SKS Service - B 1-28-10 (426337 2nd Ed) PDF

Model SKS
Rotary Blasthole Drill

Service Manual
P/N 426337
2nd Edition
59.5844
19.4852
9.2949
19.2949
158
2.2500
Bucyrus Mining Equipment, Inc.

3501 S. FM Hwy 1417
Denison, Texas 75020
USA
PARTS ORDERING AND PRODUCT SUPPORT

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

Always furnish the Model Number and Serial Number when ordering parts. This 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 dimensioned sketch or return the part to be replaced, transportation charges
prepaid. Your cooperation in furnishing as much information as possible will assist us in
filling your orders correctly and in the shortest possible time.
SHIPMENT
Unless otherwise instructed, all shipments will be made via motor freight collect, freight
forwarder or UPS prepaid and charged on our invoice. Shipments cannot be made on
open account until your credit has been approved by our accounting department.
PARTS ORDERING
In North America Telephone 1-800-854-9030
or Telefax 1-800-582-6570
Telephone (903) 786-2981
Telefax (903) 786-6407
PRODUCT SERVICE AND WARRANTY

In North America Telephone 1-800-258-0009
Telephone (903) 786-2981
Telefax (903) 786-6408
Bucyrus Mining Equipment, Inc.

3501 S. FM Hwy 1417, Denison, TX 75020
www.bucyrus.com
2010 Bucyrus International, Inc.
All Rights Reserved
Introduction
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 Operator's Manual

* Read and understand the warnings and cautions shown in Section 1
* Practice All Safety Precautions
* Make Pre-Operations Check
* Learn Controls Before Operating
It is Owner/Operator's responsibility to understand and follow manufacturer's 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 Drill Delivered :
Dealer :
Customer :
Specifications are subject to change without notice.

Information contained in this manual was current at the time of printing.
1/28/10
Introduction
Contents
INTRODUCTION
SECTION 1....................................................................................................................SAFETY
SECTION 2...........................................................................OPERATOR'S CAB / CONTROLS
SECTION 3 ................................................................................... MAINFRAME / CRAWLERS
SECTION 4................................................................................ DRIVE TRAIN/COMPRESSOR
SECTION 5................................................................................... DUST CONTROL SYSTEMS
SECTION 6................................................................... MAST / ROTARY DRIVE / PIPE RACK
SECTION 7...........................................................................................HYDRAULIC SYSTEMS
SECTION 8................................................................................ ELECTRICAL COMPONENTS
SECTION 9......................................... LUBRICATION AND PREVENTATIVE MAINTENANCE
SECTION 10....................................................................................... OPTIONAL EQUIPMENT
ii
Introduction
Product Description
This manual contains detailed instructions, maintenance information, and technical data which the Operator will need in order to properly operate the SKS Series of Rotary Blasthole Drills, and to perform the
various maintenance services that are required for keeping the equipment in good working condition at all
times. Included herein are complete descriptions of each operating control and step-by-step instructions on
how to start, operate, and stop the equipment, and recommended Operator's maintenance procedures.
Intended Use
This machine and its approved attachments are specifically designed to drill blast holes for quarry, mining and construction applications. Use of this machine in any other way is prohibited and contrary to its
intended use.
Receiving and Inspection

Upon receipt of the machine, Owner/Operator is required to inspect the machine and all items listed on
the Warranty Registration/Delivery Service Report included with the machine, complete the report and
return to manufacturer within 15 days of the In Service date.
SKS Series of Blasthole Drills

Each rotary drill in the SKS line offers a wide range of hole diameter capabilites and drilling depths ensuring flexibility, versatility and productivity. SKS models available are described in Table i-1.
The SKS rotary drill is a crawler mounted drill rig, which consist of two (2) major assemblies:
1.
2.
Rotary Drill Assembly

Excavator Type Undercarriage (Crawlers)
The rotary drill assembly is made up of the engine package, compressor package, hydraulic system,
rotary drive, pull-down and hoisting system and drill pipe handling mechanism.
The crawlers are powered by two (2) hydrostatic motors. Each crawler has its own independent, variable
and reversible speed control, and is equipped with 29.5 inch (750 mm) wide triple cleated grousers.
Manual Contents
This manual is furnished with your rotary blasthole drill to acquaint you with the correct operating procedures and to provide the necessary daily equipment maintenance information required to maintain your
machine in a reasonable condition.
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 this machine, nor do they intend
to provide for every possible contingency that may be encountered in connection with the daily operation
or maintenance of this machine.
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.
Introduction
iii
Safety Stand Placement

SKSW AND SKSS
IF DURING MAINTENANCE MACHINE

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

NEVER SUPPORT THE MACHINE BY PLACING
SUPPORTS UNDER MEMBERS OF THE REAR DECK
OR COOLER SUPPORT DECK. THESE AREAS ARE
NOT STRUCTURALLY ROBUST AND ARE NOT INTENDED
TO SUPPORT THE ENTIRE MACHINE WEIGHT.
iv
Introduction
SKS Models
Table i-1 SKS Series Rotary Blashole Drills
MODEL
SKS-W
MAX
HOLE
DIA
(inch)
12 1/4
MAX
HOLE
DEPTH
(feet)
33.9 SP
210 MP
MAX
PULLDOWN
(lbs)
86,000
MAX
HOIST
(lbs)
86,000
COMPRESSOR
(cfm@psi)
2000 & 2400@100
1475@350 or 500
ENGINE
CAT C27 800 HP

Cummins QST30/C,Tier1&2
8501050 HP
SKS-13
12 1/4
44 SP
244 MP
84,101
43,745
2000 & 2400@100

1475@350 or 500
CAT C27 800 HP

8501050 HP
SKS-16
12 1/4
54 SP
104 MP
86,000
35,207
2000 & 2400@100

1475@350 or 500
CAT C27 800 HP

8501050 HP
SKSS-13
12 1/4
44 SP
244 MP
84,010
43,745
2000 & 2400@100

1475@350 or 500
8501050 HP
SKSS-16
12 1/4
54 SP
104 MP
86,000
35,207
2000 & 2400@100

1475@350 or 500
8501050 HP
SP Single Pass
MP Miltiple Pass
SKS General Arrangement

The following figures show the general arrangment and locations of major components of the various models of SKS rotary blasthole drills. Due to the variety of options offered, not all configurations are shown.
Introduction
SKS-W Component Locator
vi
Introduction
SKS-13 Component Locator
Introduction
vii
SKS-16 Component Locator
viii
Introduction
SKSS Component Locator
Introduction
ix
Notes
Introduction
Section 1
Safety
Maximum Wind Speed = 75 MPH (120.8 Km/h) at which time drilling must be
stopped, mast lowered and machine shutdown.
Safety
1-1
Hazard Classification
The Rotary Blasthole Drill is a heavy moving machine with a mast which raises vertically for drilling.
Like all moving objects and reach extending devices, there are potential hazards associated with its use.
These hazards will be minimized if the machine is properly operated, inspected and maintained. Operator's
must read this manual and have been trained to use the machine in an appropriate and safe manner.
Non-English speaking persons must have an interpreter explain all safety and operating procedures in this
manual. Should any questions arise concerning the maintenance or operation of the machine contact the
manufacturer at 1-800-258-0009.
Safety Alert Symbol

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

death or serious injury.
Red
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
Orange
Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
Yellow
Indicates a potentially hazardous situation which, if not avoided, may result in
property or equipment damage.
Blue
1-2
Safety
Overview of Potential Hazards

Potential Hazard
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.
1-3

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.
1-4
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
1-5
Safety Guidelines
Before Operation
Do study this manual and fully understand the controls.
Do be sure all safety guards are securely in place and all access doors are closed and locked.
Do wear safety helmet, glasses and hearing protection when operating or working on machine.
Do be sure all personnel are clear of the machine and work area before starting the engine or 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.
1-6
Safety
Safety Guidelines
Maintenance
Do be sure two people are present when performing service work, both being fully trained on the
safety issues. One person shall supervise from the operator's position and have immediate access
to an emergency stop in all situations. Visual, audible or verbal communication signals must be
established and understood by both persons.
Do be sure each person is adequately trained to perform service and maintenance procedures.
Do place a warning tag on starting controls to alert personnel that someone is working on the 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 1-1
Safety
1-7
Safety Sign List

Refer to Figures 1-1 and 1-2 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.
1-8
Safety
Safety Sign Locator
Fig. 1-1
Safety
1-9
Safety Sign Locator
Fig. 1-2
1-10
Safety
Safety Signs
WARNING
WARNING
Entanglement
Hazard
Rotating parts can
cause personal injury.
3500 lbs/
1587 kg
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
1-11
Safety Signs
DANGER
WARNING
Maintain required clearance.

Electrocution Hazard
Death or serious injury can result from contacting
electric power lines.
Always contact the electric power line owner.
The electric power shall be disconnected or the
power lines moved or insulated before machine
operations begin.
Fall Hazard
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
1-12
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
429426
Combustible gas can

cause severe injury
or death.
429426
Do not spray "High Energy"

starting aid into
compressor air inlet
or engine grid heaters.
429444
429444
Safety
1-13
Safety Signs (International)
429740
Flying Object & Spray Hazard (429740)
4 29712
429720
Fall HazardMast (429715)
Explosion/Burn Hazard (429720)
T104915
Fall Hazard (T104915)
429713
Explosion HazardEther (429713)
429705
Entanglement Hazard (429705)

1-14
Safety
3500 lbs/
1587 kg
429718
Crush HazardCarousel (429718)
429721
Crush HazardWinch (429721)
429715
Crush HazardMast (429715)
Safety
429719
Crush HazardRotary Head (429719)
1-15
429709
Electrocution Hazard (429719)
429722
Modification or Alter Hazard (429722)

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

429738

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

The following is a listing of the graphic symbols found on the cab control consoles and their basic 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
2-2
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
2-3
Control Console
Fig. 2-1 Operator Control Panel
NOTE
NOTE
1.
"PUSH" LEVERMove lever AWAY FROM OPERATOR

"PULL" LEVERMove lever TOWARDS OPERATOR
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 your
machine and your machine may have different controls than those shown. Consult
with manufacturer if you are 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 (Cat engines).
3.
Engine Diagnostic Lamp

Light flashes to indicate engine fault.
Refer to engine manual for fault codes and remedy.
2-4
Operator Controls
Control Console
4.
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. Machines equipped with "tram interlock" option have an indicator
light under the jack levers. When jacks are fully retracted, the green light comes on. If light is not
on, jacks are not fully retracted, and machine will not tram until jacks are fully retracted.
4a.
Right Rear Jack
4b.
Front Jacks
4c.
Left Rear Jack
5.
Mast Lever
Controls the lowering and raising of the mast.
Pull lever to raise mast.
Push lever to lower mast.
6.
Propel Levers
Controls the speed and the direction of the tracks.
Push levers to propel forward (radiator end).
Pull levers to propel in reverse (cab end).
6a.
Right Track Lever
6b.
Left Track Lever
7.
Rotation Lever
Controls rotary head speed and direction.
Push lever for forward rotation.
Pull lever for reverse rotation.
8.
Hoist/Pulldown System Lever

Controls the raising and lowering of the rotary head.
Push lever to raise the rotary head.
Pull lever to lower the rotary head.
Operator Controls
2-5
Control Console
Fig. 2-2 Instrument Panel
9.
Compressor Air Filter Indicator

Shows RED when filter element needs to be changed. Indicates differential pressure across filter
element.
10.
Engine Air Filter Indicator

Shows RED when filter element needs to be changed. Indicates differential pressure across filter
element.
11.
Rotation/Left Track Pressure

Gauge indicates hydraulic pressure required to rotate the drill string and when in propel mode,
indicates pressure to left track motor.
Maximum pressure 5000 PSI (344.7 bar). Avoid stalling the rotary head for extended
periods.
12.
Rotary Head Tachometer (Optional)

Gives digital reading of rotary drive RPM.
13.
Pulldown Pressure
Gauge indicates hydraulic pressure at feed cylinder.
Maximum pressure 5000 PSI (345 bar). Higher pressures may cause the machine to tip.
2-6
Operator Controls
Control Console
14.
Drilling Air Pressure

Gauge indicates the air pressure in the drilling air line and receiver tank.
15.
Hydraulic System Pressure

Indicates auxiliary pump pressure.
16.
Compressor Discharge Temperature

Gauge indicates the temperature of the compressor discharge air.
17.
Engine Coolant Temperature

Gauge indicates the temperature of the engine coolant.
18.
Engine Tachometer
Gauge indicates engine revolutions per minute.
19.
Engine Oil Pressure

Gauge indicates engine oil pressure.
20.
Engine Hourmeter
Meter records total engine hours.
21.
Drill Hourmeter
Meter records actual drilling hours.
22.
Engine Stop (optional)
23.
Ether Injection (optional)

Aids in starting cold engine.
(a) Press for 3 seconds.
(b) Release to discharge.
(c) Wait 3 seconds to start engine.
24.
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.
25.
Voltage
Gauge indicates voltage output of the electrical charging system.
26.
Fuel Level
Gauge indicates fuel level in tank.
Operator Controls
2-7
Control Console
Fig. 2-3 Instrument/Control Panel
27.
Compressor Start-Run Valve, Low Pressure Machines (optional)

When starting machine, valve should be in the "Start" position and selector #28 in low position
(if used) so compressor is unloaded or in low pressure mode. When machine is warmed up, turn
valve to "Run" position.
28.
Compressor Start-Run Valve, High Pressure Machines (350/500 PSI) (optional)

When starting machine, valve should be in the "Low" position. When machine is warmed up, turn
valve to "Med" or "High" position as required.
29.
Compressor Low Oil Pressure Light used on High Pressure Machines

Light ON indicates low oil pressure at compressor bearings.
30.
Rotary Torque Control used on Low Pressure Machines or Holdback Control on High Pressure Machines
Turn knob clockwise to increase rotary torque.
2-8
Operator Controls
Control Console
31.
Test Switch (optional)

Turn switch ON to check filter indicator lights.
32.
Loop Filter Indicator Lights (4) (optional)

Light ON, indicates filter needs to be changed.
33.
Charge Filter Indicator Lights (2) (optional)

34.
Main Hydraulic Return Filter Indicator Light (optional)

35.
Case Drain Filter Indicator Light (optional)

36.
Compressor Oil Filter Indicator Light (optional)

37.
10 AMP Circuit BreakerAir Conditioner
38.
15 AMP Circuit BreakerHeater
Operator Controls
2-9
Control Console
NOTE
39.
Some machines have options for which additional switches are required to operate.
Generally, these functions are self-explanatory. In some cases switch functions may
not be in the location shown in fig. 2-4. Just be sure of the label or graphic symbol associated with the switch.
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.
40.
Oil Injection Light (optional)

Light comes on when oil injection pump for down-the-hole hammer is running.
2-10
Operator Controls
Control Console
41.
Not Used
42.
Drill Pipe LoaderSwing

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.
43.
Water Injection/Dust Collector

This switch is used to engage the water injection or dust collector systems to control drilling dust.
Push switch up to engage water injection system.
Push switch down to engage dust collector system.
44.
Hydraulically Operated Break-Out Wrench (HOBO)Swing

The break-out wrench is used to undo tight thread connections. This switch is used to swing the
break-out wrench into or away from the drill pipe.
Push and hold switch up to swing break-out wrench out.
Push and hold switch down to swing break-out wrench in.
45.
Drill Pipe Support

The drill pipe support is used to support the drill pipe in the center of the mast when using the drill
pipe loader for multiple pass drilling.
Push and hold switch up to engage drill pipe support. Red light will come on.
Push and hold switch down to disengage drill pipe support. Red light will go out.
46.
Hydraulically Operated Break-Out Wrench (HOBO)Clamp

The break-out wrench is used to undo tight thread connections. This switch is used to clamp and
unclamp the break-out wrench and to turn the wrench.
Push and hold switch right to disengage (open) break-out and unclamp wrench.
Push and hold switch left to clamp wrench and engage (close) break-out.
47.
Remote Tram (optional)

When switch is toward pendant symbol, machine can be trammed using remote pendant control.
48.
Viewing Hatch
Push switch DOWN to open viewing hatch. Push switch UP to close viewing hatch.
49.
Drill Stem Thread Lube (optional)

Push and hold switch down to activate grease pump to lubricate drill pipe threads.
50.
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.
51.
Air Line Lubricator (high pressure machines)

Push switch down to activate lubricator pump to provide lubrication for "In The Hole Hammers".
Operator Controls
2-11
Control Console
Continued from previous page
52.
Mast Lock
Switch UNLOCKS or LOCKS mast in the vertical or angle drilling positions.
Push and hold switch left to unlock (retract) mast pins. Green light will come on.
Push and hold switch right to lock (engage) mast pins into mast. Red light will come on.
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.
53.
Drill Pipe LoaderLock

This switch is used to lock or unlock the drill pipe loader so the loader can be indexed left or right
to the next position.
Push and hold switch down to lock pin IN.
Push and hold switch up to move pin OUT.
2-12
Operator Controls
Control Console
54.
Drilling Air
Turns the air ON/OFF for drilling procedures.
Push switch up to turn drilling air ON.
Push switch down to turn drilling air OFF
55.
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.
56.
Tool (Deck) Wrench

