hydraulic fluid. Other fluids may be used if they meet
the specifications listed in this section.
4.
Indicators may show change or by-pass when fluid is cold; reset and check again.
5.
For severe operating conditions (extreme cold or tropical), use appropriate viscosity of lubricants or use fully
synthetic lubricants as shown on the Cold Weather Lubricants chart is this section..
6.
Tropical conditions require initial change at 50 hours then every 250 hours.
7.
Optional for use with down-the-hole hammer.
8.
See compressor oil lubrication chart for alternate oils and change intervals.
9.
Lithium Base with 3% Molydbenum Disulfide.
10.
Replacement of the retaining pins is recommened whenever mast raise/lower cylinder is removed or replaced.
8-11
Lubricant Specifications
Hydraulic System
Selection of Hydraulic Oil
These selections assume "normal operating conditions" as expected in quarry or quarry-like operations.
Hydraulic oils meeting the following specifications will be acceptable for use in the drill. Machines are
factory filled with ISO 32 oil, unless specified otherwise when ordered. Consult manufacturer before switching to an oil of different viscosity.
CHEVRON AW MV or EQUAL
ISO Grade
15
32
46
68
100
CPS Number
232953
255678
255679
232952
232950
API Gravity
27.3
32.6
31.9
30.9
30.7
Viscosity, Kinematic
cSt at 40oC
cSt at 100oC
15.8
4.0
30.4
6.1
43.7
8.0
64.6
10.6
95.0
13.5
Viscosity, Saybolt
SUS at 100oF
SUS at 210oF
85.3
39.7
155
46.6
222
53.0
329
62.3
487
73.4
Viscosity Index
159
153
157
154
143
-54 (-65)
-48 (-54)
-42 (-44)
-42 (-44)
-39 (-38)
150 (302)
190 (374)
186 (367)
212 (414)
232 (450)
3000+
3000+
3000+
2000+
Pour Point,
oC (oF)
oC (oF),
Flash Point,
min.
Oxidation Life
ASTM D 943 hr.1
DO NOT use these products in high pressure systems in areas subject to fire hazard.
1
6000+ hours for IS0 32, 46 & 68 from the West Coast (Richmond, El Segundo and Willbridge).
NOTE
Diesel fuel or kerosene used as dilutants for cold weather operation are not recommended, as they are not sufficiently refined products. Do not use any fire resistant
fluids or non-petroleum oils without consulting the manufacturer.
Hydraulic Tank Capacity

Model
Capacity
Notes
MD6290
223.5 gal. (846 L)
Fluid level should be at the half-way point on the

sight gauge on the tank, when all cylinders are
fully extended.
MD6290
178 gal. (674 L)

Fluid level should be near the top of the sight
gauge, when all cylinders are fully retracted.
8-12
Compressor Lubrication
The chart below lists manufacturer approved oils.
Ambient
Temperature
Range oF (oC)
Lubricant
Change Interval Hours
-20 to 120 (-29 to 49)

10 to 110 (-12 to 43)
0 to 100 (-18 to 38)
0 to 100 (-18 to 38)
Sullair AWF
*D-A Torque Fluid
SAE 10W SE, SF, SG, CD
MIL-L-2104E 10W
1200
300
300
300
* Product of D-A Lubricant Company Inc.

Ambient
Temperature
Range oF (oC)
Lubricant
Change Interval Hours
-20 to 120 (-29 to 49)

-20 to 100 (-29 to 38)
-20 to 100 (-29 to 38)
0 to 100 (-18 to 38)
Sullair AWF
Dexron III ATF
Mobil SHC-624
Mobil SHC-626
250 to 300 PSIG

(1724 to 2068 kPa)
350 PSIG
(2413 kPa)
600
400
1200
1000
500
300
1000
800
Compressor Lubricant Specifications
Compressor oil should conform to the following specifications:

A. Non-Detergent Turbine or Hydraulic Type Oil
Viscosity @ 100oF
o
160200 SSU
Viscosity @ 0 F
11,000 SSU Maximum
Viscosity Index
90 Minimum
Pour Point F
o
20o Lower than minimum starting temperature
Flash Point F
400 Minimum
Rust Inhibitor
ASTM, D665-54 No Rust after 24 hours
Oxidation Inhibitor
ASTM, D949-54 Neutral No. 2.0 or less after 1000 hours
Anti-Foam Inhibitor
ASTM, D892-46T, 3 cycles stability nil.
B. Automatic Transmission Fluid (ATF)

Viscosity @ 100oF
184.2 SSU
Viscosity @ 210oF
49.1 SSU
Viscosity Index
150
Pour Point F
-40
Flash Point
390
C. Premium quality heavy-duty engine oil which meets the performance classification, letter
designation, SE or CD of SAE J183 or MIL-L-210.
Ambient Temperature
o
-10 F to 90 F
o
Above 90 F
Grade
SAE 10W
SAE 20W, 20
8-13
Final Drive Oil
Specifications
Use only the lubricants listed below or oil that meets the specifications in the chart on the next
page. Unit is filled at factory with 80W-90 gear oil, unless special request is made.
Oil must meet the specification listed on the final drive label.
o
o
o
o
For ambient temperatures of 50 F to 86 F (10 C to 30 C) use oil with a viscosity of
ISO-VG 150 or ISO-VG 220.
o
o
o
o
If ambient temperature is 14 F to 50 F (-10 C to +10 C) use an oil that is one viscosity class
lower.
o
o
o
o
If ambient temperature is 86 F to 122 F (30 C to +50 C) use an oil that is one viscosity class
higher.
Recommended Oils (per ISO Specifications)

ARAL
Degol BG 150
AVIA
Degol BG 220
Avilib RSX 150
BP
Energol GR-XP 150
CASTROL
Energol GR-XP 220

Alpha SP 150
CHEVRON
Alpha SP 220
NL Gear Compound 150
DEUTSCHE SHELL
NL Gear Compound 220

Omala EP 150
ESSO
Omala EP 220
Spartan EP 150
FINA
Spartan EP 220
Giran 150
FUCHS
GULF
Giran 220
Renep Compound 104
EP Lubricant Oil HP 150
MOBIL
EP Lubricant Oil HP 220