Switch retracts or extends the deck wrench to hold the drill pipe when breaking thread joints or
when multiple pass drilling is required.
Push and hold switch up to retract tool wrench.
Push and hold switch down to engage tool wrench.
57.
Drill Pipe LoaderRotate

This switch is used to rotate the drill pipe loader left or right to the next position.
Push and hold switch left to rotate drill pipe loader left.
Push and hold switch right to rotate drill pipe loader right..
58.
Winch
Push and hold switch up to raise winch hook.
Push and hold switch down to lower winch hook.
59.
Drill Pipe LoaderInterlock

This switch is connected to a proximity switch in the mast. If the pipe rack moves off it's 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, you need to 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.
60.
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.
Operator Controls
2-13
Control Console
Fig. 2-5 Instrument PanelLight Switches and Circuit Breakers
61.
Light Switches
Turns drilling lights, cab lights and other additional lights on and off.
62.
15 AMP Circuit BreakerCab Lights
63.
15 AMP Circuit BreakerIgnition 24V
64.
10 AMP Circuit BreakerWipers
65.
50 AMP Circuit BreakerMain Power
66.
15 AMP Circuit BreakerControl Panel
67.
5 AMP Circuit BreakerHeater & Drill Lights
68.
15 AMP Circuit BreakerStarter
69.
5 AMP Circuit Breaker12 Volt Circuit
70.
50 AMP Circuit BreakerDrill Lights
71.
15 AMP Circuit BreakerAdditional Lights
72.
15 AMP Circuit BreakerECM
73.
10 AMP Circuit BreakerFront Lights
2-14
Operator Controls
Control Console
Fig. 2-6 Instrument Panel with optional Murphy

Power View display.
74.
Fig. 2-7 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.
75.
Ether Injection (optional)

Aids in starting cold engine.
76.
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).
77.
Engine Fault Code Switch

Turn switch ON (towards operator) to activate fault code signals from amber light (80).
78.
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.
79.
Engine Protection Light (Green)

Light comes on at start-up to indicated engine systems are normal.
80.
Engine Fault Code Light (Amber)

When light is on, it indicates there is a fault in the engine system.
81.
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 (74)
display.
Operator Controls
2-15
Cab Controls
Fig. 2-8 Water Control under Control Console
82.
Fig. 2-9 Cab Heater/Air Conditioner Unit
Water Injection Pump Motor Flow Control (optional)

Controls hydraulic flow to water pump motor. Turn COUNTERCLOCKWISE to INCREASE flow.
83.
HeaterA/C Temperature Control

Controls temperature of A/C or heat.
84.
OFFHeatA/C Switch
Selects OFF, HEAT, or A/C.
85.
Fan Switch (3 position)

Selects fan speed, LOWMEDIUMHIGH.
86.
Vent Control
Selects FRESH AIR or RECIRCULATION.
2-16
Operator Controls
Cat EMS
Caterpillar EMS (Electronic Monitoring System) Panel
Fig. 2-10 Optional Instrument Panel with Caterpillar EMS Panel installed.
Figure 2-10 shows the optional Caterpillar EMS panel installed.

This is an electronic monitoring system that displays various engine parameters. Each time the engine is
started, the EMS undergoes an automatic self-test. Refer to Caterpillar instructions in the optional equipment manual for complete information.
This panel replaces the engine hour meter (20), engine oil pressure gauge (19), engine tachometer (18),
engine coolant temperature gauge (17), and voltage gauge (25) shown in fig. 2-2.
Operator Controls
2-17
Cab Heater
Cab Heater Fault Isolation
Check out the heater as follows:
1.
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.
2.
Check for heating by first allowing diesel engine to warm up thoroughly, then turning on blower and
assuring that the circulated air is warm.
3.
If heater fails to heat, check cutoff valves at plumbing connections to engine (fig. 2-11) to be sure
they are turned on, then check the heater plumbing.
Fig. 2-11 Heater Connections and Cutoff Valves (Cat. C27 Engine shown)
1. Water Outlet to Heater
2. Water Inlet from Heater
2-18
Operator Controls
AC/Heater/Pressurizer Unit
Fig. 2-12 AC/Heater/Pressurizer Unit (ref. 425136)
Operator Controls
2-19
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
2-20
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
2-21
Air Conditioner
Daily
Service
Weekly
Service
Monthly
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
General Service Information

System should be thoroughly serviced before and after the cooling system. Breakdown maintenance is
invariably more expensive, extensive and is not carried out to the same level as preventive maintenance.
This can lead to more problems down the line.
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.
2-22
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
2-23
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
2-24
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 ices up intermittently.
Unit icing up may be caused by excessive 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
2-25
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.
2-26
Operator Controls
Operator Seat
Operator Controls
2-27
Operator Seat
2-28
Operator Controls
Murphy Power View

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).
PV-02124N page 1 of 18
Operator Controls
2-29
Murphy Power View

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)
3.18 in. (81 mm)

2-30
Operator Controls
Murphy Power View

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 3 RS485+
PIN 4 RS485
PIN 6 GRND
PIN 1 V+
PIN 6 GRND
Recommended Connectors:
Body: Deustch DT06-6S
Wedge Lock: W6S
Terminals: 0462-201-16141
Sealing Plug: 114017
Operator Controls
2-31
Murphy Power View

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
RS485 (+) Data
Pin 3
Back View
NOTE 4
RS485 (-) Data
NOTE 2
Green-CAN_L
Yellow-CAN_H
Pin 4
Pin 4
See
NOTE 6
Pin 3
120
See Note
Pin 2
PVA Gage
NOTE 1
Pin 1
Red-V+
Ignition
Switch
V+
Pin 1
Pin 5
(SAE J1939
Compliant)
Gray-CAN_SHLD
Pin 6
ENGINE
CONTROL
MODULE
120 ohms
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
NOTE 4
RS485 (-) Data
NOTE 2
Green-CAN_L
Yellow-CAN_H
Pin 4
Pin 4
120
See Note
Pin 3
Pin 2
Red-V+
Ignition
Switch
Pin 6
NOTE 1
Gray-Ground
Blue-Back Light
NOTE 7
Battery
Note 4: Only use 120 ohm

characteristic impedance cable,
ex Belden 9841.
Pin 5
(SAE J1939
Compliant)
Gray-CAN_SHLD
Pin 1
ENGINE
CONTROL
MODULE
to MODBUS Output
See NOTES 6 and 8
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
Illumination Control*(optional)
For a complete listing of MODBUS Registers

visit our website at www.fwmurphy.com
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.
2-32
Operator Controls
Murphy Power View

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
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
57 PSI
OIL PRES
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.
Operator Controls
2-33
Murphy Power View

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
98%
3000
LOAD@RPM
ENG RPM
1800 RPM
ENG RPM
SPN110 FMI10
HIGH COOLANT TEMP
1000 RPM
14.2
COOL TEMP
BAT VOLT
MORE
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
GO TO 1-UP DISPLAY
STORED CODES
ENGINE
ENGINE CONFG
CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
MORE
SPN110 FMI10
HIGH COOLANT TEMP
HIDE
2-34
Operator Controls
Murphy Power View

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
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.
1000 RPM
ENG RPM
57 PSI
OIL PRES
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
Operator Controls
2-35
Murphy Power View

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
1500
ENG RPM
57 PSI
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
OIL PRES
WARNING
MORE
98%
3000
1800 RPM
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
!
57 PSI
14.2
OIL PRES
BAT VOLT
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
HIDE
2-36
Operator Controls
Murphy Power View

3. To acknowledge and "Hide" the fault and return to the single or
four parameter display touch the "Enter Button".
to scroll through the menu until the "Adjust Backlight" is highlighted.
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%
1800 RPM
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
1000 RPM
LOAD & RPM
3000
3. Once the "Adjust Backlight" menu item has been highlighted touch
the "Enter Button" to activate the "Adjust Backlight" function.
ENG RPM
!
57 PSI
14.2
ENG RPM COOL TEMP!
OIL PRES
BAT VOLT
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
Operator Controls
2-37
Murphy Power View

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
GO TO 1-UP DISPLAY
98%
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
1000 RPM
ENG RPM
57 PSI
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
OIL PRES
to scroll through the menu until "Adjust Contrast" is highlighted.
Select Units
"Menu Button".
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
98%
0
1500
1800 RPM
ENG RPM
3. Once the "Adjust Contrast" menu item has been highlighted touch
the "Enter Button" to activate the "Adjust Contrast" function.
4. Use the "Arrow Buttons" to select the desired contrast intensity.
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
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
ADJUST CONTRAST
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
ADJUST CONTRAST
3000
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
ADJUST CONTRAST
PV-02124N page 10 of 18
2-38
Operator Controls
Murphy Power View

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
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
1000 RPM
ENG RPM
57 PSI
OIL PRES
6. Touch the "Enter Button" to activate the "Use Defaults" function.

USE
USEDEFAULTS
DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
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.
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
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP1-UP
1-UPDISPLAY
DISPLAY
SETUP
SETUP 4-UP DISPLAY
SELECT UNITSD
ADJUST BACKLIGHT
PV-02124N page 11 of 18
Operator Controls
2-39
Murphy Power View

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.
13. Touch the "Enter button" to select the highlighted parameter for inclusion in the Single Engine Parameter Display.
USE DEFAULTS
CUSTOM
CUSTOMSETUP
SETUP
AUTOMATIC SCAN OFF
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.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC
OFF
AUTOMATICSCAN
SCAN
OFF
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.
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
Note that the numbers

now indicate the new
order of display for
the parameters.
PV-02124N page 12 of 18
2-40
Operator Controls
Murphy Power View

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
RESTORED TO
DEFAULTS
3000
1800 RPM
ENG RPM
COOL TEMP
6. Select the "4-Up Custom Setup" from the "4-Up Setup" menu.
Setup 4-Up Display
USE DEFAULTS
CUSTOM
CUSTOM SETUP
SETUP
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.
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.
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.
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.
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
125F
COOL TEMP
1000 RPM
ENG RPM
14.2
14.2
BAT VOLT
57 PSI
OIL PRESP
PV-02124N page 13 of 18
Operator Controls
2-41
Murphy Power View

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
143F
OIL TEMP
143F
OIL TEMP
143F
OIL TEMP
125%
1500
3000
1800 RPM
ENG RPM
1000 RPM
ENG RPM
57 PSI
OIL PRES
COOL TEMP
COOL TEMP
143F
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
1
Note the number to the right of
the selected parameter indicating
that the parameter is now
assigned to that display location.
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
RPM
1000
RPM
ENG RPM
57 PSI
OIL PRESP
13. Repeat the parameter selection process until all spaces are filled.
125F
COOL TEMP
COOL TEMP
1. Starting at the single or four engine parameter display, touch the Menu button.
2
4
125%
Utilities (Information and troubleshooting)
1
2
12. The parameter in the selected quadrent has changed to the parameter selected in the previous screen.
125F
COOL TEMP
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
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
RPM
1000
RPM
ENG RPM
57 PSI
OIL PRESP
PV-02124N page 14 of 18
2-42
Operator Controls
Murphy Power View

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
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
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
FAULT
FAULTCONVERSION
CONVERSION
PV-02124N page 15 of 18
Operator Controls
2-43
Murphy Power View

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.
PV-02124N page 16 of 18
2-44
Operator Controls
Murphy Power View

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
Injector Metering Rail 1 Pres

Injector Metering Rail 2 Pres
INJ PRES1
INJ PRES2
5.3.46
Engine Fluid Level/Pressure #2
65243
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
PV-02124N page 17 of 18
Operator Controls
2-45
Murphy Power View

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.
2-46
Operator Controls
Section 3
Main Frame / Crawlers
SKS Main Frame / Crawlers
3-1
Main Frame Troubleshooting

Troubleshooting generally consists of troubleshooting the individual subsystems; however, you should
observe the following:
1.
Fuel Level Indicator Sender - Improper fuel gauge indication noted during operation or functional
check could indicate a faulty level sender in the fuel tank.
2.
Detecting Leveling Jack Troubles - Faulty leveling jacks may be detected through inspection,
through operating difficulties encountered, or during hydraulic pressure tests outlined in Section 7.
Main Frame Repair

In general, repair of the main frame components entails removing the faulty component and replacing it with the correct part as designated in the parts manual. However, you should observe the following
procedures as applicable.
Leveling Jack Cylinders

Extend
Retract
Cap
Cap Screw
(Torque to 300 ft. lbs.)
Outer Casing
Inner Casing
Hydraulic Cylinder
Retainer Cap
Lower Bolt
Jack Pad
Fig 3-1 Leveling Jack Cylinder

3-2
Leveling Jacks
Leveling Jacks
Detecting Leveling Jack Troubles - Faulty leveling jacks may be detected through
inspection, through operating difficulties encountered, or during hydraulic pressure
tests outlined in Section 7.

Remove
1.
Lower jack pad to ground, but do not have weight of machine on jacks.
2.
Shut down machine.
WARNING:
Relieve pressure on hydraulic and pneumatic systems before

loosening connections or parts.
3.
Remove lower bolt that holds retainer cap/jack pad to cylinder.
4.
With hydraulic pressure relieved, disconnect upper fittings to cylinder and clamps.
5.
Remove cap screws and cap from top of cylinder outer casing.
6.
Hydraulic cylinder may have a lifting eye installed or it will have tapped holes to install a lifting eye.
Using a suitable crane or heavy lifting device lift cylinder out of casing.
Repair
Refer to parts manual for specific cylinder and repair parts. Refer to cylinder repair information in
section 7 for type of cylinder on machine.
Replace
1.
Replacement is reverse of removal procedure.
2.
Rotate jack pad to align bolt hole with cylinder.
3.
Cycle cylinder several times to remove trapped air before putting machine into service.
Lubricating Jack Casings

If jack casings are equipped with a grease fitting, grease it by applying a small quantity of grease. If
cylinder is not equipped with a grease fitting, extend the jack fully and apply grease directly to the inner
casing.
3-3
Mast Elevating Cylinders
Fig. 3-3 Upper Cylinder Pins

2. Bolt
3. Pin, Bolt Retained
4. Grease Fitting (2)
Fig. 3-2
1. Mast Hoist Cylinders
Fig. 3-4 Lower Cylinder Pins

5. Bolt (2)
7. Grease Fitting
3-4

Remove
1.
Removal of mast cylinders is easier with mast in up position.
WARNING:
BE SURE mast lock pins are engaged before removing mast

elevating cylinders, or mast will fall.
2.
Be sure mast lock pins are engaged in mast and shut down machine. If machine is fitted with a
central lube system, remove and cap grease lines from cylinder pins.
3.
Support both cylinders and remove upper pins (fig. 3-3). Start machine and retract mast hoist
cylinder rods all the way in. This will get all of the oil out of the cylinders, which allows you to save
that much more oil and make teardown less messy. DO NOT touch mast lock switch! If mast lock
pins are retracted, mast will fall ! Shut down machine and place a DO NOT START tag on the ignition
switch. Disconnect battery.
4.
Attach lifting strap to cylinder eye and support weight of cylinder while removing lower pin (fig. 34) and lift cylinder from machine for repair.
Repair
Refer to parts manual for specific cylinder and repair parts. Refer to cylinder repair information in
section 7 for type of cylinder on machine.
Replace
1.
With cylinder supported, install lower pivot pin and retainer bolts and grease fitting or grease line.
DO NOT attach cylinders to mast yet.
WARNING:
BE SURE to cycle cylinder at least six times up and down to

remove trapped air before attaching to mast, otherwise mast
may fall suddenly when lowered.
2.
Connect hoses, start up machine and cycle cylinders at least six times up and down to remove
trapped air, then slowly extend cylinder to line up rod end with clevis on mast.
3.
Install upper pivot pin and retainer bolt. Install grease fittings or grease line.
4.
DO NOT stand under mast while lowering. Lower mast and raise up again. Check for leaks. Grease
all pivot pins.
3-5
Crawler Assembly
Fig. 3-5 Crawler Assembly

2. Side Frame
3. Final Drive
4. Capscrew, M24x2x100 (32)
5. Washer, 25mm (64)
6. Sprocket
7. Capscrew, M24x2x110 (32)
8. Track Roller (13)
9. Capscrew, M20x100 (52)
10. Washer, 21mm (80)
3-6
11. Idler Unit

12. Nitrogen Tensioner
13. Hydraulic Tensioner
15. Grease Fitting
16. Sealing Ring (2)
17. Cover
19. Cover
20.
21.
22.
23.
24.
25.
26.
27.
28.
Capscrew, M12x25 (9)

Cover
Washer, 17mm (4)
Nut, 16mm (4)
Grease Fitting
Chain Guide
Track Chain with Shoes
Crawler Assembly
Crawler Component Repair
It is recommended not to repair component parts of the crawler assembly. NEVER attempt to repair
the track tensioner unit. The track tension spring is assembled in a fixture with several tons of force. For
your safety and that of others DO NOT attempt to repair this unit. Replace the worn or damaged components with a new ones.
When ordering parts for the crawler, give the serial number of the unit to be sure to get the correct
parts. The serial number is stamped on the side frame adjacent to the final drive sprocket (see fig. 3-6).
Fig. 3-6 Crawler Serial Number Location
3-7
Metric Bolt Torque Specifications
3-8
Track Maintenance
Before Operating the Machine:
After a long period of standstill:
Check oil level in final drive. Top off with 80W-90 gear oil (factory fill).
After a short period of running:
Check track chain tension; adjust as required.
Check the idler wheel and rollers for leakage.
Check oil level in final drive. Top off with 80W-90 gear oil (factory fill).
After a long period of running:
Check track chain tension; adjust as required.
General Maintenance
Track Rollers and Support Rollers:
No maintenance is required. The rollers are filled with oil and use high quality metal to metal seals,
which prevents the entering in of dirt or loss of lubrication.
Oil Level:
Check every 200 hours.
Initial oil change at 200 hours, then annually.
3-9
Track Tension Adjustment
Fig. 3-7 Track Assembly

1. Idler Assembly
4. Support Roller
5. Track Frame
Fig. 3-8 Release Track Tension

3-10
6. Final Drive
7. Track Roller
8. Access Cover - Hydraulic Tensioner

9. Access Cover - Nitrogen Tensioner
Fig. 3-9 Increase Track Tension


WARNING
Grease in the hydraulic tensioner is under high pressure. Grease
coming out of the relief valve at the back of the hydraulic tensioner
is under high pressure and can penetrate the body causing personal injury or death.
When loosening the tension on the track, loosen the relief valve
only one turn.
DO NOT visually inspect the relief valve to see if grease is being
released from the track adjuster. Instead, watch the track to see if
it loosens. If the track does not loosen after opening the relief
valve, move the machine forward and backward to release the
tension.
Hydraulic Tensioner
Proper Track Tension
If chain is too tight, it will cause increased wear of the bearings at the front idler and drive sprocket.
Also, wear will be increased at the bushings and pins of the track chain.
If chain is too loose, it will not fit properly on the idler and the chain will slide when tramming the
machine. This sliding will cause rapid wear of the chain links.
To Check Tension:
Lay a straight edge across top of tracks between support roller and idler or support roller and final
drive sprocket. The unsupported distance must be at least three feet.
Measure track sag at mid-point. It should be about 1" to 1-3/16" (25mm to 30mm).
If track is too tight:

1.
Remove access cover plate on track side frame and loosen grease relief valve one turn maximum
(fig. 3-8). If track does not loosen after opening the grease relief valve, move the machine forward
and backward until tension is released, then tighten grease relief and adjust as required.
2.
Replace access cover plate.
If track is too loose:

1.
Remove access cover on track side frame and attach a grease gun to the grease fitting located
inside the hole on the side of the track (fig. 3-9). A special adapter is required for this. Reedrill part
no. V006626.
2.
Pump grease in until the track chain is properly adjusted. Do not over tighten the track.
3.
Replace access cover plate.
3-11
Fig. 3-10 Idler Unit and Track Tension Assembly

1. Idler Unit - complete
2. Idler Wheel and Side Bars
3. Sliding Block
Description
3-12
The idler wheel is filled with oil and the running surfaces are induction hardened for reduction in wear.
The sliding block (3) is designed in such a way that no dirt can enter the idler.
The hydraulic tensioner (4) serves to tighten the track chain when grease is inserted with a grease
gun.
The nitrogen tensioner (5) is pressurized at the factory and normally requires no other maintenance.

WARNING
HIGH PRESSURE: The nitrogen tensioner is under high pressure.
Bleed off all pressure before any service work is performed on the
unit. Follow instructions in this section.
It is recommended that service work on the nitrogen tensioner be
done only by factory authorized service agents.
If service work is performed by non-factory authorized personnel,
all liability and/or damage is assumed by party (ies) performing
the work.
If unit is disassembled, always discard all fasteners and replace
with new ones.
Nitrogen Tensioner
If pressure is lost, it is usually due to one of the following reasons:
1.
Seal distortion due to extreme cold or hot temperatures.
2.
Seal deterioration due to exposure to ultra violet light.
3.
Worn seals or scored cylinder caused by piston cocking in bore.
NOTE
It is recommended that the nitrogen tensioner be repaired only by factory authorized service agents. If cylinder is scored, the entire unit should be replaced.
The use of a charging kit is required for charging or checking pressure (see following instructions for
charging). The nitrogen tensioner is pretensioned at the factory. DO NOT exceed the recommended
pressures.
Normal Charging Pressure is 2320 PSI (160 bar)
Maximum Allowable Pressure is 4640 PSI (320 bar)
3-13
Hydraulic Tensioner
Fig. 3-10a Hydraulic Tensioner Assembly

1. Hydraulic Tensioner Complete
2. Piston
3. Groove Seal
4. Cylinder
Repair
Normally the hydraulic tensioner is not repairable.
If the cylinder is grooved, it will not seal and the entire unit must be replaced.
3-14
Nitrogen Tensioner Assembly
Fig. 3-10b Nitrogen Tensioner Assembly

1. Nitrogen Tensioner Complete
2. Cover
3. O Ring
4. Cylinder
5. Circlip
6. Support Ring
7. Groove Ring Seal
8. Piston Guide Ring (2)
9. Piston Seal
10. Flange
11. O Ring
12. O Ring
13. Wiping Ring
14. Piston
15. Plug
16. Capscrew (30)
17. Protection Cap

18. Capscrew (2)
19. Sealing Ring (2)
20. Check Valve
21. Protection Cap
22. Manometer
23. Sealing Ring
3-15

Nitrogen Tensioner - Filling
Instructions
1.
Remove protective cap on the nitrogen tensioner,

then remove the brass cap at the gas valve (1).
Fig. 3-11 Nitrogen Tensioner
2.
Be sure the hand wheel (4) on the filling valve is

CLOSED. Note: Left Hand Thread.
Screw filling valve and extension (3) by means of
union nut (2) to gas valve (1).
Fig. 3-12 Nitrogen Tensioner - Filling Valve Hook-up
3.
Screw gauge/valve (6) onto the nitrogen cylinder

(8) and connect hose (5) to filling valve (4) and
gauge/valve (6).
Fig. 3-13 Nitrogen Charging Set-up
3-16

Nitrogen Tensioner - Filling
Instructions - continued
4.
Turn hand wheel of the filling valve (4) to the right

(clockwise) so that the gas valve (1) opens. Open
the nitrogen cylinder valve (8). Turn counterclockwise.
Fig. 3-14 Nitrogen Filling
5.
Check pressure on gauge on nitrogen bottle with

nitrogen flowing. When the desired pressure is
reached, close the valve (clockwise) on the nitrogen bottle. Normal charging pressure is 2320
PSI (160 bar). Wait about five minutes and equalize the pressure again. Turn filling valve (4) counterclockwise to close gas valve.
6.
Remove charging set-up from nitrogen tensioner.

Always keep gas valve clean and free from any
dirt or debris.
Apply Loctite 270 to brass cap and replace the
brass cap on the gas valve. Replace the protecFig. 3-15 Nitrogen Filling
tion cap.
3-17

Nitrogen Tensioner - Pressure
Check
1.
Follow steps 1 to 3 in the "Nitrogen Tensioner Filling Instructions".
2.
Turn the hand wheel (4) of the filling valve to the

right (clockwise) to open the valve at the nitrogen tensioner. Keep the valve (8) at the nitrogen
bottle closed. Read pressure on gauge at nitrogen tank. Wait five minutes to equalize pressure.
3.
Turn hand wheel (4) of the filling valve to the left

(counterclockwise) to close the valve at the ni- Fig. 3-16 Nitrogen Charging/Checking Hook-up
trogen tensioner. Remove charging set-up. Replace brass gas valve cap using Loctite 270.
Replace protective cap.
The pressure loss during checking is equal
to 73 PSI (5 bar).
Nitrogen Tensioner - Pressure

Release
1.
Follow steps 1 to 3 in the "Nitrogen Tensioner Filling Instructions".
2.
Turn the hand wheel (4) of the filling valve to the

right (clockwise) to open the valve (1) at the nitrogen tensioner. Keep the valve (8) at the nitrogen
bottle closed.
3.
Release pressure by opening the vent screw (7)

at the gauge valve (8).
4.
Turn hand wheel (4) of the filling valve to the left

(counterclockwise) to close the valve at the nitroFig. 3-17 Nitrogen Charging/Checking Hook-up
gen tensioner. Remove charging set-up. Replace
brass gas valve cap using Loctite 270. Replace
protective cap.
3-18
Notes
3-19
Track Chain - Separate

WARNING:
Grease in the hydraulic tensioner is under high pressure.

Grease coming out of the relief valve of the hydraulic tensioner
is under high pressure and can penetrate the body causing
personal injury or death.
When loosening the tension on the track, loosen the relief
valve only one turn.
DO NOT visually inspect the relief valve to see if grease is
being released from the hydraulic tensioner. Instead, watch
the track to see if it loosens. If the track does not loosen
after opening the relief valve, move the machine forward
and backward to release the tension.

1. Put the machine on a flat level surface.
2.
Release the tension on the track assembly (see track tension adjustment). Access the hydraulic
tensioner by removing the access plate (farthest from idler) in the track side frame. Loosen relief
valve for the track adjuster only one turn. If the track assembly does not loosen after opening the
relief valve, move the machine forward and backward until the tension is released.
WARNING:
To Prevent possible injury during removal of master pin,

keep away from the area outside the track assembly near
the master pin. The master pin may come out of the track
links with force during the removal procedure.
3.
4.
Fig. 3-18
3-20
Locate the master pin and position pin between the sprocket and support roller. It is easier to
access the pin by removing the track shoes directly above the pin (fig. 3-20). Drive the pin out with
a hammer and driving pin (fig. 3-18).
Remove the track chain in the direction of the sprocket (fig. 3-19).
Master Pin - removal
Fig. 3-19
Track Chain - removal


5.
Remove the four capscrews and nuts that

secure the track shoe to the track chain.
Fig. 3-20 Track Shoe - removal
3-21
Track Chain Repair

Track Link - Repair & Replace
1.
Remove track shoe from damaged link (fig. 3-20).
2.
Cut damaged link as shown in fig. 3-21 with a oxy/acetylene torch. Cut the chain completely through
the damaged area and lay the chain on the ground.
3.
Now, cut the bushings and pins of the damaged link as shown in fig. 3-22. Remove the cut-up parts.
Fig. 3-21 Cut out damaged link
4.
Burn a hole into the center of the pin stumps and drive them out (fig. 3-23).
5.
Cut off the ends of the bushing and grind smooth (fig. 3-24).
Fig. 3-23 Remove pin stumps
6.
3-22
Fig. 3-22 Cut out links, bushings & pins as shown
Fig. 3-24 Grind bushings smooth
Before assembling the track link, be sure you have on hand the following new parts:
(1) Track Link, R.H.
(1) Track Link, L.H.
(1) Master Bushing
(2) Master Pins
(4) Master Collars
(4) Bolts and Nuts (for attaching Track Shoe)
Track Chain Repair

7.
Assemble the new parts using the following procedure (see fig. 3-25): Be sure the links are facing
the proper direction (see fig. 3-27).
A.
B.
C.
D.
Connect the track link by putting two

master collars in place as shown.
Attach the two ends by driving in the
master
pin.
Place track chain onto track frame
and join the two ends by putting two
master collars in place as shown and
driving in the master pin.
Assemble track shoe to track chain
with the four bolts and nuts. Torque
bolts according to specifications
listed in Bolt Torque Chart in this
section.
Fig. 3-25 Track Chain Assembly
8.
Tension track chain according to procedure outlined previously.
Track Link - Description
Each track link is made up of the components listed in fig. 3-26. The links are pressed together to
form a compound unit, called the track chain.
Fig. 3-26 Track Link Assembly

1. Track Link - R.H., L.H.
2. Pin
3. Bushing
4. Master Collar
3-23
Track Shoes Installation

Track Link Position
Be sure, when assembling the track link, that the pin boss of the link always faces forward and the
front nose of the track shoe faces forward (toward the idler end).
Fig. 3-27 Track Link Position

1. "Nose" of track shoe
2. Pin boss of track link
Track Shoe - Mounting to Track Chain

The purpose of this instruction is to describe the correct fastening procedure of the track shoe to
the track chain. Improper mounting procedure is the most common cause for track shoe failure.
3-24
1.
Mounting surface of track chain must be clean and free of paint. Any damaged areas must be
ground smooth, so as not to protrude above the mounting surface. The same applies to the track
shoes.
2.
Bolts and nuts must be free of nicks and burrs in the thread area. Threads must be lightly oiled to
maintain a proper and equal friction factor.
Track Shoes Installation

Track Shoe - Mounting to Track Chain
3.
Before assembly, verify that the track chain and shoe will accept the same bolt size. Align the track
chain before starting.
4.
Place track shoes on the track chain and insert bolts. Align the track shoes parallel with each other.
Hand start the nuts, making sure the rounded corners of the nuts are showing towards the track link
and the nuts are parallel to the securing edge of the nut seat.
NOTE
When assembling in a workshop, the "straight torque" or "torque turn" methods

can be used as an option.
When assembling in the field, only the "torque turn" method can be used.
For either method, make sure the track shoes are not misaligned when torquing.
Use a criss-cross pattern when torquing the bolts.
After torquing all bolts, there is a possibility of contact between the track shoes
on certain profiles, which by design have a small gap. The same applies to extremely wide shoes. The contact area is only permissible at the end of the shoes,
Direct Torque Method
With an air wrench or a torque wrench, tighten the bolts to 11 ft. lbs. (15 Nm). When starting, make
sure to secure the nuts in the nut seat to keep from twisting. Next, proceed to torque the bolts with a
torque wrench or computer controlled torque system to the specified torque value as listed in the Grouser
Bolt Torque Chart (KN111) - Direct Method, in this section.
Torque Turn Method

With an air wrench or a torque wrench, tighten the bolts to 11 ft. lbs. (15 Nm). When starting, make
sure to secure the nuts in the nut seat to keep from twisting. Next, proceed to torque the bolts with a
torque wrench or computer controlled torque system to the specified torque value as listed in the Grouser
Bolt Torque Chart (KN111) - Torque Turn Method, in this section.
Now tighten the bolts by a third of a turn (120 degrees).
When assembling the track shoes in the field, this method must be used because the final torque is
not done with a calibrated torque wrench and although the deviation may be small, the tightening of a
third of a turn more, gives the necessary clamping force independent for the required friction factor.
Track Shoe - Retightening

DO NOT merely retorque the bolts in the field. This would lead to failure of the joint due to the altered
friction factor and a reduced preload of the bolts.
The CORRECT METHOD of retightening the bolts, is to loosen the bolts until they turn freely. Now
torque the bolts using the "torque turn" method described above.
NOTE This can only be done once and only after a short time of machine operation
(approximately 50 hours). After extended operation, loose bolts and nuts must be
replaced with new ones for safety reasons.
3-25
Track Shoe Bolt Torque
3-26
(Direct Torque Method)
Track Shoe Bolt Torque
(Torque Turn Method)
3-27
Track Chain and Shoe Installation

Track Chain with Shoes
Fig. 3-28 Track Chain with Shoes

1. Track Link, R.H. (50)
2. Track Link, L.H. (50)
3. Master Bushing (1)
4. Pin (49)
5. Bushing (49)
6. Master Spacer (2)
7. Master Pin (1)
8. Track Shoe (50)

9. Track Bolt (200)
10. Track Nut (200)
Track Chain & Shoe - Assembly & Installation

1.
Align both links to each other (fig. 3-29).
2.
Set pin in place and drive in until knurled end caught. Place a guiding pipe over the pin and using a
driving pin, drive in until both ends protrude the same amount (fig. 3-30).
3.
Place the grousers on the track chain and be sure they are facing the right direction (see fig. 3-28).
Install grouser bolts (fig. 3-31) and tighten according to mounting procedure outlined previously.
Fig. 3-29 Align Links

3-28
Fig. 3-30 Install Pin
Fig. 3-31 Install Grousers

Track Chain and Shoe Installation

Track Chain & Shoe - Assembly & Installation
4.
Lay track chain with grousers attached, flat on ground. Place crawler assembly over track chain
(fig. 3-32) so that the idler is near the end of the track chain.
5.
Pull the track chain over the crawler assembly from the sprocket end (fig. 3-33).
6.
The end position should be the top of the idler (fig. 3-34).
Fig. 3-32 Crawler to track chain
Fig. 3-33 Pull track chain over sprocket
Fig. 3-34 End position of track

chain.
7.
Grease two master collars and place in link pin boss (fig. 3-35).
8.
Align the pin bores of the track links and insert master pin (fig. 3-36).
9.
Drive pin in all the way (fig. 3-37).
Fig. 3-35 Master collars - grease

and install.
Fig. 3-36 Align pin bores and

insert pin.
Fig. 3-37 Drive in pin.
10. This completes the track chain installation.
3-29
Final Drive
Final Drive - General Description
The final drive is a 3-stage planetary gear drive which is totally enclosed. The bearings are protected by special slide ring packings.
It has an internal multi-disc brake which is spring applied and released by hydraulic pressure. The
brake is therefore, maintenance free and no repair work should be done on the brake except by factory
authorized specialists. The brake unit should be exchanged for a complete unit.
Fig. 3-38 Final Drive Assembly