GF 629 (Mobilgear 629)
TEXACO
TOTAL
GF 630 (Mobilgear 630)

Meropa 150
Carter EP 150
Carter EP 220
8-14
Final Drive Oil (cont.)
Recommended Oils (per API/MIL Specifications)
For heavy duty gearbox operation use fully synthetic oils only.
8-15
Lubricating Grease
Use SAE designation MPGM which contains 35% Molybdenum disulfide conforming to MIL-M-7866
and a suitable corrosion inhibitor.
From 30 to 125oF (-1 to 51.6oC) ambient use NLGI No. 2
From 10 to 100oF (-12 to 37.7oC) ambient use NLGI No. 1
From -20 to 50oF (-289 to 10oC) ambient use NLGI No. 0
From -65 to 50oF (-54 to 10oC) ambient use Mobiltemp SHC 32 synthetic
Gear Lubricant
Use any oil which meets EP gear lubricant specification MIL-L-2105C or API-GL-5 of SAE J3083C.
Lubricant Grades:
Below -10oF (-23oC) ambient use 40W
Above -10oF (-23oC) and up to 100oF (37.8oC) ambient use 80W-90 or EP90
Above 100oF (37.8oC) ambient use 85W-140
Optional: Mobil SHC 635 synthetic or equivalent (all temperature ranges)
8-16
Engine Oil (Caterpillar)
Caterpillar Diesel Engine Oil (DEO) is the preferred oil for use in Caterpillar engines. If Caterpillar DEO
multigrade is not used, use only commercial oils that meet the following classifications.
API CH-4 multigrade oils and API CI-4 multigrade oils are acceptable if the requirements of Caterpillar's ECF-1 (Engine Crankcase Fluid-1 specification) are met. API CH-4 oils and API CI-4 oils
that have not met the requirements of ECF-1 specification may cause reduced engine life.
API CG-4 multigrade oils are acceptable for all Caterpillar diesel engines. When API CG-4 oils are
used, the oil drain interval should not exceed the standard oil drain interval for your engine.
Engine Oil Viscosities For Ambient Temperatures
Viscosity Grade
Min.
SAE 0W-20
Max.
Min.
Max.
-40
10
-40
50
SAE 0W-30
-40
30
-40
86
SAE 0W-40
-40
40
-40
104
SAE 5W-30
-30
30
-22
86
SAE 5W-40
-30
50
-22
122
SAE 10W-30
-18
40
104
SAE 10W-40
-18
50
122
SAE 15W-40
-9.5
50
15
122
Engine Oil (Cummins)

Cummins recommends the use of oil that meets American Petroleum Institute (API) performance categories of CF-4, CG-4, CF-4/SG, or CG-4/SH.
Special break-in oils are not recommended for new or rebuilt Cummins engines. Synthetic or partially
synthetic oils can not be used during break-in period. Use standard recommended petroleum based oil for
the first drain interval. After that, synthetic oils may be used.
8-17
Extreme Weather Lubricants

The following chart lists replacement lubricants that are recommended for the temperature ranges
shown, typically in extreme cold or tropical weather operating conditions. Consult manufacturer for proper
application.
Component Description
Operating Temperature
Range (Ambient)
Lubricant Required
Compressor
Mobil SHC 1024 Synthetic
Below -20 to 100oF (-28.9 to 37.8oC)
Engine Crankcase Oil
SAE 15W-40
5 to 120oF (-15 to 48.9oC)
Hydraulic Tank
Mobil Synthetic ATF
Below -10 to 100oF (-23 to 37.8oC)
Pump Drive Gearbox
Mobil Delvac 75W-90 Synthetic
-67 to 100oF (-55 to 37.8oC)
Rotary Head
-67 to 100oF (-55 to 37.8oC)
Undercarriage Final Drive
-67 to 100oF (-55 to 37.8oC)
General Grease
Lubrication Points
NLGI
MobilTemp SHC32
10 to 100oF (-12 to 37.8oC)

-65 to 50oF (-54 to 10oC)
Drill Rod Thread Grease
Mobil CM-L NLGI 1

Citgo Lithoplex CM1
-30 to 350oF (-34.4 to 177oC)
DTH Hammer Oiler
Rock Drill Oil
All
Note: These recommendations are based on each systems component manufacturer's recommendations, requirements and/or manufacturer's requirements for maximum and minimum oil viscosity values
during start-up and continuous operation.
8-18
Preventative Maintenance
In order for an operator to be sure his drill is ready for operation at any time, a regular program of preventive maintenance should be adopted. It is recommended that such a maintenance program be established
on the basis of the operator and/or maintenance personnel performing specific maintenance work during
various periods of equipment operations, at intervals during which the equipment will be idle, and during
extended periods of time when the equipment will be in storage.
When the drill is in continual, daily use, it is further recommended that a program of daily service requirements be established with preventive maintenance being performed on a "before operation", "during
operation", and "after operation" schedule.
NOTE
For additional preventive maintenance information, refer to vendor manuals provided

in the drill Service Manual.
Mast Trunnion Bolt Torque

Model
Dry Torque
Lube Torque
MD6290
1-1/4-7 UNC Gr8 (4)
1820 ft. lbs. (2468 Nm)
1360 ft. lbs. (1844 Nm)
MD6240
1-1/2-6 UNC Gr8 (4)
3160 ft. lbs. (4284 Nm)
2360 ft. lbs. (3200 Nm)
Fig. 8-7 Mast Trunion Assembly

Check Torque
NOTE
See additional bolted joint maintenance guidelines in this section.
8-19
Preventive Maintenance
Fig. 8-8 Hydraulic Tank Oil Level and