1. Planetary Gear Drive
2. Drive Sprocket
3-30
Final Drive Unit Removal

Removal from Track Frame
1.
Release track chain tension and separate track according to preceding instructions.
2.
Clean all dirt from parts and loosen the sprocket mounting bolts in a criss-cross pattern (fig. 3-39).
3.
Place three puller screws in the corresponding holes (fig. 3-40) and tighten equally to loosen sprocket.
Remove sprocket with a suitable lifting device.
Fig. 3-39 Sprocket Bolts - remove
Fig. 3-40 Puller Screws (3) - install & tighten
4.
Remove all but two of the final drive mounting bolts (fig. 3-41).
5.
Weight of final drive with motor is 1085 lbs. (492 kg.). Attach a suitable hoist to the final drive,
remove the two remaining bolts and lift the final drive free of the track frame (fig. 3-42).
6.
Drain the oil from the final drive into a suitable container (fig. 3-43). Oil capacity is 4.8 qts. (4.5 L).
Fig. 3-41 Final drive bolts - remove
Fig. 3-42 Final drive - remove
Fig. 3-43 Drain oil
3-31
Final Drive
Installation into Track Frame
1.
Clean all mounting surfaces thoroughly. Lift final drive into place with an adequate lifting device (fig.
3-44).
2.
Install the capscrews and washers, hand tight only. Check to make sure the final drive flange is
seated properly. The maximum torque is 148 ft. lbs. (200 Nm). Tighten bolts in the sequence shown
in fig. 3-46. Final torque to be according to "Metric Bolt Torque specification" in this section.
Fig. 3-44 Install Final Drive
Fig. 3-46 Bolt tightening sequence
3.
Fill final drive gearbox with clean oil of the specified type (see oil recommendations in this section).
Position fill plug as shown in fig. 3-39 with drain plug at bottom. Fill to bottom of filler hole. Check
sealing condition of fill plug, replace if damaged.
4.
Clean mounting surfaces for sprocket and lift into position with an adequate lifting device. Install
capscrews and washers (fig. 3-40).
5.
Tighten bolts (fig. 3-41) to specified torque according to "Metric Bolt Torque specification" in this
section.
Fig. 3-47 Oil Filler Plug
3-32
Fig. 3-45 Tighten Mounting Bolts
Fig. 3-48 Install Sprocket
Fig. 3-49 Torque sprocket bolts
Final Drive Maintenance

WARNING:
HOT OIL will burn. Always wear work gloves and let final
drive cool down after a long period of operation, before
draining oil.
Place an "Out of Service" tag on the ignition switch before
doing any service or maintenance work on the machine.
CAUTION:
Drain oil into an approved container and dispose of according to local environmental regulations.
Operation of final drive with low or incorrect oil may cause
irreparable damage to the gearbox. Follow recommended
oil check and change intervals.
Oil Check / Change

1.
Machine must be on level surface. Position final drive so drain plug is at bottom and fill plug is at
position shown in fig. 3-50.
Fig. 3-50 Final Drive Position for Oil Filling and Draining
1. Fill Plug
2. Drain Plug
2.
Remove fill plug and check oil. Oil should be at bottom edge of fill plug hole. Check to see that
sealing surface of fill plug is not damaged, and install plug. Add oil if necessary. Factory fill is 80W-90
gear oil.
3.
Initial oil change is at 200 - 250 hours of operation.
4.
Regular oil change interval is 300 - 2000 hours of operation, or at least once a year.
5.
When changing oil, machine must be on level surface and final drive in position as shown in fig. 3-50.
Place an "Out of Service" tag on the ignition switch. Place a suitable container under the drain plug.
Remove drain plug and fill plug.
6.
Check sealing surface of drain and fill plug and replace if necessary. Install drain plug and fill with
correct oil type to bottom of fill plug hole. Install fill plug. Refer to recommended oil list on following
page. Factory fill is 80W-90 gear oil.
3-33
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.
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.
If ambient temperature is 14 F to 50 F (-10 C to +10 C) use an oil that is one viscosity class
lower.
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
ARAL
Degol BG 150
Degol BG 220
AVIA
Avilib RSX 150
BP
Energol GR-XP 150

Energol GR-XP 220
CASTROL
Alpha SP 150
Alpha SP 220
CHEVRON
NL Gear Compound 150

DEUTSCHE SHELL Omala EP 150

Omala EP 220
3-34
ESSO
Spartan EP 150
Spartan EP 220
FINA
Giran 150
Giran 220
FUCHS
Renep Compound 104
GULF
EP Lubricant Oil HP 150

MOBIL
GF 629 (Mobilgear 629)

TEXACO
Meropa 150
TOTAL
Carter EP 150
Carter EP 220
Final Drive Oil
3-35
Final Drive Assembly
Fig. 3-51 Final Drive Assembly

3-36
Final Drive Assembly

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
QTY.
1
1
2
1
5
5
5
1
1
3
3
3
1
1
1
1
1
3
3
3
1
2
1
18
2
2
1
1
1
1
2
DESCRIPTION
Final Drive with motor
Housing
Capscrew
Planetary Carrier
Spur Gear
Roller Bearing
Circlip
Washer
Planetary Carrier
Spur Gear
Roller Bearing
Circlip
Washer
Spur Gear
Spur Gear
Pinion Gear
Planetary Carrier
Spur Gear
Roller Bearing
Pin
Washer
O Ring
Cover
Capscrew
Screw Plug
Sealing Ring
Nut
Washer
Washer
Washer
Roller Bearing
ITEM
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
59
60
61
62
63
QTY.
2
1
1
1
1
1
2
3
1
1
1
2
1
1
2
1
1
1
2
2
1
1
1
1
1
1
1
6
1
1
DESCRIPTION
Roller Bearing
Hub
Ring
Gasket
Ring
Hub
Screw Plug
Sealing Ring
Valve
O Ring
Hydraulic Motor
Capscrew
Brake
Circlip
Washer
Circlip
Roller Bearing
Hub
Support Ring
O Ring
Brake
Sleeve
Cover
Circlip
Bushing
Flange
Disengagement Cover
Capscrew
O Ring
O Ring
The circled item number represents a module that can be ordered as a complete unit.
The item number represents the spare part.
5-7
Those parts following the first item number are supplied with that part, but may also be ordered
separately.
Parking Brake - Description
The multiple -disc parking brake is integrated as a complete unit into the gearbox. It must be removed and installed as a complete unit. After any repair work on the brake, the brake line must be
bled.
3-37
Final Drive Disconnect
Fig. 3-52 Final Drive Disengagement Hub

59. Flange
60. Disengagement Cover
3-38
Final Drive - Disconnect & Parking Brake

WARNING:
DO NOT service, perform maintenance or make adjustments

while machine is running.
The parking brake is nonfunctional when the gear drive is disengaged for towing.
BE SURE machine is on level ground and secured from movement, i.e. via tow bar to pulling vehicle prior to disengaging the
gear drive and while reengaging the gear drive.
Towing Procedure - Gear Drive Disconnect

Refer to fig. 3-52.
1.
Be sure machine is secured from movement before gear drive is disconnected, via tow bar attached to towing vehicle or by blocking tracks. When drive is disconnected the brakes are nonfunctional.
2.
Remove the two M10 X 25 capscrews (61) from disengagement cover (63). Install two M10 X 50
capscrews into the two threaded holes in the cover and screw in all the way. There should be a
space of about 1" (23 - 25mm) from the outside of the cover to the flange (59) as shown in fig. 3-52.
This will disengage the internal splines of the cover from the pinion gear shaft (16). Repeat on other
side. Machine is now ready to tow. Do not exceed normal tram speed of machine when towing.
3.
After towing, but before disconnecting from tow vehicle, replace disengagement covers (63) to
their normal position, so the pinion gear shaft is again connected to the cover.
Parking Brake - Removal & Installation

Refer to fig. 3-51
1.
Be sure machine is on level ground and tracks are blocked to prevent movement of machine.
2.
Drain oil from final drive into a suitable container. Dispose of old oil according to local regulations.
3.
Remove capscrews (43) and hydraulic motor (42) from final drive. Remove circlip (55).
4.
Remove capscrews (24) and cover (23).
5.
Remove pinion gear shaft (16).
6.
Insert a brass drift through the opening where the pinion gear shaft was and drive out the brake
assembly (44).
7.
Installation is basically the reverse of removal. Be sure to check condition of o-ring (22).
8.
Fill final drive with correct type of oil. See "Oil Check/Change" procedure in this section.
3-39
Idler Assembly
Fig. 3-53 Idler Unit and Track Tension Assembly

1. Idler Unit - complete
2. Idler Wheel and Side Bars
3. Sliding Block
3-40
Idler Assembly
Fig. 3-54 Idler Assembly

ITEM
QTY.
1
2
3
4
5
6
7
1
1
1
1
1
2
2
DESCRIPTION
Idler complete with Fork
Sliding Block
Idler Assembly
Idler with Bushings
Idler Wheel
Bushing
Sliding Rail
ITEM
QTY.
8
9
10
11
12
13
14
1
2
2
2
4
4
2
DESCRIPTION
Shaft
Duo-Cone Seal
Roll Pin
O Ring
Screw
Spring Washer
Screw Plug
3-41
Idler Unit Removal

WARNING:
DO NOT work on track system or undercarriage unless

engine is off and controls are locked out and machine is
on level ground.
MAKE SURE machine and components are well supported
before servicing or replacing parts.
RELIEVE PRESSURE on hydraulic or pneumatic systems
before loosening connections or parts.
Idler Unit - Removal

1.
Release track chain tension and separate track

chain. Follow instructions outlined previously.
Fig. 3-55 Release Track Tension and

remove track chain
2.
Clean dirt from all parts. Using an adequate lifting

device, pull out the complete idler unit (fig. 3-56).
Fig. 3-56 Idler Unit - removal
3-42
Idler Unit Removal

Idler Unit - Removal
3.
If either the idler or nitrogen tensioner is damaged,

separate them and replace or repair as required.
4.
If the hydraulic tensioner is defective, loosen the

attaching bolts and remove the unit. Replace or
repair unit as necessary. See fig. 3-57.
Fig. 3-57 Hydraulic Tensioner - removal
5.
If the nitrogen tensioner is defective, loosen the

attaching bolts from the sliding block (fig. 3-58)
and remove tensioner.
Fig. 3-58 Nitrogen Tensioner - removal
6.
If idler unit needs repair, first loosen the sliding

block (fig. 3-59). To disassemble the idler components, refer to "Idler Assembly" instructions and
carry out procedure in reverse order.
Fig. 3-59 Sliding Block - loosen

3-43
Idler Unit Assembly

Idler Unit - Assembly
1.
Clean all mounting surfaces thoroughly. Press

bushings (6) into idler wheel (5).
Fig. 3-60
5. Idler Wheel
2.
Place both seals (9) into the corresponding retainer of the idler (5) and sliding rails (7).
Note: If reusing the duo-cone seals (9) be
sure they are replaced the same way they
were removed or sealing is not guaranteed.
Fig. 3-61
5. Idler Wheel
3.
7. Sliding Rail (2)
9. Duo-Cone Seal (2)
Place the two o-rings (11) onto the two grooves

in the shaft (8). Install the shaft (8) to one of the
sliding rails (7). Note: Oil groove (arrow) must
face toward the rear of the machine.
Fig. 3-62
7. Sliding Rail (2)
3-44
6. Bushing (2)
8. Shaft
11. O Ring (2)

Idler Unit Assembly

4.
Align hole in shaft with hole in siding rail (7). Drive

in roll pin (10) to secure shaft to sliding rail. Note:
Roll pin may go in through the top or end.
Fig. 3-63
7. Sliding Rail
5.
10. Roll Pin
Install shaft through idler wheel.
Fig. 3-64 Install Shaft into Idler Wheel
6.
Install duo-cone seals as in step 2 and attach other

sliding rail (7). Secure with roll pin (10) as in step
4.
Fig. 3-65
7. Sliding Rail
10. Roll Pin
3-45
Idler Unit Assembly

7.
Position the idler wheel so the fill plug is 45 from

vertical as shown in fig. 3-66. Remove plug using
a 6mm allen wrench and fill the idler wheel with
SAE 90 oil until it runs out the hole. Install plug
and tighten.
Fig. 3-66 Oil Fill Position
8.
Place the sliding block (2) onto the sliding rails (7)
and fasten with four capscrews and spring washers.
Fig. 3-67 Sliding Block Installation

2. Sliding Block
7. Sliding Rail
9.
Place the nitrogen tensioner onto the sliding block

and fasten with four capscrews and spring washers.
Fig. 3-68 Nitrogen Tensioner Installation

3-46
Idler Unit Assembly

10. Screw the grease fitting into the back of the hydraulic tensioner and tighten.
Fig. 3-69 Install Grease Fitting into Hydraulic Tensioner.
11. Position hydraulic tensioner to cross bulkhead

from under track frame. Install with two capscrews
and spring washers.
Fig. 3-70 Install Hydraulic Tensioner onto Cross Bulkhead.
12. Clean and grease the inside of the track frame

channels where the sliding rails will ride. Using a
suitable lifting device, push assembled idler unit
into track frame. Push unit in until the nitrogen
tensioner contacts the hydraulic tensioner.
Fig. 3-71 Install Assembled Idler Unit into Track Frame.
Fig. 3-72 Idler Unit Installed All The Way.

3-47
Track and Support Rollers

General Description
On this track assembly, the ten lower track rollers and three upper support rollers are of the same
type. The track roller unit serves two purposes:
1.
To guide the track chain and therefore lead the dynamic forces of the track chain to the ground.
2.
To absorb the loads coming from the machine itself.
The roller is specially designed and surface hardened.

The roller also has special metal to metal seals which prevent dirt from entering the roller body.
Fig. 3-73 Track Roller Unit

1. Roller Body
2. Metal to Metal Seals
3-48
Fig. 3-74 Track Roller Assembly

ITEM
1
2
3
4
5
QTY.
1
2
2
2
2
DESCRIPTION
Track Roller (complete)
Bracket
Roll Pin
Duo-Cone Seal (set of 2)
O Ring
ITEM
6
7
8
9
QTY.
1
1
1
2
DESCRIPTION
Shaft
Roller Body
Plug
Bushing
3-49

WARNING:
Grease in the track adjusting cylinder is under high pressure.

Grease coming out of the relief valve of the track adjuster is
under high pressure and can penetrate the body causing personal
injury or death.
only one turn.
released from the track adjuster. Instead, watch the track to see
if it loosens. If the track does not loosen after opening the relief
tension.
Track Roller - Removal & Disassembly

1.
Release track chain tension, by loosening the grease fitting on the track tensioner. Refer to "Track
Tension Adjustment" at the front part of this section.
2.
Using and adequate lifting device, lift crawler frame off of track chain high enough to gain access to
the track rollers for removal (fig. 3-75). Support track frame with an adequate support so it can not
fall.
3.
Clean all dirt and debris from track rollers.
4.
Remove attaching bolts and remove track roller from frame (fig. 3-76). If track frame is fitted with a
chain guide, it will have to be removed first.
Fig. 3-75 Track Frame - lift
5.
3-50
Fig. 3-76 Track Roller - remove
To disassemble track roller, refer to "Track and Support Roller - Assembly" instructions and carry out
procedure in reverse order.

WARNING:
Grease in the track adjusting cylinder is under high pressure.
Grease coming out of the relief valve of the track adjuster is
under high pressure and can penetrate the body causing personal
injury or death.
only one turn.
released from the track adjuster. Instead, watch the track to see
if it loosens. If the track does not loosen after opening the relief
tension.
Support Roller - Removal & Disassembly

1.
Release track chain tension, by loosening the grease fitting on the track tensioner. Refer to "Track
2.
Using an adequate lifting device, lift the track chain up off the support roller. Support track chain so
it cannot fall.
3.
Clean all dirt and debris from support rollers.
4.
Remove attaching bolts and with an adequate lifting device, remove support roller from frame (fig's.
3-77 & 3-78).
Fig. 3-77 Support roller - lift track
5.
Fig. 3-78 Support roller - remove
To disassemble support roller, refer to "Track and Support Roller - Assembly" instructions and carry
out procedure in reverse order.
3-51

Track and Support Roller - Assembly
1.
Clean all parts thoroughly and press the bushings (9) into the roller body so that the oil grooves in the
bushing are aligned with the oil fill hole (fig. 3-79).
2.
Place the seals (4) in position in the roller body (7) and brackets (2), (fig. 3-80). Be sure the seal lips
face away from each other.
If reusing the old seals, be sure to mark them, so they go back into the same
bore they came out of. Otherwise they may not seal properly.
Install o rings (5) onto shaft (6). Install shaft into one bracket (2) making sure the oil groove (A) faces
the same direction as the mounting surface (B) of the bracket (fig. 3-81).
NOTE
3.
Fig. 3-79 Bushing - install

7. Roller Body
9. Bushing
NOTE
Fig. 3-80 Seals - install

2. Bracket
4. Seals (2 per side)
8. Roller Body
Place a block of wood under the bracket when driving in roll pin to avoid damage
to the seal retainer.
4.
Align hole in shaft (6) with hole in bracket (2), place a wood block under bracket and install roll pin
(3).
5.
Push assembled shaft into roller body (fig. 3-82).
6.
Install other bracket (2) onto shaft, align holes as in step 4, place a wood block under bracket and
drive in roll pin (3). Fig. 3-83.
Fig. 3-82 Shaft - install into roller body

3-52
Fig. 3-81 Shaft - install

2. Bracket
5. O Ring (2)
6. Shaft
Fig. 3-83 Roll Pin - install

2. Bracket
3. Clamping sleeve

Track and Support Roller - Test and Install
1.
Check the end play. Check for air tightness by applying air pressure through the oil fill hole. Test
pressure should be not more than 87 PSI (6 bar). Fig. 3-84.
2.
If the air test is satisfactory, with no air leakage around the seals, fill roller with SAE 90 oil through
the oil fill hole (fig. 3-85).
3.
Hold the roller in such a way so the oil groove is at the bottom and the oil fill hole is at the top. Now
apply air pressure into the roller as in step 7 so the oil is pressed into the seal retaining spaces (9).
Fig. 3-86.
Fig. 3-84 Track roller - air leakage test
Fig. 3-85 Track roller - oil fill

1. Oil
Fig. 3-86 Track roller - air/oil

1. Oil
9. Seal retaining spaces
4.
After filling with oil, check for correct level (fig. 3-87).
MAX Oil Level o

Turn the roller so the oil fill hole is 40 from a horizontal line through the center. Oil should not
spill out of the oil fill hole in this position.
MIN Oil Level o

Turn the roller so the oil fill hole is 10 from a horizontal line through the center. Oil MUST spill
out of the oil fill hole in this position.
5.
Put some loctite on the threads of the oil fill plug and install with a 6mm allen wrench (fig. 3-88).
Fig. 3-87 Track roller - oil level
Fig. 3-88 Track roller - fill plug
3-53

6.
Install track roller assembly on track frame (fig. 3-89). Torque capscrews according to "Metric Bolt
Torque Specifications" in this section.
7.
Install support roller on track frame (fig. 3-90). Torque capscrews according to "Metric Bolt Torque
Specifications" in this section.
8.
Remove supports and lower track frame onto track chain. Adjust track tension according to "Track
Fig. 3-89 Track Roller - install
3-54
Fig. 3-90 Support Roller - install
Section 4
Drive Train / Compressor
SKS Drive Train / Compressor
4-1
Engine and Drive Train Service Procedures
Fig. 4-1 Engine Air Filter - Right Side
Fig. 4-1a Compressor Air Filter - Left Side
2
4
5
6
7
8
19
9
18
17
14
15
13
12
11 10
16
Fig. 4-2 Engine and Compressor Air Cleaner Assembly

1. Cap
8. Gasket
2. Body Assembly
9. Nut
3. Flange Assembly (Outlet) 10. Clip
4. Safety Element
11. Washer Gasket
5. Washer Gasket
12. Primary Element
6. Nut
13. Body Assembly
7. Nut
4-2
14.
15.
16.
17.
18.
19.
O-Ring
Clamp Assembly
Cup
Nut
Gaskets
Bolt
Engine and Drive Train Service Procedures

Service procedures outlined in this section include:
1.
2.
3.
4.
5.
6.
Diesel Engine
Air Cleaners
Drive Shaft
Pump Drive and Pumps
Compressor Drive Coupling
Air Compressor System
For hydraulic pump adjustment see Section 7.
Engine Service Procedures

Lubrication requirements, fluid levels, and general service requirements are covered in Section 9.
Refer to the engine manufacturer's manual on the specific engine for more detailed service requirements.
Engine Fault Codes:
Caterpillar Engines - see Caterpillar operator/maintenance manual.

Cummins Engines - see end of electrical section 8.
Engine and Compressor Air Cleaner Service

Service for the disposable-filter type air cleaner includes general inspection and replacing the elements as required.
A. Inspection and General Service
1.
Inspect air transfer duct between air cleaner and engine to be sure all clamps and joints are tight
and there are no cracks in ducting.
2.
Verify that air cleaner mounting bolts and clamps are tight, holding air cleaner securely.
3.
Check dust cup to make sure it is sealing completely around air cleaner body.
4.
Be sure vacuator valve is in place (if so equipped), not inverted or damaged, and free from
obstruction.
5.
Check body of air cleaner for dents and damage which could cause a leak or damage the elements.
6.
Make sure all inlet accessories are free from obstruction and securely mounted.
7.
Check pre-cleaner tubes for plugging.
4-3
Engine and Compressor Air Cleaners

Engine and Compressor Air Cleaner Service (continued)
B. Air Cleaner Service
Proper air cleaner servicing will result in maximum engine protection against the ravages of dust,
and can also save time and money by increasing filter life and dust cleaning efficiency. Two of the most
common servicing problems are: 1) Over-Servicing - New filter elements increase in dust cleaning efficiency as dust builds up on the media. Don't be fooled by filter appearance, it should look dirty. By using
proper filter restriction measurement tools, you will use the full life of the filter at maximum efficiency. 2)
Improper Servicing - Your engine is highly vulnerable to abrasive dust contaminants during the servicing
process. The most common cause of engine damage is careless servicing procedures. By following the
steps shown, unnecessary dust contamination to the engine can be avoided.
1.
A filter indicator is used to measure the filter restriction. There are two indicators mounted on the
operator control console to monitor the right and left filters.
2.
Dust cups should be dumped when 2/3 full. Make sure it seals 360 around the air cleaner body.
On Vacuator Valve equipped models, dust cup service is cut to a minimum; a quick check to see
that the Vacuator Valve is not inverted, damaged, or plugged is all that is necessary.
3.
Light dust plugging of tubes can be removed with a stiff fiber brush. If heavy plugging with fibrous
material is evident, remove lower body section for cleaning with compressed air or water not
o
o
exceeding 160 F (71.7 C).
CAUTION:
NEVER clean tubes with compressed air unless both the primary
and safety elements are installed in the air cleaner.
DO NOT steam-clean tubes.
C. Element Servicing
4-4
1.
When restriction indicates that element servicing is required, loosen wing nut and remove primary
element. Before installing new element, inspect the element and gasket for shipping or storage
damage. Carefully install element and wing nut. Reset the restriction indicator to green. For
minimum downtime, replace dirty filter with new or properly cleaned XLP filter element. If element
is to be serviced for immediate re-use, reinstall outer cover to protect induction system while
cleaning element.
2.
Inspect and tighten all air cleaner induction system connection.
3.
Inspect all gaskets. Replace if worn or damaged. Annual replacement of all gaskets is recommended.
Engine and Compressor Air Cleaners

Engine and Compressor Air Cleaner Service (continued)
D. Safety Element Service
The safety element is not intended to be cleaned. For maximum engine protection and air cleaner
service life, replace the safety element with a new safety element every third primary element
change or cleaning, or as indicated by the Safety Signal Service Indicator (this is the special nut
that holds the safety element in place).
E. Element Replacement
To replace the elements refer to Figure 4-1 or 4-2 (depending upon how your machine is equipped)
and proceed according to the steps below. Anytime the elements are replaced or cleaned, the
dust cup and the lower body assembly should also be cleaned.
1.
Release clamp assembly and remove dust cup. Remove and wash lower body and dust cup.
2.
Release catches (STG Type) and remove cover and o-ring from upper body assembly.
3.
Remove wing nut and gasket securing outer (primary) element.
4.
Remove primary element.
5.
Remove inside nut and gasket and remove small (safety) element.
6.
To replace elements with new components, obtain correct replacement elements, with o-ring and
two gaskets, and replace them in reverse order of disassembly.
7.
When replacing elements, gaskets, and o-rings, it is a good idea to replace two o-rings (STG Type)
on lower element, also.
F. Element Cleaning Methods

Clean the Duralife element either by using compressed air or by washing. Compressed Air is recommended when element will be re-used immediately because a washed element must be dried before reuse. However, washing does a better job and must be used when exhaust soot has lodged in fine pores of
the filter media. Use Donaldson D-1400 detergent which contains a special additive for removing soot
and carbon.
Replace element after 6 cleanings or annually, whichever occurs first. Do not remove plastic fin
assembly - back-flowing with compressed air or washing will remove dust from beneath the fin assembly.
Compressed Air - Direct air through element in the direction opposite to normal air flow through the
element. Move nozzle up and down while rotating element. Keep nozzle at least one inch from
pleated paper. Maximum air pressure to prevent damage of element is 100 PSI.
Washing - Soak element 15 minutes or more in Donaldson D-1400 and water solution. See carton for
instructions. Rinse until water is clear (Maximum water pressure - 40 PSI). Air dry or use warm
o
o
flowing air, max. 160 F (71.7 C). Do not use compressed air or light bulbs.
Inspection - Place bright light inside element and rotate element slowly. If any rupture, holes or
damaged gaskets are discovered - replace.
4-5
Flexible Drive Coupling

Flexible Drive Coupling Service
Normally the flexible drive coupling requires no maintenance, however it may be necessary to remove the flexible drive coupling to service another component such as pump drive or engine. Follow the
steps below for repair or removal and installation of flexible drive coupling.
Removal
1.
Remove flex drive cover.
2.
Remove the socket head capscrews (items 5, 7 & 10) and slide the flexible flanges (4 & 9) back
far enough to be able to move the inner plate (3) back away from the outer plate (2). When the lip
of the inner plate clears the outer plate, you can lift the complete assembly out.
Installation
NOTE
Use a torque wrench when installing the radial and axial capscrews.
DO NOT use anaerobic adhesives, such as LoctiteTM as they have a detrimental
effect of the bond between the rubber and the inserts.
Pre-coated capscrews provided can be used up to three (3) times. Recommended
adhesives are 3MTM 2353 or Nylok Precote 80.
Mounting Screws and Adhesive

The axial and radial mounting screws are treated for corrosion resistance (minimum grade DIN 8.8,
SAE Grade 8). The threads are coated with micro-encapsulated adhesive. The adhesive is released at
assembly and further enhances the performance and safety of the coupling. For adequate effect, the
adhesive should be allowed to harden for 4 to 5 hours prior to installation.
Fig. 4-3a Flex Drive Coupling (ref. 419519)

2. Outer Plate (2)
3. Inner Plate (2)
4. Flexible Flange
5. Axial Socket Head Capscrew (4)
6. Tube
4-6
7.
8.
9.
10.
Axial Socket Head Capscrew (4)

Sleeve (4)
Flexible Flange
Radial Socket Head Capscrew (8 per side)
Flexible Drive Coupling

Installation - continued
Fig. 4-3b Correct and Incorrect installation of axial and radial capscrews.
1.
Be sure the flange hubs on the engine and pump drive are not damaged. Be sure they are free of
nicks and burrs and that all mounting bolts are tight.
2.
Place a small amount of grease under the head of each capscrew. This reduces the possibility of
twisting the rubber element (see fig. 4-3b). Install all pre-coated axial capscrews (longer) finger
tight. Be sure the flexible flange with the steel sleeves is on the engine side (fig. 4-3a).
3.
Rotate the tube (item 6, fig. 4-3a) so all radial capscrews (shorter) can be installed finger tight.
Use caution when tightening capscrews to prevent twisting of the flexible flange, see
fig. 4-3b. This is particularly important for the radial capscrews. If the part is twisted,
the cylindrical surface between the insert and the hub does not carry the load with
the whole surface, but with the two corners only. If this happens the other radial
bolts can loosen and the coupling will be destroyed.
Tighten all axial capscrews first, torque to 370 ft. lbs. (503 Nm), then tighten all radial capscrews
to same torque value.
NOTE
4.
5.
Install flex drive cover.
4-7
Notes
4-8
Pump Drive
Pump Drive Assembly - Removal and Replacement
WARNING:
Be sure to relieve pressure from hydraulic and pneumatic

systems before loosening connections or parts.
Two types of pump drives are used, they are Cotta and Funk Mfg. Removal and replacement is
similar both. Repair procedures are discussed separately for each.
1.
Remove drive shaft cover.
2.
Disconnect drive shaft or flex drive coupling from pump drive unit.
3.
Drain oil from pump drive gearbox before removing pumps. Oil capacity for the Cotta pump drive
is 3.5 gal. (13 L). Oil capacity for the Funk pump drive is 9 qts. (8.5 L). Support hydraulic pumps
with a suitable lifting device. Remove mounting bolts and separate from pump drive.
4.
For pump drive service only, it is not necessary to remove hoses from hydraulic
pumps. Move pumps back far enough to clear pump drive unit for removal. Provide adequate support for hydraulic pumps.
DO NOT let pumps hang from hydraulic hoses.
Support pump drive assembly with a suitable lifting device.
5.
Remove the four mounting bolts from each side and lift out pump drive assembly.
NOTE
Refer to parts manual for pump drive repair parts.

Replacement is reverse of removal.
Fig. 4-4 Pump Drive Assembly

1. Pump Drive
2. Mounting Bolts (8)
3. Drive Shaft Cover
4-9
Pump Drive Gearbox (Cotta)
Fig. 4-5 Pump Drive Gearbox with Disconnect (ref. 0095133)

1. End Rod
9. Oil Splash Disc
2. Spring
10. Lifting Plate (2)
3. Dowel Pin (2)
11. Spline Adapter (2)
4. Clutch
12. Shift Rod
5. Spacer
13. Gear, 40T
6. Spacer
14. Gear, 40T (2)
7. Fork
15. Case
8. Shaft
16. Cover
4-10
17.
18.
19.
20.
21.
22.
23.
24.
Capscrew, Hex (18)

Capscrew, Hex (2)
Nut, Hex
Nut, Flexlock (20)
Nut, Stop
Ball Bearing
Ball Bearing (4)
Ball Bearing (2)
Fig. 4-5a
Fig. 4-5b
25.
26.
27.
28.
29.
30.
31.
Bushing
Plug
Steel Ball, 1/2" dia.
Setscrew, Hex
Expansion Plug
Washer
Snap Ring (2)
32.
33.
34.
35.
36.
37.
38.
Snap Ring
Snap Ring
Snap Ring (2)
Snap Ring
Seal
Seal (2)
Nameplate
39.
40.
43.
44.
45.
46.
Plug
Window, Oil Level
Companion Flange
Breather
Bearing
Spacer
4-11
Notes
4-12

Pump Drive Gearbox - Repair
Disassembly:
1.
After removing pump drive from machine as outlined previously, place unit on a workbench or on
the machine deck if space and conditions permit. It is best to work in a clean sheltered environment whenever possible.
2.
Remove the companion flange with a gear puller. Disassemble the disconnect assembly if
equipped. Remove capscrews and separate the gearcase halves.
3.
Remove the driven gears and their bearings from the gearbox.
Inspection and Repair:

1.
Check gears and bearings for damage, look for metal particles or flaking from bearings.
2.
Check splines on output shafts for excessive wear.
3.
Check bearing bores, the O.D. of the ball bearings are a slip fit. If there is excessive play, the
bearing bores will have to be built up and re-machined.
4.
Check condition of input shaft oil seal. Replace all seals when overhauling the unit.
5.
Clean mounting surfaces of old sealant, clean and remove any debris from inside of gearcase.
Assembly:
1.
Assembly is basically the reverse of disassembly procedure. Remember to follow the notes with
the assembly drawing.
2.
If bearings need to be replaced, press them onto both sides of gears as far as they will go. There
is no bearing pre-load on units with ball bearings, as the O.D. of the bearings are a slip fit. On units
with tapered roller bearings add shims to obtain correct shaft end play (see fig. 4-5)
3.
Apply anti-seize compound or a good grade of wheel bearing grease to the splines of the output
shafts.
4.
Apply silicone sealant at all split lines of gearcase.
Installation:
1.
Refer to "Removal and Replacement" procedures as outlined previously.
Lubrication:
1.
After installing pumps, fill gearbox with proper lubricant (see section 9). Oil level should be to midpoint of oil level window. DO NOT OVERFILL, this will result in overheating and possible malfunction
of the unit.
2.
Maximum operating oil temperature is 225 F (107.2 C).
4-13
Pump Drive Gearbox (Funk)
Fig. 4-5c Funk Pump Drive Gearbox with 5" input shaft (ref.414347). Gearbox with 3" input shaft (ref. 421997)
1. Housing
9. Washer, Lock (24)
17. Screw, Drive (2)
25. Drive Shaft D/E, 19T (2)
2. Gasket, Housing
10. Elbow, 90 Deg.
18. Shaft, Input Assembly 26. O Ring
3. Oil Trough
11. Bushing, Reducing
19. Adapter, SAE C
27. O Ring (4)
4. Capscrew (2)
12. Breather
20. Ring, Adapter
28. Pin, Dowel (2)
5. Gear, 30T (3)
13. Plug, Magnetic
21. Adapter, Pump, SAE B 29. Plate, Cover
6. Bearing (6)
14. Plug, Pipe (3)
22. O Ring
30. O Ring
7. Capscrew (24)
15. Plug, Pipe (2)
23. Drive Shaft C, 19T
31. Capscrew (4)
8. Nut, Hex (24)
16. Plate, I.D.
24. Sleeve, Adapter
Fig. 4-5d 5" Input Shaft Assembly (item 18, fig. 4-5c)
(see fig. 3-5e for 3" Input Shaft Assembly)
1. Retainer, Bearing
2. Shaft, Drive
3. Bearing
4. Ring, Snap
5. Seal, Oil
8. Capscrew (4)
10. Flange, Companion
11. Washer, Retainer
12. Capscrew (2)
4-14