Temperature Gauge
Charge and Loop Filters

The charge and loop filters have an o-ring that
helps seal the filter bowl. If the bowl is leaking the
o-ring should be replaced. Do not continue to
tighten the bowl up, because this will not stop the
leak and will lead to damage of the bowl and filter
assembly. The o-ring should be changed every time
the filter is changed.
The filters have a differential indicator and a
bypass check valve to indicate when the filter is
blocking, allowing time to change the filters before
they are fully blocked.
Fig. 8-9 Hydraulic Loop FilterTwo filters

mounted on each side of mast "A" frame.
Fig. 8-10 Hydraulic Pump Charge FilterOne filter

mounted on each side of pump drive.
1. Head Assembly
2. Bowl
3. O-Ring, Bowl
4. Filter Element
5. O-Ring, Element
6. Indicator
7. O-Ring, Indicator
8. O-Ring, Indicator
9. Bleed Plug
10. O-Ring, Bleed Plug
8-20
Hydraulic System Maintenance
The hydraulic components of the drill are built for many years of trouble-free operation. Only one preventive maintenance step is necessary to ensure the expected life of the systemCLEANLINESS.
When dirty filters are indicated, change the filter as follows:
Clean the area around the filter covers to prevent dirt entering the filter housings.
Pull filters from the housings. Install new filter and install the covers making sure the cover O-ring is
in place.
Sight gauges are provided on the sides of the tank for

checking oil levels.
Oil level should be at the halfway point of the

sight gauge when all cylinders are extended.
A temperature gauge is also provided on the

sight gauge.
CLEANLINESS cannot be overstressed:
Use new oil only from previously unopened containers.
Clean all tank openings.
Fill tank through return filter.
Compressor Lubrication Procedure
Drain Receiver Condensate
Service Indicators
Fig. 8-11 Return Filters Mounted on Hydraulic Tank
In periods of cold weather and/or high humidity, crack receiver drain valve prior to start-up to
remove water. Close when oil appears.
Tabbed Nut
Check Oil Level

The oil level is checked at the sight glass with
machine level at each shift. The machine must be
shut down long enough to permit oil foam to settle
or check before start-up at the beginning of the
shift. Oil level should be at the center of the sight
glass.
Change Oil
Every 300 hours or as specified in compressor
lubrication chart. Use Dexron III ATF or consult
factory for specific recommendations if extremely
severe duty is encountered. Change oil filter element.
Lubricate control and linkage. Clean oil return line

strainer.
Blocked filter indicator will pop up red if the element needs changing.
If the filter bowl is leaking, the O-ring needs to be

changed. Flogging up the tabbed locking nut will
not stop the leak.
Fig. 8-12 Compressor Oil Filter
8-21
Preventative Maintenance
Winch Lubrication
Check oil level every 3 months or 500 operating hours whichever occurs first. Remove the large
plug located in the center of the drum support. Oil level should be at the bottom of this opening.
Gear housing should be drained and filled with new oil after the first 100 hours of operation. Then
oil should be changed every 1000 hours of winch operating time or every six (6) months, whichever
occurs first.
Remove and clean vent plug in solvent every time oil is changed. Vent plug must be kept clean and
free from obstructions.
The standard factory fill from Braden for the BG8 winch is Texaco Meropa150. Other oils may be
used if they meet the following specifications: Do not mix different kinds of oil.
AGMA 4EP or API GL-2 with ISO viscosity grade 150.
The following are recommended oils:

Texaco
Exxon
Mobil
Shell
Chevron
Meropa 150
Spartan EP 150
Mobilgear 629
Omala 150
American Industrial Oils 150
Meropa 220
Spartan EP 220
Mobilgear 630
Omala 220
American Industrial Oils 220
NOTE: All gearcases are factory filled with Mobillube SCH 75W-90 Synthetic gear lube for cold weather operation.
Water Pump (Cat Pump)

The Cat Pump, Model 1050 is factory filled with Mobil SHC 626. This is suitable for temperatures below
0oF (-17.8oC). Special oil is available from Cat Pump dealers. If another type oil is used, be sure it meets
the specifications for Cat Pumps.
Fill with oil to red dot in sight window on back of pump (Fig. 8-13).
Lubricate the wicks monthly with 2-3 drops of oil in each hole on top of the crankcase (Fig. 8-14).
DO NOT lubricate the wicks at initial start-up. Operate pump for 1015 minutes, then lubricate the
wicks. Use crankcase oil as lubricant.
Fig. 8-13 Cat Pump Oil Level Sight Window

(back of pump)
8-22
Fig. 8-14 Cat Pump Oil Filler Cap

and Wick Lubrication Points
Remove the radiator pressure cap slowly and only when the engine is cool or serious
burns could result.
Cooling SystemCummins
The engine's cooling system is designed to provide adequate cooling during all normal operating conditions. Engine overheating can become the primary cause for extensive repair work, lost operating time,
and possibly result in eventual complete engine failure. Cooling system maintenance should, therefore,
hold an important place in the drill maintenance program.
The engine cooling system is filled with a 50/50 mix of anti-freeze and water. Refer to engine operating
manuals for complete cooling system specifications and maintenance. The Cummins QST30 is equipped
with two coolant filters (Fig. 8-15). These are to be changed every 250 hours of operation. Cooling system
is to be drained, flushed, and refilled every 2 years, or 6000 hours of operation, whichever occurs first. Cummins recommends filling system with Fleetguard Compleat, a fully formulated anti-freeze which contains
supplemental coolant additive
Every 250 Hours: Change Coolant Filters

1.
Turn valve to OFF position, and remove filters.
2.
Clean mounting base and be sure old gasket is not stuck to it.
3.
Apply a thin film of oil to the gasket and install new filters. Screw filter on until gasket contacts
base, then tighten 1/2 to 3/4 turn by hand. Turn valve to ON position.
Fig. 8-15 Cummins QST30 Engineright side