Pump Drive Gearbox - Repair
Disassembly:
1.
After removing pump drive from machine as outlined previously, place unit on a workbench or on
the machine deck if space and conditions permit. It is best to work in a clean sheltered environment whenever possible.
2.
Drive out the two dowel pins (28). Drive out pins toward input side of case.
3.
If air breather (12) is damaged, replace with a new one. Be sure elbow (10) is not plugged.
4.
Lay gearbox on bench with input shaft facing up. Remove input shaft assembly (18) from gearbox.
5.
Remove the 24 capscrews, nuts, and lock washers (7, 8, & 9). Lift the upper half of the housing
straight up and lay aside. Remove housing gasket (2) from lower half of housing.
6.
Remove the two capscrews (4) that hold the oil trough (3) in place, and remove oil trough. If
though cannot be tipped and pulled out from under gears, it will be necessary to lift each gear and
bearing assembly from the output housing until trough can be removed.
7.
With oil trough removed, lift gears and their bearings from the output housing. This can be done by
hand since bearings are slip fitted to the housing bores and press fitted to gear hubs.
8.
To remove bearings from gear hubs, use a gear puller or arbor press.
9.
Disassemble input shaft assembly, refer to fig. 4-5d (see fig. 4-5e for alternate construction).
A.
Remove the two capscrews (12) and retainer washer (11). Remove companion flange (10).
B.
Remove oil seal (5) and snap ring (4).
C.
Remove bearing (3) by pressing shaft out from the rear using an arbor press. Then press
bearing off of shaft (2), or use a gear puller.
Inspection and Repair:

1.
Check gears and bearings for damage, look for metal particles or flaking from bearings.
2.
Check splines on output shafts for excessive wear.
3.
Check bearing bores, the O.D. of the ball bearings are a slip fit. If there is excessive play, the
bearing bores will have to be built up and re-machined.
4.
Replace all seals, o-rings, and gaskets when overhauling the unit.
5.
Clean mounting surfaces of old sealant, clean and remove any debris from inside of gearcase.
Assembly:
1.
Assembly is basically the reverse of disassembly procedure.
2.
If bearings need to be replaced, press them onto both sides of gears as far as they will go. There
is no bearing pre-load on units with ball bearings, as the O.D. of the bearings are a slip fit.
3.
Apply anti-seize compound or a good grade of wheel bearing grease to the splines of the output
shafts.
4.
Install new housing gasket (2) and assemble the two housing halves (1) together with the 24
capscrews, nuts, and lock washers (7, 8, & 9). Torque capscrews to 75 ft. lbs. (102 Nm).
5.
Refer to fig 4-5d or 4-5e. Reassemble input shaft assembly (18) and install to housing with new oring (6). Install four new capscrews (8) using Loctite 262.
4-15
Fig. 4-5e 3" Input Shaft Assembly (item 18, fig. 4-5c) used on Pump Drive 421997
2. Flange
5. Ring, Retaining
8. Capscrew (4)
3. Spacer
6. Shaft, Input
9. Ring, Retaining
4. Seal, Oil
7. Bearing
10. O Ring
Fig. 4-5f Funk Pump Drive Gearbox (ref. 414347)
4-16

3" Input Shaft Assembly
Two different input shaft assemblies are used. One is 5" in length (fig. 4-5d) and the other is 3" in
length (fig. 4-5e). Measure from the face of the gearbox to the face of the driveline flange. Assembly and
disassembly procedures are outlined on the previous page for the 5" input shaft. The following instructions are for the 3" input shaft. Refer to fig. 4-5e.
Disassembly
1.
Remove retaining ring (5) and spacer (3) from input shaft (6).
2.
Press input shaft out of flange (2) using an arbor press or remove with a gear puller.
3.
Remove and discard oil seal (4).
4.
Remove retaining ring (9), then remove bearing (7).
Assembly
1.
Install bearing (7) into flange bore, then install retaining ring (9). Be sure bearing is seated all the
way in the bore and retaining ring is fully seated into groove.
2.
Install oil seal (4) with the lip facing out as shown in fig. 4-5e. Coat seal lip with oil before installing
input shaft.
3.
Coat input shaft shoulder with oil where it will contact the oil seal, then press the input shaft into
place using an arbor press. Be sure shaft is seated against the bearing.
4.
Install spacer (3) and retaining ring (5). Be sure retaining ring is seated into the groove all the way.
5.
Lubricate and install new o-ring (10) onto flange (2). Install input shaft assembly to pump drive
housing. Use four new capscrews (8) and install with Loctite 262. Torque bolts to standard
torque values.
Installation of Pump Drive Gearbox:

1.
Refer to "Removal and Replacement" procedures as outlined previously.
Lubrication:
1.
After installing pumps, fill gearbox with proper lubricant (see below). Oil level should be to bottom
edge of oil level check plug (fig. 4-5f). DO NOT OVERFILL, this will result in overheating and possible malfunction of the unit.
2.
If operating oil temperature is above 180 F (82 C) a synthetic oil is recommended.
Use any oil which meets EP gear lubricant specification MIL-L-2105C or API-GL-5 of SAE J3083C.
Lubricant Grades:
o
Below -10 F (-23 C) ambient use 75W.

o
Above -10 F (-23 C) and up to 100 F (37.8 C) ambient use 80W-90 or EP90.
o
Above 100 F (37.8 C) ambient use 85W-140.

Optional: Mobil SHC 635 synthetic or equivalent (all temperature ranges).
4-17
Hydraulic Piston Pumps

Hydraulic Piston Pumps - Removal and Replacement
WARNING:

systems before removing hoses, or loosening parts or
connections.
1.
Tag and remove hoses from pump unit.
2.
Cap or plug all connections.
3.
Support pump with a suitable lifting device.
4.
Remove mounting bolts and lift pump out.
5.
Be sure to fill case of pump with oil before starting.
Replacement is the reverse of removal.
Hydraulic Piston Pumps - Repair
Right Track & Pulldown Pump - Model AA4VG180HD

Left Track & Rotary Pump Model AA4VG180HD
Overhaul of hydraulic piston pumps in the field is not recommended. Special tools, expert knowledge and absolute cleanliness are essential. It is usually best to exchange the pump for a new or factory
rebuilt unit. However, if you choose to do the work yourself, the following service manuals will be of help to
you.
Fig. 4-8 Shaft Seal Replacement

4-18
4-19
4-20
4-21
4-22
4-23
4-24
4-25
4-26
4-27
4-28
4-29
4-30
4-31
4-32
4-33
4-34
4-35
4-36
4-37
4-38
4-39
4-40
4-41
4-42
4-43
4-44
4-45
4-46
4-47
4-48
4-49
4-50
4-51
4-52
4-53
4-54
4-55
4-56
4-57
4-58
4-59
4-60
4-61
4-62
4-63
4-64
4-65
4-66
4-67
4-68
4-69
4-70
4-71
4-72
4-73
4-74
4-75
4-76
4-77
4-78
4-79
4-80
4-81
4-82
4-83
4-84
4-85
4-86
4-87
4-88
Notes
4-89
Hydraulic Gear Pumps

Hydraulic Gear Pumps - Removal and Replacement
WARNING:

systems before loosening parts or connections.
1.
Tag and remove hoses from pump unit.
2.
Cap or plug all connections.
3.
Support pump with a suitable lifting device.
4.
Remove mounting bolts and lift pump out.
Replacement is the reverse of removal.
Hydraulic Gear Pumps - Repair

Refer to the following service manual for repair of gear pumps.
Cooler Fan Pump Auxiliary Functions Double Pump -
4-90
Model 350
Model 330
4-91
4-92
4-93
4-94
4-95
4-96
4-97
4-98
4-99
4-100
4-101
4-102
4-103
4-104
4-105
Notes
4-106
Compressor Drive Coupling

Compressor Drive Coupling - Removal and Replacement
The compressor is driven off the rear of the engine via a Torsional Drive Coupling (fig 4-4). The
coupling consists of a rubber element, flange, and taper lock bushing. Usually no service is required other
than replacement when the rubber element is worn out. You can inspect the coupling through the opening
in the side of the bell housing / adapter plate (fig. 4-10).
WARNING:

systems before loosening parts or connections.
Compressor Unit - Removal:
1.
Support the compressor unit with a suitable lifting device.
2.
Remove bolts that attach compressor to engine and lower compressor mounting bolts (fig's. 410, 4-11 and 4-11a).
NOTE
Be sure not to lose shims at lower mounting.
NOTE
Some couplings have a negative reaction to thread lock chemicals.
3.
Loosen main air connection so compressor unit can be moved back far enough to allow access
to drive coupling.
4.
Inspect drive coupling and taper lock bushing. Normally the rubber element is the only part that
requires replacement. Refer to parts manual for part numbers.
5.
Repair or replace as required.
Fig. 4-9 Torsional Drive Coupling

1. Rubber Element
2. Flange
3. Taper Lock Bushing
4-107
Compressor Installation
Before Installation and Start-Up of New or Rebuilt Compressor:
1.
Drain all lubricant from receiver tank and system.
2.
Replace compressor oil filter element.
3.
Remove separator and check receiver tank for foreign material, metal cuttings, varnish and
sludge. The system must be completely cleaned out.
4.
Flush out compressor oil cooler.
5.
Check all valves for foreign material and proper operation.
6.
Install new filter elements and separator element. Install compressor unit (see "Compressor Unit Installation" below).
7.
Reconnect all hoses and valves that were removed.
8.
Fill system with new, clean lubricant (see section 9 for lubricant specifications) and pour 2 quarts
(1.9 liters) of lubricant down the inlet.
9.
Start compressor and set the full load RPM and the idle RPM (refer to Sullair service manuals in
this section).
10.
Set the controls at the rated pressure and RPM.
11. Checks engine and compressor operating temperature. The engine water temperature should not
o
o
be above 200 F (93.3 C) in radiator top tank. Compressor discharge temperature should not be
o
o
above 210 F (98.9 C).
12. Check all shutdown devices for proper operation and temperature range.
Compressor Unit - Installation:

1.
Move compressor unit back into place with a suitable lifting device. Keep weight of compressor
suspended with lifting device until all bolts and shims are installed.
2.
Tighten mounting bolts to engine flywheel housing (fig. 4-10).
3.
Be sure to install the same number of shims that were removed from the rear compressor mounts
and install bolts (fig.4-11). If a new or rebuilt compressor is being installed, install as many shims
that will fit between the rear compressor mount and frame pads. This must be done to keep weight
of compressor off the engine flywheel housing, which can lead to premature bearing and seal failure.
Tighten all bolts according to standard torque specifications listed in section 9 of this manual.
4.
Reconnect any hoses or fittings that were removed.
4-108
Compressor Installation
Fig. 4-10 Compressor Mounting Bolts (engine adapter)
and Inspection hole
Fig. 4-11 Rear Compressor Mounting Bolts

and Shims.
Fig. 4-11a Front Compressor Mounting Bolts

and Shims.
4-109
Main and Auxiliary Air

The physical and functional aspects of the compressed air system are described briefly in the
following paragraphs. However, you should refer to the parts manual for installation details and to the
Sullair manual for technical information and troubleshooting.
Compressed Air Subsystem Components (low pressure)
Fig. 4-12 Low Pressure Compressor Cooling and Lubrication System Functional Diagram.
The compressed air subsystem consists of an engine driven air compressor, a separator tank, and
the miscellaneous control and plumbing elements required to control the operation of the subsystem and
to direct the air flow as desired. Figure 4-12 illustrates the compressor lubrication and cooling functions.
Although the following topics briefly describe the functions of the compressor and separator tank, you
should refer to the Sullair manual for functional details of these units.
1.
Air Compressor - A single-stage, positive-displacement, oil-flood-lubricated type air compressor

is located behind the engine. The compressor operates in association with the separator tank to
provide compressed air at a given CFM to the rotary drill and to other air operated components
as required. The air compressor is engine driven by means of a torsional drive coupling.
In operation, the compressor unit receives oil from the separator tank sump. Besides acting as a
coolant for the compressor, the oil seals the leakage paths between the rotor and stator and
between the rotor meshes. Forming a lubricating film between the rotors, the oil allows one rotor
to directly drive the other. As the air is compressed, it becomes mixed with oil which must be
separated out before the air is used.
2.
4-110
Separator Tank - The separator tank is both a sump for the compressor oil and a reservoir for
the compressed air. The tank serves to separate the cooling and lubricating oil from the air in the
air/oil mixture delivered by the compressor. A built-in filter in the separator tank filters the oil from
the air, and the recovered oil is returned to the compressor. A sight gauge in the return line
enables the operator to see that oil is flowing in the line. A blow-down valve is located in a common line between the compressor and tank.
Main and Auxiliary Air

Compressed Air Functions
The main function of the compressed air system is to provide air to the drill bit to propel the particles out of the hole. A secondary function of the system is to provide auxiliary air for control functions
and for operation of air tools, etc.
An air cleaner assembly on the intake to the air compressor cleans the air before it goes into the
compressor. Similar to the air cleaner for the diesel engine, the unit has the same type of filter elements.
The lower element traps the larger particles and a double filter unit that filters out the fine particles. Both
the safety (inner) element and the primary (outer) element are disposable. The lower permanent element
is designed to be removed for cleaning, while the upper safety (inner) element and the primary (outer)
element are disposable. Although cleaning of these elements is possible, replacement is recommended.
Refer to the parts manual for installation and assembly details and to the beginning of this section for
service instructions.
1.
Main Air System - Filtered air to the drill bit passes through a check valve and the butterfly
control valve, then through the main air header to an air hose that connects with a stand pipe.
From the stand pipe the air is applied through a hose and swivel connector to the rotary element
where it passes into the drill stem to emerge from the drill bit, blowing out the particles from the
blast hole. Water is injected into the main air manifold by means of an air loop to the water
injection system.
2.
Auxiliary Air - The auxiliary air is used to control the main air butterfly valve, and is also available for special tool applications such as indexing the optional pipe rack and operating the
automatic tool wrench.
3.
Air subsystem Control Functions - The main air control valve, controlled by a switch on the
control console, can be operated in two directions.
4.
Air System Indicators - Three pressure gauges indicate the various air pressures in the system. The air "T" tank pressure gauge indicates the pressure in the tank itself, while the filter
pressure gauge indicates the air pressure on the delivery side of the filter. The difference between
the filter pressure gauge and the "T" pressure gauge readings indicates the condition of the filter.
A pressure differential greater than ten PSI indicates incomplete air/oil separation, and thus
indicates the need to service the air compressor. The bit pressure gauge indicates the pressure
at the main air header, and hence the air pressure of the air delivered to the drill bit.
A pressure switch on the main air header completes the circuit to the drill hour meter. Thus, when
air is applied for drill operation the hour meter begins to count, measuring the time of operation.
When the air is cut-off, the hour meter ceases to run, thereby indicating the number of hours the
engine has operated (as indicated on the engine hour meter).
4-111
Sulliscrew Compressor Unit

Functional Description
This unit provides continuous pulse-free compression to meet your needs. With a Sullair Compressor, no internal inspection of the compressor unit is required.
Fluid is injected into the compressor unit and mixes directly with the air as the rotors turn, compressing the air. As a coolant, it controls the rise of air temperatures normally associated with the heat of
compression. The fluid also seals the leakage paths between the rotors and the stator and also between
the rotors themselves. It acts as a lubricating film between the rotors allowing one rotor to directly drive
the other, which acts as an idler. After the air/fluid mixture is discharged from the compressor unit, the
fluid is separated from the air. At this time, the air flows to your service line and the fluid is cooled in
preparation for reinjection.
Control System
The purpose of the compressor control system is to regulate the compressor air intake to match
the amount of compressed air being used. The inlet valve consists of a butterfly valve controlled by an air
cylinder as shown in fig. 4-13. For high pressure machines refer to Sullair Drill Compressor manual for high
pressure units in this section. Fig. 4-12a shows the high pressure control circuit.
Fig. 4-12a High Pressure Compressor Control System.
4-112
Butterfly Inlet Control System (high pressure)