1. On/Off Valve
2. Coolant Filters
Fig. 8-16 Engine Radiator
Cooling SystemCaterpillar
Caterpillar recommends the following coolant types:
PreferredCaterpillar Extended Life Coolant (ELC) or a commercial extended life coolant that
meets the Caterpillar EC-1 specification.
AcceptableCaterpillar Diesel Engine Antifreeze/Coolant (DEAC) or a commercial heavy-duty

coolant/antifreeze that meets ASTM D4985 or ASTM D5345 specifications.
8-23
Supplemental Coolant Additive (SCA)
Cummins recommends DCA4 as the supplemental coolant additive. DCA4 is compatible with all type
of coolant except Methoxy Propanol. Supplemental coolant additive prevents the buildup of corrosion and
scale deposits in the cooling system. The correct concentration is 1.5 units for each gallon (3.8 L) of coolant. Concentration must never drop below 1.2 units, nor exceed 3 units per gallon (3.8 L).
If coolant is added between drain intervals, the SCA concentration must be checked, and added, if
required. A coolant test kit no. CC2626 is available from Cummins dealers.
When the system is initially filled, the correct amount of liquid SCA is added to make 1.5 units of SCA
per gallon (3.8 L) of coolant. In this case, total system capacity is 71 gallons (269 L), so 47.3 SCA units are
required. When changing coolant filters at 250 hours, normally 4 SCA units will bring the system up to the
required amount. Filters contain SCA in crystal form that dissolves in the system. Filters come in 2, 4, 6,
8, 12, 15, and 23 SCA units. A filter is also available with no SCA units.
At each filter change, check the system with a Cummins coolant test kit. This kit contains strips, to dip
in the coolant that will determine the SCA level. If additional SCA is required, add liquid SCA to bring up to
correct concentration.
Air Cleaners
The air cleaner should be inspected periodically
to maintain engine and compressor protection and
maximum service life. These inspections should
include the following points:
1.
Inspect the air transfer duct between the air
cleaner and the engine to be sure all clamps
are tight, all flange joints are tight, and there
are no cracks in the ducting.
2.
Air cleaner mounting bolts and clamps must

be tight to hold the air cleaner securely.
3.
Check the dust cup to make sure it is sealing 360o around the air cleaner body.
4.
Vacuator valve must be in place, not inverted, and free from obstruction.
5.
Check for dents and damage to the air

cleaner which could mean a leak.
Fig. 8-17 Air Cleaner Assembly
Air Filter Elements

Replace air filter elements as required per maintenance schedule, or when indicated by pressure differential indicator on filter.
DO NOT clean filter element with high pressure air (30 PSI maximum). Advise replacement of filter element.
DO NOT start engine when the filter element(s) is removed from the air cleaner
NEVER attempt to clean the element by rapping it. Rapping the element will dent the
metal covering. The inner paper element will in turn rub this dent, causing the element to
puncture.
8-24
Track Final Drive Gearbox
Recommended Service for F130 Gearbox
Oil Change
1.
See Lubrication and Maintenance Chart in this section.
Oil Analysis
1.
Oil analysis should be performed on a regular basis (example: quarterly).
2.
Particle ppm levels should be compared to Warning Level Guidelines below and necessary actions
should be taken.
3.
Upon high Fe-Cr contamination levels, the sun gear/input shaft should be inspected for wear and
replaced as necessary. If the sun gear is ok, further internal gearbox inspection should be performed.
Sun Gear
1.
The sun gear/input shaft should be changed out upon initial wear indication.
2.
The sun gear/input shaft generally has the highest wear rate and needs to be replaced periodically
to prevent other gearbox component failures. It is suggested that a maintenance program should
consider replacing the sun gear at 6,0008,000 machine hours.
Warning Level Guidelines for Contamination and Wear Metals

Normal
Caution
Serious
Si (Silicon)
200 ppm
>400 ppm
>600 ppm
Fe (Iron)
500 ppm
>1500 ppm
>3000 ppm
Cu (Copper)
80 ppm
>160 ppm
>240 ppm
Cr (Chromium)
10 ppm
>15 ppm
>25 ppm
Al (Aluminum)
50 ppm
>100 ppm
>150 ppm
Caution: In this case the gearbox must be kept under control.

Serious: In this case the gearbox manufacturer suggests changing the oil and repeating the tests after
a short period of work. If the values are still serious, the manufacturer suggests rebuilding or
replacing the gearbox.
These values are only guidelines and can be modified due to specific applications.
Notes:
Si-Al Contamination also from external sources
Fe-Cr Wear metals by gears and bearings
''Cu Wear metal be brake discs
8-25
Preventative MaintenanceMast Pivot

Mast Pivot Shaft Inspection and Repair Procedure
A visual inspection should be performed with the
mast in the horizontal position by removing the trunnion
cap and bushing. Clean the shaft and shoulder radius
free of lubricant and inspect visually for any indication
of cracking in the radius. Perform visual inspection at
the mid point of non-destructive test (NDT) interval #1
and #2.
Intervals for magnetic particle inspection will be in
accordance with AS1171 or a dye penetrant test, post
repair. Same inspection intervals apply to new machines
or replaced shafts. Intervals are operating hours on
shaft.
SHAFT DETAIL
MD6240
Interval #1
<15,000 Hours
Inspect every 3000 Hours
Interval #2
>15,000 Hours but <25,000 Hours
MD6290/MD6420
Interval #1
Interval #3
<15,000 Hours
>25,000 Hours
Interval #2
SHAFT DETAIL
RO.25 ORIGINAL RADIUS
>15,000 Hours but <30,000 Hours

Interval #3
RO.38 MAXIMUM RADIUS
30 MAX ANGLE
>30,000 Hours
Approved Pivot Shaft Repair Procedure

Fatigue cracking in the A-Frame pivot shaft radius of rotary blashole drills may be repaired by completely
grinding out cracks up to a maximum depth of 0.12 in. or 3mm. This approved repair method is intended
only to extend the service life of a shaft that is in the first stages of fatigue where the cracking is not extensive and is just becoming visible. Shafts with more extensive cracking, i.e. crack depths exceeding 0.12 in.
(3mm) should be replaced by removing the shaft from the A-Frame structure and rewelding a new shaft in
place in accordance with the factory repair procedure.
Unapproved Repair
No grinding that undercuts the diameter of the bearing
surface is allowed. Cracking outside of the hatched area
is not repairable by grinding and requires replacement of
the shaft. All known fatigue cracking has occured in the
hatched area.
8-26
NON-REPAIRABLE
FATIGUE CRACK
Rev A
Preventive MaintenanceWeld Inspection
8-27
Preventative MaintenanceBolted Joints

Bolted Joint Maintenance for Rotary Drills
Introduction
To properly maintain bolted joints, some technical understanding of threaded fasteners will be helpful.
Threaded fasteners are often taken for granted and are seldom viewed as the highly engineered
items that they are. Their proper selection and proper joint design are critical to ensure structures and
machine elements perform as intended. This is a detailed subject and what is intended here, is to
present a few highlights to assist with good maintenance practices for rotary drills. This guide is not
all inclusive.
Proper Bolt Tension
Proper Preload or residual tension in a tightened bolt means more to assembly strength than
actual bolt strength. In a bolted joint, a bolt torqued to its proper load level can resist a maximum
amount of external load without loosening. Ensuring that the intended preload is achieved and
maintained is the objective of this guide.
These rotary drills typically use SAE guidelines which are commonly recognized throughout most
industries, for non-permanent connections. All bolted joints in the drills are non-permanent joints
(bolted joints of a bridge or building structure would be considered permanent joints.) Standard SAE
torque specifications for bolt tensioning recommends that bolts be pre-tensioned to 75% of yield
strength or Proof Load. Bolts torqued to this level are re-useable if in good condition otherwise.
There are a couple of exceptions in these drills where bolts are tightened beyond this value, and
these will be identified. See the following chart for recommended torque values for different bolt sizes.
Reasons Properly Tensioned Bolts Loose their Preload and Require Maintenance
x Surface Degradation
Surfaces under bolt heads can degrade due to creep failure, embedment, high bearing stress,
corrosion or a combination of these. These rotary drills use hardened washers in many situations to
help prevent surfaces from degrading. Critical joints may use Nordlock washers which are a
hardened, zinc coated, two-piece serrated washer incorporating inclined planes at the mating
boundary of the two pieces. To loosen a bolt using this locking device, the bolt must be significantly
stretched. Critical bolted joints are identified in the Critical Fastener ID & Inspection Schedule
drawing in this manual. Joints that are assembled with Nordlock washers and hardened washers are
less likely to experience surface degradation, as the hardness of the washer is close to the hardness
of the fastener and is harder than the surface of most nuts used in these drill assemblies.
x Corrosion
Most critical bolted joints on these rotary drills contain components that are made from steel. Most
bolts used are also steel, and therefore susceptible to rusting. Water is a small molecule and can find
its way into the smallest spaces to attack the surfaces of a bolted joint and the bolt head, body and
threads. We recommend that all critical fasteners be lubricated using a lubricant that contains
Molybdenum Disulfide (NLGI 2 Molycoat or Never-Seize are readily available Worldwide. Good
quality NLGI 2 grease can be substituted if a Moly product is not available at the time of service.)
8-28
Preventive MaintenanceBolted Joints

x Vibratory Overload
Abusive, unusual or unforeseen loads can cause bolted joint separation. This can result in the
loosening of bolts, which in turn can cause bolt fatigue failure. Bolt fatigue will generally result in a
fracture surface and ultimately failure at the first engaged thread of the bolt or sometimes in the fillet
under the bolt head. Loose bolts can also fail quickly in fatigue. As an example, tests conducted by a
bolt manufacturer indicated that a bolt tightened to 1420 lb tension and stressed cyclically to 9215 lb
failed after 5960 load cycles. Identical bolts tightened to 8420 lb and stressed to the same 9215 lb
survived 4.65 million cycles before failure. If the bolts had been tightened beyond 9215 lb, it would
have been impractical to cycle them to failure.
x Thermal Relaxation
Bolted joints exposed to high temperatures or thermal cycling have a tendency relax or lose bolt
tension over time, due to stress creep. Since pre-loading stretches bolts, and only stretches them a
few thousandths of an inch. It is easy to imagine that a bolt heated to the operating temperature limits
of an air compressor could increase the plasticity of the bolt material, allowing it to lose some of its
initial loading. Bolted joints of a new machine that are subjected to high heat should be checked and
re-torqued to specification after the first 500 hours of operation.
Critical Bolted Joint Maintenance
Critical bolted joints are those joints which hold major structures together or hold overhead loads.
Failure of these joints could endanger personnel or seriously damage equipment. As stated earlier,
these are identified in the drawing Critical Fastener ID & Inspection Schedule. We recommend that
critical bolted joints of drills should be checked for proper torque every 120 days or 2000
operating hours for machines that have less than 10,000 operating hours, and every 90 days or
1500 operating hours for machines that have greater than 10,000 operating hours.
If a bolt is found to be loose (less than 90% of specified torque value), it should be removed and
replaced. If the joint contains more than one bolt, all bolts in the joint should be replaced. The joint
mating surfaces and bolts should be inspected for signs of corrosion, surface degradation, and the
presence of hardened washers or Nordlock washers. Joints with Nordlock washers require the
replacement of the washers as well. Hardened washers can generally be reused as long as the
washer is undamaged. The new bolts should be lubricated with NLGI2 molycoat grease and torqued
to the proper specification. Bolts should be replaced with the same grade bolt that was originally in
the assembly. These drills primarily use SAE Grade 5 and Grade 8 bolts. These are identified by the
markings on the head of the bolt. Chart #1 of the drawing for each machine titled Critical Fastener
Torque Values graphically depicts the standard indentifying bolt markings.
Bolts in critical joints should also be removed and visually inspected for corrosion and relubricate every 2.5 years or 15,000 hours of operation. If bolts are not damaged, they maybe reinstalled and returned to service. Any damaged or corroded bolts should be discarded and replaced.
In addition, bolts in critical joint should be replaced every 5 years or 30,000 hours of operation,
regardless of apparent condition.
Other Bolt Maintenance
All bolts contained in these drills are subject to the same topics described above, but generally do not
have the same degree of risk involved should a bolt failure occur. Every machine should have a
walk-around inspection performed at the beginning of each operating shift, which includes looking
for loose hardware. Other significant bolted joints include all pressurized fittings, flange connections
and all bolted pin retainer/keeper plate bolts. All machine bolts should be inspected for proper torque
specification annually at a minimum.
8-29
8-30
LESS THAN 10,000 HOURS