Refer to Sullair Drill Compressor Model 20/12 500 - 1350 CFM (high pressure 250 500 PSIG) Operator's Manual #02250136-659 in this section.
This manual covers instructions for compressor set-up and inlet valve adjustment.
4-113
Butterfly Inlet Control System (low pressure)

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

1. Air Cylinder
2. Stop Screw
4-114
3. Butterfly Valve
4. Return Manifold

Butterfly Inlet Control System (low pressure)

11. Open main air partially and let the butterfly open and close.
12. Adjust reducing regulator (fig. 4-13a) to 20 PSI (1.4 bar).
Maintenance
1.
Keep linkage and area around inlet clean.
2.
Be sure clamps are tight and rubber inlet boot has no tears or holes.
3.
Grease the butterfly valve weekly at the grease fittings (5) located at each end of the shaft.
Fig. 4-13a Low Pressure Air Control Piping (ref. 425365)

4-115
Compressor Maintenance
Please refer to the following Sullair manuals for proper operation and maintenance of the compressor:
250 to 2000 CFM Single Stage Low Pressure Manual No. 02250150-154
or
500 to 1350 CFM High Pressure (250 - 500 PSI) Manual No. 02250136-569
4-116
Notes
Notes
Notes
4-117
Compressor Oil Filter
Fig. 4-14 Compressor Oil Filter Assembly

1. Visual Service Indicator
2. O-Ring
3. Locking Screw
4. Cannister Assembly
5. Filter Element
6. Filter Bowl
7. Filter Head
4-118

Routine Maintenance
Compressor Filters do not normally require special attention except for periodic monitoring of the
differential pressure warning device.
1.
If external leakage is noted, replace o-ring at leak. For bowl seal leaks, replace o-ring (2). If
leakage persists, check sealing surfaces for scratches or cracks; replace any defective parts.
2.
Differential pressure devices actuate when the element needs changing or because of high fluid
viscosity in "cold start" conditions. If visual indicator is fitted and actuates during "cold start",
reset by depressing the rubber button when the normal operating temperature is reached. If
indicator actuates after resetting, replace element.
Changing Filter Elements

WARNING:

Failure to depressurize system before proceeding could result
in explosive loss of fluid, damage to equipment, or possible
personal injury.
1.
Turn off and depressurize the system. Open bleed plug (if fitted) one and one half turns.
2.
Unscrew and remove filter cover bowl (6) from head assembly (7), counterclockwise when viewed
from above. It may be necessary to use a lever on the "Rotolok Ring" of the filter bowl (6) to
loosen the bowl initially.
3.
Remove filter element (5) and carefully inspect the surface for visible contamination. Normally no
dirt should show, but visible dirt or particles can be an early warning of system component breakdown and can indicate potential failure. Discard both the filter element and its o-ring. The filter
element is not cleanable. Any attempt to clean the filter element can cause degradation of the
filter medium and allow contaminated fluid to pass through the filter element.
CAUTION:
DO NOT attempt to clean or reuse element.
4-119
Fig. 4-14 Compressor Oil Filter Assembly

2. O-Ring
3. Locking Screw
4. Cannister Assembly
5. Filter Element
6. Filter Bowl
7. Filter Head
Fig. 4-15 Compressor Oil Filter Assembly - may be mounted on either side.
1. Compressor Oil Filter
4-120

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

bowl.
6.
Bleed the system and check for leaks. To bleed filter, open bleed plug, if fitted, one and one half
turns. Jog system and fill filter until all air bleeds through plug, then tighten plug. Pressurize system
fully and check for leaks; if leaks occur, check o-rings and sealing surfaces.
7.
After element change, ensure differential pressure device is reset by pushing in the button; electrical switches reset automatically. When system reaches normal operating temperature, check
that the electrical switch has not actuated and/or the visual warning button has remained depressed. If visual indicator rises due to a cold start condition, reset again as outlined in "Routine
Maintenance".
Fig. 4-15a Compressor Oil Filter Assembly - may be mounted on either side
depending on compressor installation.
1. Compressor Oil Filter
4-121
Compressor Oil Filter Service Bulletin
4-122
Radiator/Oil Cooler Assembly

Unauthorized service will void the warranty. Read the service information carefully before performing any repair work. Refer to parts manual for your particular machine for correct parts ordering.
Fig. 4-16 Radiator/Oil Cooler Assembly with Single Fan (ref. dwg. 419821)
4-123
Fig. 4-17 Radiator/Oil Cooler Assembly with Two Fans (ref. dwg. 419914)
4-124
Fig. 4-18 Dual Fan Motor Hydraulic Circuit (ref. 420107)
4-125

Square Tube Installation Tools - L&M Radiator (Mesabi)
Use of proper tools makes radiator/oil cooler repair faster and reduces risk of damage to tubes.
Following is a list of installation tools for square and round tubes, other special tools are available, if
needed. Refer to the L&M Radiator service information at the end of this section.
Fig. 4-19 Square Tube Installation Tools (L&M Radiator)
4-126

Round Tube Installation Tool - L&M Radiator (Mesabi)
Fig. 4-20 Round Tube Installation Tool (L&M Radiator)
4-127

Maintenance and Repair
Refer to the following pages for detailed maintenance and repair information on the L&M Radiator
(Mesabi) units:
Mesabi Radiators & Cores
Mesabi Aluminum Tube Air To Oil Coolers
Mesabi Copper Tube Air To Oil Coolers
NOTE Be sure to check whether your machine has copper or aluminum tube oil coolers.
Copper tube units are good to 150 PSI (10.3 bar).
Aluminum tube units are good to 350 PSI (24.1 bar).
4-128
Radiator & Core Assembly
4-129
4-130
4-131
4-132
4-133
4-134
4-135
Notes
4-136
Aluminum Tube Oil Cooler
4-137
4-138
4-139
4-140
4-141
4-142
4-143
Notes
4-144
Copper Tube Oil Cooler
4-145
4-146
4-147
4-148
4-149
4-150
4-151
Notes
4-152
Section 5
WARNING:
HEALTH HAZARD
Always use dust collector or water suppression to control dust
when drilling.
Avoid breathing airborne dust particles.
Prolonged inhalation of silica dust can cause silicosis, a serious
and sometimes fatal disease.
Dust Control Systems
SKS Dust Control Systems
5-1
Dust Control System Functions

The dust control system includes a dust curtain around the drilling platform and a blower type dust
collector which acts as a vacuum to gather the dust trapped within the dust curtain. The dust control
system also contains a water injection system that injects water into the main air stream to help control
dust accumulation.
The general functions of the dust control subsystem units are described below.
Dust Curtains
The dust curtains are attached to a framework underneath the drilling platform. Part of the drilling
platform forms the base for the mast assembly.
Dust Collector Subsystem Function
The dust collector subsystem consists of a dust collector assembly connected by a hose to an
outlet of the enclosure formed by the dust curtains.
The dry filter type dust collector uses a series of filters and retention rod elements to entrap
and dump the dust into the bottom of the unit to be funneled to the outside. Significant to the effectiveness of this unit is a compressed air filter-cleaning system that automatically blows reverse flow air
through the filters during operation. This reverse flow cleaning is facilitated through use of manifold system and a timer box. Auxiliary compressed air is applied to the manifold which routes compressed air
through each filter in an endless sequence. Sequence control is a function of the timer, which sequentially
operates control valves at the individual filter elements. Compressed air for dust collector operation is
plumbed in from the auxiliary air system.
Water Injection Subsystem Function
Water is injected into the main air stream to control dust from the drilling operation. The water
injection system consists of a water tank and a hydraulically driven water pump that injects water into the
main air header. The pump provides water from the tank at a flow rate controlled by an adjustable flow
control valve on the control console. The water is directed to an air control valve which meters the water
into the air stream at the main air header.
Dust Control System Control Functions
The operator controls for the dust control system consist of a switch and a water flow control valve
on the control console. Because the water injection system and the dry dust control system are not
operated at the same time, a single switch operates the water pump hydraulic motor and the dust
collector hydraulic motor. Pushing the switch up engages the water pump motor, and pushing the switch
down engages the dust collector motor. The water flow control operates a needle valve that controls the
amount of water being injected into the main air stream.
5-2
Dust Collector
Introduction
The Filter/Clone Dust Collector is an advanced design utilizing a system of barrier filters located in
the vortex of a cyclone. The use of the cyclone to centrifugally separate the heavier material from the fine
dust has demonstrated a significant reduction in loading of the filter elements while at the same time
allowing for an increase in volume of material collected.
In order to maintain the level of performance that is designed into each Filter/Clone Dust Collector,
one should fully understand how the unit operates, so that periodic inspections and repairs can be performed. This section is intended to explain to the user proper servicing techniques and offers special
troubleshooting suggestions.
Basic Specifications
The SKS series blasthole drills are equipped with the FC-4500 dust collector. Specifications are
listed below.
TECHNICAL DATA
Air Capacity (suction)
No. Filters / Area (sq ft)
Hydraulic Power Reqd.
Suction Hose Dia. (in.)
Cross Section (in. x in.)
Height (in.)
Shipping Weight (lbs)
FC-4500
4500 SCFM
6 / 822
23 GPM @ 1500 PSI
10.0
28.0 x 75.0
89.4
1600
Fig. 5-1 FC-4500 Dust Collector

5-3
Dust Collector
Fig. 5-2 Dust Collector (Model FC-3000)

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

1. Upper Tap
2. Lower Tap
5-4
Dust Collector
Initial Startup
If the Filter/Clone dust system was installed on your drill at the factory, the unit should be set up
ready to run. However, to make yourself familiar with the operation of the unit, it is advisable for you to go
through the following setup procedures.
The dust system is divided functionally into two separate subsystems:
A. The blower assembly which provides the vacuum source.
B. The compressed air supply which cleans the filter elements.
Blower Assembly - The blower assembly consists of an aluminum blower wheel, an aluminum
blower housing, and a hydraulic motor (fig. 5-2). For the unit to operate as it was designed, the blower
wheel must turn at both the right speed and the right direction to produce the level of vacuum required.
Fan Speed Adjustment The proper speed of the blower wheel is:
3000 RPM (12-13 inches of water) - without precleaner
3300 RPM (12-13 inches of water) - with precleaner
Although this speed can be set directly by use of a tachometer, the preferred method is to set the
speed to give the desired vacuum as measured with a water manometer. A water manometer is a very
simple device consisting of a clear plastic tube bent into a "U" shape. The tube is partially filled with water
so that two columns appear side by side and extend approximately half way up the length of the manometer (fig. 5-4). If both ends of the tube are open to the atmosphere, then the water level in each leg of the
manometer will be equal. However, if one leg is connected to a vacuum source, the air pressure in the
other leg will be greater and will push the water column down on the side connected to atmosphere. At
the same time, the column connected to the vacuum will rise. The distance in inches between the two
water columns is the measurement of the vacuum in inches of water.
There are two places on the dust collector to measure the vacuum produced by the blower system
(fig. 5-3).
1.
The upper tap is connected to the clean air side of the filter element.
2.
The lower tap is connected to the dirty air side of the filter element.
5-5
Dust Collector
Setting The Fan Speed - continued
Figure 5-4 shows the manometer connected to both taps at the same time. This measurement
would reflect the pressure drop across the filter element. To measure the clean air vacuum, connect one
side of the manometer to the upper tap and the other side to atmosphere (fig. 5-4). Likewise, to measure
the dirty air side of the filter, connect one hose to the lower tap and the other hose to atmosphere.
Normal readings (in inches of water) for the various configurations are shown at the top of fig. 5-4. Using
clean filters, adjust the fan speed by using the flow control valve (item 5, fig. 5-2) to achieve these
readings.
Direction of Fan Rotation

WARNING:
ALWAYS wear safety glasses when working on or around equipment.

NEVER look directly into blower housing exhaust as small
particles could fly out at high speed, causing personal injury.
The blower wheel rotates in a clockwise direction when viewing the unit from the top. It is imperative
that the blower turn in the right direction. It will not always be immediately obvious when the blower is
turning backwards because the unit will still pull a vacuum of 2-3 inches of water. There are two methods
to ensure that the fan is turning clockwise. The first is to make the measurements above. However, the
easiest method is to physically view the fan as it is either starting or stopping and note the direction it is
turning. Always stand to one side of the blower housing exhaust and wear safety glasses, as small particles could fly out at high speed causing personal injury.
NORMAL MANOMETER READINGS:
MODEL
FC4500
UPPER TAP
12-13 inches
LOWER TAP
9-10 inches
PRESSURE DROP
2-3 inches
Fig. 5-4 Manometer Setup
5-6
Dust Collector
Air System
The compressed air supply is used to back blow the filter elements to clean the filter material. The
outside section of the top of the dust collector is a compressed air reservoir. This air tank is connected
directly to the impulse valves which supply the air pulse to clean the filter. The lines should be drained
daily using the petcock next to the timer (fig. 5-7).
Air Regulator/Filter
Adjust the air regulator/filter to 40 PSI (2.8 bar). Lift up the cap and turn to adjust, then push back
down to lock. If air pressure is too high the filter elements will be damaged. The air regulator/filter is
located on the side of the dust collector opposite the timer (fig. 5-6). The air regulator/filter is equipped
with a water separator which automatically drains the water off as it accumulates in the bowl.
Fig. 5-6 Air Regulator/Filter
Fig. 5-5 FC3000 Dust Collector

1. Air Impulse Valves (4)
2. Filters (4)
Fig. 5-7 FC3000 Dust Collector

1. Relief Valve
2. Water Drain Petcock
5-7
Dust Collector
Fig. 5-8 Electric Timer and Air Impulse Valve
Fig. 5-9 Electric Timer

1. Off Time Switch
2. Last Out Switch
3. First Out Switch
4. Reset Button
5-8
5. Power Light
6. Pulse Sequence Lights (for number of filters)
7. Fuse, 3 amp
Dust Collector
Air System (continued)
The impulse valve is connected directly to the air tank through a short threaded pipe nipple. Pressure builds in the air tank and the impulse valve is held closed as long as the port on top of the valve is
closed. Under this condition, air from the tank is allowed to flow to both the top and bottom of a rubber
diaphragm. A light weight spring is used to ensure that the diaphragm stays seated in the closed position.
When air is exhausted from the top of the valve, the pressure from air on the bottom of the diaphragm causes it to be lifted momentarily. A small orifice connecting the air tank supply to the top of the
diaphragm causes the diaphragm to re-seat within approximately 0.1 second.
There is one impulse valve for each filter and these valves are made to sequentially pulse approximately every four seconds. The pulse rate is controlled by an electric timer.
Electric Timer
The electric timer (fig. 5-9) is a 24 Volt controller designed to sequentially activate 24V solenoid
directional air valves shown in Figure 5-8. The solenoid valve, when activated, exhausts to atmosphere
the air from the top of the impulse valve. Exhausting this air causes the impulse valve to pulse. The
electric timer is set up at the factory and should need no adjustment. However, to suit your particular
drilling situation you may wish to increase or decrease the interval between pulses.
The numbers on the FIRST OUT and LAST OUT dials indicate the order in which the impulse valves
fire. Do not change these settings. The red sequence lights indicate which impulse valve is firing. If only
four filters are used, then only four lights will flash. Always check that the green POWER ON light is on and
that the fuse is not blown. Push the RESET BUTTON if power has been interrupted.
Setting Time Interval Between Pulses
Use the OFF TIME switch (item 1, fig. 5-9) to set time between pulses. Each number on the dial
represents 0.5 seconds, so 1 equals 0.5 seconds, 2 equals 1 second and so on. The factory setting is
18 pulses per minute (about 3.2 seconds between pulses).
Filter Maintenance
If dust appears at blower housing, this indicates a filter has ruptured. Shutdown machine and change
filters immediately.
To check filter performance, connect manometer to upper and lower taps. With dust collector running, the difference between the two legs of the manometer should be about 3 in. (76.2 mm) of water for
a clean filter. When the water difference is more than 4 in. (101.6 mm), filters need to be changed.
Ground Water
Shut off dust collector if ground water is encountered, so filter will not plug up.
5-9
Dust Collector
Routine Maintenance
In order to insure that your Filter/Clone Dust Control system is operating to its design specifications,
the following visual inspections should be performed on a periodic basis.
1.
Verify that the dropout hose located at the bottom of the dust collector is securely fastened to the
dropout cone. This hose should be free of any holes and should form a tight seal during the period
when the collector is pulling a vacuum. The hose will open momentarily during each back-pulse of
compressed air when the filter elements are being cleaned.
2.
The suction hose leading from the deck to the collector should be clear of obstructions such as
build-up of dirt or mud. There should be no kinks or extremely sharp bends in the suction hose.
3.
Inspect the dust curtains surrounding the hole to be sure there are no holes or gaps.
4.
Listen to the back-pulsing of filter elements. There should be a sharp pulse of air every 2-3 seconds.
If a pressure gauge is installed in the air supply line to the collector, verify that the air is pulsed at a
peak pressure of approximately 40 PSI (2.8 bar).
5.
Observe the discharge of the blower assembly. NEVER look directly into the discharge of the
blower, as small particles could come out at high speed, causing personal injury. There
should be no visible dust emerging from the outlet of the blower housing. If there is, the filter elements and/or filter gaskets should be replaced immediately to avoid damage to the blower wheel.
6.
The filters should be cleaned whenever possible by pulsing the elements with the blower system
turned off. This can be done at the end of any drilling cycle, while changing drill pipe sections, and
possibly between each hole.
MANOMETER
READING:
UPPER
LOWER
INDICATION
CAUSE
CURE
High
Low
Loss of suction.
High reading across
filter.
Plugged Filter.
Check Pulse Air

(faulty timer, impulse valves
or low pressure).
High
High
Loss of suction.
Plugged Hose.
Reading of zero across
filter.
Poor filter life.
Fan speed too high.
Low
Low
Loss of suction.
Fan speed too low.