VERIFY EVERY 120 DAYS OR 2000 HRS
REPLACE EVERY 5 YEARS OR 30000 HRS
INSPECT AND RE-LUBRICATE OR REPLACE

IF DAMAGED EVERY 2.5 YEARS OR 15000 HRS
GREATER THAN 10,000 HOURS

VERIFY EVERY 90 DAYS OR 1500 HRS
MACHINE SERVICE HOURS:
RECOMMENDED INTERVALS FOR PRE-LOAD VALIDATION BY VERIFYING FASTENER TORQUE

RECOMMENDED INTERVALS FOR VISUAL INSPECTION AND RE-LUBRICATION
RECOMMENDED INTERVALS FOR REPLACEMENT
A CURSORY VISUAL INSPECTION SHOULD BE PERFORMED BY THE OPERATOR AT THE

START OF EACH SHIFT.
SEE MACHINE PARTS BOOK FOR PART NUMBERS

OF SPECIFIC FASTNERS, WASHERS AND NUTS.
SEE BOLTED JOINT MAINTENANCE IN THIS MANUAL FOR ADDITIONAL

INFORMATION CONCERNING BOTH GENERAL AND CRITICAL FASTENERS.
WINCH MOUNTING FASTENERS
ROTARY HEAD MOUNTING FASTENERS

ROTARY HEAD WEAR PAD MOUNTING FASTENERS
LEVELING JACK CAP FASTENERS
REPLACEMENT OF THE RETAINING PINS IS

RECOMMENED WHENEVER MAST RAISE/LOWER
CYLINDER IS REMOVED OR REPLACED.
UNDERCARRIAGE MAIN AXLE FASTENERS
AFRAME PIVOT CAP FASTENERS

MAST PIVOT CAP FASTENERS
MAST RAISE/LOWER HYDRAULIC CYLINDER

PIN RETAINER FASTENERS
CRITICAL FASTENER ID & INSPECTION SCHEDULE

Standard Torque Values
SAE Recommended Torque Values
SAE Grade 5
Tightening Torque
SAE Grade 8
Tightening Torque
Size
Dry K=.2
(Ft lb)
Lub K=.15
(Ft lb)
Dry K=.2
(Ft lb)
Lub K=.15
(Ft lb)
3/8-16 UNC
3/8-24 UNF
30
35
23
25
45
50
35
35
7/16-14 UNC
7/16-20 UNF
50
55
35
40
70
80
55
60
1/2-13 UNC
1/2-20 UNF
75
90
55
65
110
120
80
90
5/8-11 UNC
5/8-18 UNF
150
170
110
130
220
240
170
180
3/4-10 UNC
3/4-16 UNC
260
300
200
220
380
420
280
320
7/8-9 UNC
7/8-14 UNF
430
470
320
350
600
660
460
550
1-8 UNC
1-12 UNF
640
700
480
530
900
1000
680
740
1-1/8-7 UNC
1-1/812 UNF
800
880
600
660
1280
1440
960
1080
1-1/4-7 UNC
1-1/4-12 UNF
1120
1240
840
920
1820
2000
1360
1500
1-1/2-6 UNC
1-1/2-12 UNF
1940
2200
1460
1640
3160
3560
2360
2660
8-31
8-32
1 - 8UNC GRD8
680 FT LBS LUBRICATED
SEE MACHINE PARTS BOOK FOR PART

NUMBERS OF SPECIFIC FASTENERS,
WASHERS AND NUTS.
LUBRICATE BOLTS WITH 3% MOLY NLGI2

EXTREME PRESSURE GREASE, P/N 966825
OR EQUIVALENT.
NOTES
5/8-11UNC GRD5
NOTE "NORDLOCK"
WASHERS
NOTE "NORDLOCK"
WASHERS
1-1/2 - 6UNC GRADE8

1/2 -13UNC GRD5

1/2 -13UNC GRD5

NOTE HARDENED
WASHERS
3/4 - 10UNC GRD5

(.85 PROOF LOAD)
NOTE "NORDLOCK"
WASHERS
NOTE "NORDLOCK"
WASHERS



1/2 - 13UNC BRASS

55 FT LBS (DO NOT LUBRICATE)
USE LOCTITE
NOTE "NORDLOCK" WASHERS
3/4 - 10UNC GRD8

Critical Fastener Torque ValuesMD6240
1 - 8UNC GRD8
1-1/4 - 7UNC GRADE8

SEE MACHINE PARTS BOOK FOR PART

NUMBERS OF SPECIFIC FASTENERS,
WASHERS AND NUTS.
LUBRICATE BOLTS WITH 3% MOLY NLGI2

EXTREME PRESSURE GREASE, P/N 966825
OR EQUIVALENT.
NOTES
5/8-11UNC GRD5
NOTE "NORDLOCK"
WASHERS
NOTE "NORDLOCK"
WASHERS
NOTE HARDENED
WASHERS
3/4 - 10UNC GRD5

(.85 PROOF LOAD)
3/8 -16UNC GRD5

1/2 -13UNC GRD5



1/2 - 13UNC BRASS

55 FT LBS (DO NOT LUBRICATE)
USE LOCTITE
3/4 - 10UNC GRD8

Critical Fastener Torque ValuesMD6290
8-33
Electrical System
Be sure battery is filled and kept charged. A discharged battery will freeze at much higher temperatures
than a fully-charged battery.
Battery terminals should be kept clean and tight for dependable operation.
See engine manual for engine electronics and diagnostic codes for electronic engines.
Extended Machine Shutdown

If machine is to be shut down for a long period of time (more than 30 days), there are certain precautions that should be followed to minimize the possibility of damage to the machine.
1.
Position the machine in a safe place on level and solid ground. Do not park close to a high wall where
the machine would be in danger of rock fall or slides. Do not park in an area prone to flooding. Extend
the jacks to contact the ground, but the tracks should also be in contact with ground.
2.
If freezing temperatures are expected, be sure cooling system has adequate anti-freeze to protect
system from freezing temperatures.
3.
Check all fluid levels, keep fuel tank full to avoid condensation.
4.
Follow pre-start checks in Section 4 before starting machine. Make walk around inspection of machine.
5.
Start the machine at least once per month. Allow system to warm up and cycle all hydraulic cylinders to their full stroke and back. Follow proper shutdown procedures, allowing engine to idle for at
least five minutes before shutdown.
Scheduled Oil Sampling Analysis

The manufacturer recommends that scheduled oil sampling be taken at regular intervals. This will
maintain all warranty requirements and monitor condition of component wear in the system.
Oil sampling must be carried out at regular intervals to serve as an effective indicator for component
wear. Intermittent oil sampling does not allow a wear pattern to be established. Samples should be taken
from the following components.
Hydraulic Oil
Compressor Oil
Engine Oil
Rotary Gearbox and Pump Drive Gearbox Oil
Sampling Criteria
Recommended interval for oil samples is every 200 hours.
Take samples when oil is warm and well mixed to assure an accurate reading.
A proper oil analysis should include the following three elements:

1. Wear Analysis
2. Chemical and Physical Tests
3. Oil Condition Analysis
8-34
Drill Stem Thread Lubricator

Description and Adjustments
The drill can be equipped with an optional automatic drill string thread greasing system. The system
uses an air powered grease pump attached to a 35 lb. (15.9 kg.) grease container. The system is activated
by a switch on the drill control console, and the pump delivers grease to the nozzle mounted adjacent to
the drill stem.
Air supply is filtered, lubricated and regulated by the filter/regulator/lubricator mounted on the left rear
jack housing. Normal pressure setting is 80 PSI (5.5 bar). See Section 10 of the Service Manual for component servcie information.
Thread Lube Pump
Thread Lube Pump Regulation
Fig. 8-18 Drill Stem thread Lubricator System

Lubricator
Water Trap
8-35
Metric Conversions
METRIC CONVERSION TABLE
English to Metric
Metric to English
LINEAR
inches (in.)
feet (ft.)
miles (mi.)
X 25.4
X 0.3048
X 1.6093
= millimeters (mm)
= meters (m)
= kilometers (km)
millimeters (mm)
meters (m)
kilometers (km)
inches2 (sq.in.)
feet2 (sq.ft.)
X 645.15
X 0.0929
= millimeters 2 (mm 2)
= meters2 (m 2)
inches3 (cu.in.)
quarts (qts.)
gallons (gal.)
inches3 (cu.in.)
feet3 (cu.ft.)
feet3 (cu.ft.)
fluid ounce (fl.oz.)
X
X
X
X
X
X
X
= liters (l)
= liters (l)
= liters (l)
= centimeters3 (cc)
= liters (l)
= meters3 (m 3)
= millileters (ml)
X 0.3937
X 3.281
X 0.6214
= inches (in.)
= feet (ft.)
= miles (mi.)
AREA
millimeters 2 (mm 2)
meters2 (m 2)
X 0.000155 = inches2 (sq.in.)

= feet 2 (sq.ft.)
X 10.764
VOLUME
0.01639
0.94635
3.7854
16.39
28.317
0.02832
29.57
liters (l)
liters (l)
liters (l)
centimeters3 (cc)
liters (l)
meters3 (m3)
milliliters (ml)
X
X
X
X
X
X
X
61.024
1.0567
0.2642
0.06102
0.03531
35.315
0.03381
=
=
=
=
=
=
=
inches3 (cu.in.)
quarts (qts.)
gallon (gal.)
inches3 (cu.in.)
feet 3 (cu.ft.)
feet 3 (cu.ft.)
fluid ounce (fl.oz.)
X
X
X
X
X
0.03527
2.2046
0.001102
1.1023
0.000984
=
=
=
=
=
ounces (oz.)
pounds (lbs.)
tons (2000 lbs.)
tons (2000 lbs.)
tons (long) (2240 lbs.)
X
X
X
X
X
X
0.2961
0.145
14.22
14.5
4.0193
0.01
= inches Hg (60oF)
= pounds/sq.in. (PSI)
o
= inches H2O (60 F)
= bars
MASS
ounces (oz.)
pounds (lbs.)
tons (2000 lbs.)
tons (2000 lbs.)
tons (long) (2240 lbs.)
X
X
X
X
X
28.35
0.4536
907.18
0.90718
1013.05
= grams (g)
= kilograms (kg)
= kilograms (kg)
= metric tons (t)
= kilograms (kg)
grams (g)
kilograms (kg)
kilograms (kg)
metric tons (t)
kilograms (kg)
PRESSURE
inches Hg (60 F)
pounds/sq.in. (PSI)
pounds/sq.in. (PSI)
pounds/sq.in. (PSI)
o
inches H2O (60 F)
bars
X
X
X
X
X
X
horsepower (hp)
ft.-lbs./min.
X 0.746
X 0.0226
3600
6.895
0.0703
0.069
0.2488
100
= kilopascals (kPa)
= kilopascals (kPa)
= kilograms/sq.cm. (kg/cm 2)
= bars
= kilopascals (kPa)
= kilopascals (kPa)
kilopascals (kPa)
kilopascals (kPa)
kilograms/sq.cm. (kg/cm2)
bars
kilopascals (kPa)
kilopascals (kPa)
POWER
= kilowatts (kW)
= watts (W)
kilowatts (kW)
watts (W)
X 1.34
X 44.25
= horsepower (hp)
= ft.-lbs./min.
X 8.851
X 0.7376
X 7.233
= pound-inches (in.lbs.)
= pound-feet (ft.-lbs.)
= pound-feet (ft.-lbs.)
X 0.6214
X 3.281
X 3.281
= miles/hour (m/h)
= feet/second (ft./sec.)
= feet/minute (ft./min.)
TORQUE
pound-inches (in.-lbs.) X 0.11298
pound-feet (ft.-lbs.)
X 1.3558
pound-feet (ft.-lbs.)
X .1383
= newton-meters (N-m)
= newton-meters (N-m)
= kilograms/meter (kg-m)
miles/hour (m/h)
feet/second (ft./sec.)
feet/minute (ft./min.)
= kilometers/hour (km/hr)
= meter/second (m/s)
= meter/minute (m/min)
newton-meters (N-m)
newton-meters (N-m)
kilogram/meter (kg-m)
VELOCITY
X 0.11298
X 0.3048
X 0.3048
kilometers/hour (km/hr)
meters/second (m/s)
meters/minute (m/min)
TEMPERATURE
o
Celsius = 0.556 ( F - 32)

o
Fahrenheit = (1.8oC) + 32
COMMON METRIC PREFIXES

mega
kilo
hecto
deka
8-36
(M)
(k)
(h)
(da)
=
=
=
=
1,000,000 or 106
1,000 or 103
100 or 102
10 or 101
deci
centi
milli
micro
(d)
(c)
(m)
(m)
=
=
=
=
0.1 or 10-1
0.01 or 10-2
0.001 or 10-3
0.000.001 or 10-6
Torque Values for Split Flange Connections

The following chart provides the tightening torques for split flange connections used in hydraulic systems.
Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then torque evenly.
NOTE
Over-torquing bolts will damage the flanges and/or bolts, which may cause leakage.
Bolt Torque
Flange Size
in Inches (*)
1/2
3/4
1
1-1/4
1-1/2
2
2-1/2
3
3-1/2
Bolt Size
in Inches
5/16
3/8
3/8
7/16
1/2
1/2
1/2
5/8
5/8
Newton Meter
(Nm)
2024
3037
3747
4761
6279
7588
107123
187203
159180
Pound-Force/Foot
(ft. lb.)
1518
2227
2735
3545
4658
5565
7991
138150
117133
(*) Inside diameter of hydraulic tube or hose fitting.
8-37
Torque Values for Hydraulic Tubes & Fittings

O-Rings Boss Plugs
and Swivel Nuts
JIC 37o Seat
Tube Nuts
for 37o Flared Fittings
Torque
Torque
Size
Tubing
O.D.
in Inches
Thread
Size
in Inches
Newton
Meter
(Nm)
PoundForce/
Foot
(ft. lb.)
Newton
Meter
(Nm)
PoundForce/Foot
(ft. lb.)
1/4
7/16-20
1427
1020
814
610
5/16
1/2-20
2034
1525
1420
1015
3/8
9/16-18
3447
2535
2027
1520
1/2
3/4-16
5475
4055
3441
2530
10
5/8
7/8-14
75102
5575
4754
3540
12
3/4
1-1/16-12
102129
7595
8195
6070
14
7/8
1-3/16-12
129156
95115
95108
7080
16
1-5/16-12
156197
115145
108122
8090
20
1-1/4
1-5/8-12
203244
150180
129156
95115
24
1-1/2
1-7/8-12
271339
200250
163190
120140
32
2-1/2-12
407475
300350
339407
250300
NOTES:
1. Above Torque figures are recommended for plain, cadmium or zinc plated fittings, dry or wet installations.
2. Swivel nuts either swaged or braxed.
3. These torques are not recommended for tubes with wall thickness of 0.89 mm (0.035 in.) or less.
8-38
Maintenance Record
DATE
HOUR METER
MAINTENANCE PERFORMED
WORK
WORK
PERFORMED AUTHORIZED
BY
BY
8-39
Maintenance Record
DATE
8-40
HOUR METER
WORK
WORK
BY
BY
Maintenance Record
DATE
HOUR METER
WORK
WORK
BY
BY
8-41
Maintenance Record
DATE
8-42
HOUR METER
WORK
WORK
BY
BY
2012 Caterpillar All Rights Reserved. CAT, CATERPILLAR, their respective logos, Caterpillar Yellow,
the Power Edge trade dress as well as corporate and product identity used herein, are trademarks of
Caterpillar and may not be used without permission.
Printed in U.S.A.

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February 2012

PARTS ORDERING AND PRODUCT SUPPORT

IDENTIFICATION OF THE MACHINE

PART NUMBER AND DESCRIPTION

PRODUCT SERVICE AND WARRANTY

Caterpillar Global Mining LLC

Before Starting Engine, Study Operators Manual

Drill Model : ___________________________________

OPERATOR CONTROLS ...................................................................SECTION 3

OPERATING INSTRUCTIONS ...........................................................SECTION 4

DRILLING PRACTICES ......................................................................SECTION 5

MACHINE TRANSPORT ..................................................................SECTION 6

OPTIONS AND ACCESSORIES.........................................................SECTION 7

LUBRICATION AND PREVENTATIVE MAINTENANCE ....................SECTION 8

Up to 22,680 kg (50,000 lb);

Rated hoist capacity

Up to 21,364 kg (47,100 lb)

0-42.9 m/min (0-141 fpm)

0-44.8 m/min (0-147 fpm)

Pull-down cylinder stroke

513.08 cm (202 in) for 30 ft configuration

Head travel (30 foot config)

1,026.16 cm (404 in)

Pull-down cylinder stroke

589.28 cm (232 in) for 35 ft configuration

Head travel (35 foot config)

1,178.56 cm (464 in)

Head travel (11 m config)

1,249.68 cm (492 in)

Radiator-CAC-Oil Cooler Assembly

139.70 cm (55 in)

269.24 cm (106 in)

121.92 cm (48 in) diameter; 10 blades

Sealed top tank, pressure cap,

17.78 cm diameter (7 in)

12.70 cm diameter (5 in)

Nominal line tension

5 to 1 factor against working

Cable sheaves (cylinder)

40.64 cm OD (16 in)

Cable sheaves (top and bottom)

55.88 cm OD (22 in)

5.08 cm (2 in) diameter with roller bearing

Standard at bottom plate

63.5 mm (2.5 in) O-ring boss

Radiator-CAC-Oil Cooler Assembly

Rotary Drive System

12,880 Nm max (0-9,500 ft-lb)

165.01 cm (65 in) dual fan

138.7 kW (186 hp)

Main thrust bearing

289.56 cm (114 in) dual fan

Sealed deaeriation tank, pressure cap,

Performance ratings are based on 100% efficiency and on engineering

Radiator-CAC-Oil Cooler Assembly

Tier III; 485 hp or 535 hp, single, front-end mounted

269.24 cm (106 in)

Sealed-top tank, pressure cap,

41.28 mm O-ring boss (1.625 in)

Radiator-Coolant-Oil Cooler Assembly

Dry-type with safety element/STG 16

Air-to-oil cooler, thermostatically controlled