Fan runs backwards.
Dump hose missing.
5-10
Clear obstruction
Reduce hydraulic flow to
fan motor.
Adjust hydraulic flow to fan
motor.
Check hydraulic hookup.
Replace dump hose.
Dust Collector
Troubleshooting Guide
If, upon inspection of your dust control system, it is obvious that the unit is not operating properly,
the following discussion should help you to troubleshoot the problem.
All the problems with the Filter/Clone Dust Control System can be isolated through the use of a
single test instrument, namely the water manometer discussed earlier. Measurements should be made
separately on the upper and lower vacuum taps located on the dust collector housing (see fig. 5-3).
Typical readings for proper operation are listed in fig. 5-4. Depending on whether your readings are higher
or lower than the normal values, the following explanations will apply.
Upper Tap HIGH - Lower Tap LOW
This situation indicates that the blower assembly is being "choked off", causing the vacuum in the
clean air section to go up. The fact that the area around the filter elements (lower tap) is low
indicates that air is not moving through the filters (i.e. plugged filter elements). The main reason that
this occurs is failure of the back-pulsing system of compressed air. Three probable causes are:
1. The incoming air pressure is too low. This pressure should be maintained at approximately 40
PSI. Insert a gauge at the point where air enters the collector to make your measurement.
2. The timer could be malfunctioning. Check the timer to see that each station is being fired at the
set timer interval of about 2-3 seconds between stations.
3. The impulse valves over the filter elements may themselves be faulty. If one of the diaphragms of
the impulse valves develops a hole or a rock becomes lodged in the valve causing the diaphragm to
seat improperly, the compressed air may never be allowed to build up to the required 40 PSI pressure and/or the valve may not fire properly. Also, the electric-air solenoid valve operating the impulse valve may be faulty.
Upper Tap HIGH - Lower Tap HIGH
This condition indicates that the system is being "choked off" prior to the filter elements. This generally results from a plugged suction hose due to the build-up of dirt and mud or obstruction by a
foreign obstacle such as a shot-sack.
Upper Tap LOW - Lower Tap LOW
This condition points to a loss in suction capacity. The primary concern here is fan speed. The fan
may be turning below the suggested 3000 RPM because of a problem in hydraulic oil supply. Another situation often occurs when the motor is changed out or repaired. The motor may be reconnected incorrectly to cause the blower wheel to turn in a reverse direction. When this happens, a
vacuum will be produced and some air-flow will occur. The best way to verify proper rotation of the
wheel is to observe it visually upon start-up or shut-down. NEVER look directly into the blower
discharge, as small particles could come out at high speed causing personal injury. The
blower wheels on all Filter/Clone units should turn clockwise when viewed from the top looking down
at the collector.
As a final comment, one should note that the dust collector fan should be run as close to 3000 RPM
as possible. Although the fan can easily tolerate higher speeds and the system will indeed pull more
air at higher speeds, operating the system at such speeds can cause unnecessary wear of filter
elements, dust collector housing, and suction hose.
5-11
Water Pump
Item No.
Description
Qty.
1
2
3
4
5
6
7
8
9
10
10A
10B
11
12
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Hex Capscrew, 1/2"-13 x 1-1/2

Clamp, Valve Cover
Valve Cover
O-Ring, 1-3/16" OD
Spring & Disc
Valve Cage
Valve Seat
Hex Capscrew, 3/8"-16 x 5"
Valve Chamber
Gasket Cylinder
Ring Seal
O-Ring
Cylinder
Capscrew, 5/16"-18
Packing Washer
Packing
Packing Holder
O-Ring, 3/4" OD
Umbrella
Washer, Umbrella
Sleeve, Crosshead
Case, Pump
Pipe Plug, 3/4"
Crosshead
Wrist Pin
Connecting Rod Assembly
Bearing Insert, Con. Rod
Machine Screw, #10-24 x 1/2"
Speed Nut
Oil Slinger
Crankshaft
Bearing
Oil Seal
Snap Ring
Gasket, Pump Base
Mounting Base, Pump
Cup Washer, 3/8"
Capscrew, 3/8"-16 x 3/4"
Pipe Plug, 1/4"
Valve Seat Remover
1
1
2
6
4
4
4
3
1
4
2
2
2
2
2
2
2
2
2
2
2
1
1
2
2
2
4
2
1
1
1
2
2
2
1
1
6
6
1
1
Fig. 5-10
5-12
Water Pump
Servicing Instructions
WARNING:
Relieve pressure on hydraulic and pneumatic systems before loosening connections or parts.
General Care of the Pump
a.
Drain and refill the pump crankcase with clean SAE 30 API service classification MM or better oil
after the first 100 hours of operation. Following the first 100 hours of operation, for best results
always change the oil every 750 hours of operation.
b.
Keep all piping and mounting bolts tight.
c.
Replace all worn parts promptly with Bean exact replacement parts.
d.
The water relief valve mounted on the discharge of the water pump should be set 50 PSI higher
than air pressure in order to inject water into the air stream (e.g.: Low Pressure = 150-200 PSI,
High Pressure = 400-450 PSI).
Care in Freezing Weather

NOTE
Precautions must be taken to avoid damage to the pump from liquid allowed to
freeze in the valve chamber.
a.
Drain all connecting piping.
b.
Remove Capscrew (1), Clamp (2), Valve Cover (3) and Valve Disc and Spring (5) to drain the Valve
Chamber (9) when freezing temperatures are expected (See Fig. 5-8). Remove "top" Discharge
Valves or raise them to be sure that no liquid is trapped under the "inner" Suction Valves.
Servicing the Plunger Packings

1.
Release the Valve Chamber (9) from the Pump case by removing the three capscrews (8).
2.
Lift the chamber free of the cylinders (11). Remove the capscrews (12), cup washers (14), and
plunger packings (15).
3.
Lift the cylinders (11) from the pump case (21).
4.
Inspect the o-rings (17) and the umbrellas (18). If either of these parts are damaged, they should
be replaced. A pocket knife can be used for easiest removal of the umbrellas. Clean all parts
thoroughly - replace worn parts with exact replacement parts.
5-13
Water Pump
Item No.
Description
Qty.
1
2
3
4
5
6
7
8
9
10
10A
10B
11
12
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39

Clamp, Valve Cover
Valve Cover
O-Ring, 1-3/16" OD
Spring & Disc
Valve Cage
Valve Seat
Valve Chamber
Gasket Cylinder
Ring Seal
O-Ring
Cylinder
Capscrew, 5/16"-18
Packing Washer
Packing
Packing Holder
O-Ring, 3/4" OD
Umbrella
Washer, Umbrella
Sleeve, Crosshead
Case, Pump
Pipe Plug, 3/4"
Crosshead
Wrist Pin
Speed Nut
Oil Slinger
Crankshaft
Bearing
Oil Seal
Snap Ring
Gasket, Pump Base
Mounting Base, Pump
Cup Washer, 3/8"
Capscrew, 3/8"-16 x 3/4"
Pipe Plug, 1/4"
Valve Seat Remover
1
1
2
6
4
4
4
3
1
4
2
2
2
2
2
2
2
2
2
2
2
1
1
2
2
2
4
2
1
1
1
2
2
2
1
1
6
6
1
1
Fig. 5-10
5-14
Water Pump
Reassembling Plunger Packings
1.
Inspect bottom gasket (10) and replace if necessary. (Torque capscrews to 15 to 20 lb-ft).
NOTE
If it is necessary to replace one gasket at either top or bottom of the cylinders,

then both bottom and top cylinder gaskets should be replaced.
For easier installation of the Umbrella, immerse in hot water for approximately
two to three minutes to soften.
2.
Fold the plastic Umbrellas (18) to insert them through openings and over ends of Crosshead Rods.
3.
Press tops of Umbrellas to place Pilot Washers (19) over ends of rods with groove up.
4.
Place O-Rings (17) and Packing Holders (16) in position on ends of crosshead rods.
5.
Place cylinders (11) in position in the mounting plate recess.
6.
Oil the plunger packings (15) and place them in the open end of the cylinders, with the cup "up".
Use the thumb to press the packings into each cylinder, firmly and squarely on the plunger rod
end.
7.
Turn the pump by hand to raise each plunger rod to the top of the stroke, as needed.
8.
Place the cup washers (14), with the ribbed side against the plunger packing inside the cups of
the packing.
9.
Secure packing and washers to plunger rods with capscrews (12), tightening them until the
washers and cups seat firmly on the plunger rods.
10. Inspect top cylinder gaskets (10) and replace both if either shows defect, holding them in place in
the valve chamber by using heavy oil or grease if necessary.
11. Return the valve chamber to position over the cylinder, making sure that gaskets (10) and cylinders (11) are properly positioned in the recesses top and bottom.
12. Retighten capscrews (8) alternately and evenly until the parts are snugly seated. Torque
capscrews to 20-25 lb-ft.
Servicing the Pump Valves

1.
Remove the Capscrew (1) and Clamp Bar (2) from the rear of the Valve Chamber (9) and lift out
Valve Covers (3) and O-Rings (4) attached.
2.
Remove the Discharge Valve Springs and Seat Assemblies (5) and Valve Cages (6).
3.
Insert the round end of Valve Seat Puller (tool 39) through the opening at the center of the Valve
Seats (7) and loosen the Seats from the Valve Chamber (9) with a "rocking" motion of the tool
(39).
4.
Remove the Valve Seats from the recesses with the opposite end (curved end) if Tool (39).
5.
Repeat the four preceding steps to remove the suction valve parts which are identical to the
Discharge Valve Parts and are located immediately under them in the Valve Chamber.
6.
Clean all parts and inspect them - replace all worn parts as needed.
5-15
Water Pump
Item No.
Description
Qty.
1
2
3
4
5
6
7
8
9
10
10A
10B
11
12
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39

Clamp, Valve Cover
Valve Cover
O-Ring, 1-3/16" OD
Spring & Disc
Valve Cage
Valve Seat
Valve Chamber
Gasket Cylinder
Ring Seal
O-Ring
Cylinder
Capscrew, 5/16"-18
Packing Washer
Packing
Packing Holder
O-Ring, 3/4" OD
Umbrella
Washer, Umbrella
Sleeve, Crosshead
Case, Pump
Pipe Plug, 3/4"
Crosshead
Wrist Pin
Speed Nut
Oil Slinger
Crankshaft
Bearing
Oil Seal
Snap Ring
Gasket, Pump Base
Mounting Base, Pump
Cup Washer, 3/8"
Capscrew, 3/8"-16 x 3/4"
Pipe Plug, 1/4"
Valve Seat Remover
1
1
2
6
4
4
4
3
1
4
2
2
2
2
2
2
2
2
2
2
2
1
1
2
2
2
4
2
1
1
1
2
2
2
1
1
6
6
1
1
Fig. 5-10
5-16
Water Pump
Pump Specifications
Stroke
Oil Type
Direction of Rotation
Number of Pistons
Crankcase Material
-----------
1"
SAE 30
either
2
Cast iron
Oil Capacity
GPM
Maximum Pressure
RPM
---------
1 quart
9
550 PSI
500
Torque Requirements
Valve Chamber Studs
Rear Cover HHCS
--- 15 ft-lb.
--- 15 ft-lb.
Conn Rod Nuts

--- 7 ft-lb.
Packing Assembly Nut --- 10 ft-lb.
Reassembling Valve Parts

NOTE Valve seats are used with the thin seating area pointing toward the valve disc.
1.
With the O-Ring (4) in place on each Valve Seat (7), place a few drops of light oil on the ring and
seat and place each squarely in the bottom of the recess in the Valve Chamber.
2.
Place the Valve Cages (6) on the Valve Seats (7) and the Spring and Disc (5) inside each Cage.
3.
Repeat steps 1 and 2 to install the outer discharge valve parts.
4.
Place the Valve Covers (3) (with O-Rings on bottom groove) over each Valve Assembly.
5.
Replace Clamp Bar (2) and Capscrew (1), tightening Capscrew (1) only snugly. Overtightening
Capscrew (1) can damage Valve Parts. Torque to 30 lb-ft.
Servicing the Crankshaft

1.
Remove Pipe Plug (38) and drain oil from Pump Case.
2.
Disconnect piping and remove Pump from mounting.
3.
Remove Capscrews (37), Cup Washers (36) and Mounting Base (35) carefully to protect Gasket
(34).
4.
Remove Capscrews from Rod Assemblies (25). Use a center punch or other suitable instrument
to mark caps and rods for proper matching when they are reassembled.
5.
Remove Oil Slinger (29) from the Crankshaft (30).
6.
Push the Connecting Rods and Crosshead Assemblies into the Pump Case to clear the Crankshaft
(30).
7.
Remove the driven sheave from the Crankshaft extension.
8.
Remove the Snap Rings (33).
5-17
Water Pump
Item No.
Description
Qty.
1
2
3
4
5
6
7
8
9
10
10A
10B
11
12
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39

Clamp, Valve Cover
Valve Cover
O-Ring, 1-3/16" OD
Spring & Disc
Valve Cage
Valve Seat
Valve Chamber
Gasket Cylinder
Ring Seal
O-Ring
Cylinder
Capscrew, 5/16"-18
Packing Washer
Packing
Packing Holder
O-Ring, 3/4" OD
Umbrella
Washer, Umbrella
Sleeve, Crosshead
Case, Pump
Pipe Plug, 3/4"
Crosshead
Wrist Pin
Speed Nut
Oil Slinger
Crankshaft
Bearing
Oil Seal
Snap Ring
Gasket, Pump Base
Mounting Base, Pump
Cup Washer, 3/8"
Capscrew, 3/8"-16 x 3/4"
Pipe Plug, 1/4"
Valve Seat Remover
1
1
2
6
4
4
4
3
1
4
2
2
2
2
2
2
2
2
2
2
2
1
1
2
2
2
4
2
1
1
1
2
2
2
1
1
6
6
1
1
Fig. 5-10
5-18
Water Pump
Servicing the Crankshaft (continued)
CAUTION:
NEVER pound directly on bearings (31) when removing

or replacing them on the crankshaft.
9.
Place a wood block against either end of the Crankshaft and drive the shaft from the Pump Case
(21). A block of wood, with a suitable sized opening or block supports to assure reasonably equal
support around the bearing, in a press is best for this important work.
10. After inspecting and replacing all worn parts, press new Bearings (if needed) against the shoulders
of the Crankshaft.
11. With the Crankshaft and Bearings assembly in place in the Pump Case, carefully place the Oil
Seals (32) over the ends of the Crankshaft with the "lip" of the Seals facing the inside of the Pump
Case.
12. Seat the Snap Rings (33) in the grooves in the bearing housings against the Oil Seals and tap the
Crankshaft to allow a Slight end play in the Crankshaft.
13. Reassemble the Connecting Rods and Crossheads, being sure to match the Rod and Cap properly
as marked when disassembled. Use 6 to 8 lb-ft on Capscrews.
14. Complete the reassembly by reversing steps 1-8, being sure to replace Drain Plug (33).
Torque mounting base capscrews 20-25 lb-ft.
Remove Plug (22) and fill the Crankcase with clean SAE 30 API service classification MM or better
oil, to the Filler plug level.
Turn the Pump a few revolutions by hand, to be sure all parts are running freely before using the
Pump.
Servicing the Crossheads

1.
Remove the Valve Chamber, Cylinders, and Plunger Packings.
2.
Remove O-Ring Seal (17), Back-up Washer (19), and the Crosshead Umbrellas (18).
3.
Remove the Mounting Base and the Connecting Rods as described in "Servicing the Crankshaft".
4.
Turn the Crankshaft by hand to allow removal of the Crossheads through the Pump Case Opening.
5.
Reverse steps 1-3 when reassembling the Crossheads, be sure that all parts are reassembled in
their EXACT former positions.
5-19
Hydraulic Motor for vertical pump

Refer to the following Char-Lynn H - Series Service Manual for repair information on the hydraulic
drive motor for the vertical water pump.
5-20
5-21
5-22
5-23
5-24
5-25
5-26
5-27
5-28
Notes
5-29
Water Injection Pump (horizontal)

Water Pump Repair:
Refer to the following CAT Pumps Service Manual which covers the Model 1050 for repair and
maintenance information. Refer to machine parts manual for parts ordering.
Water Pump Drive Motor Repair:
Refer to the Char-Lynn 2000 Series Repair Manual which covers the Model 104-1002 Hydraulic Motor for repair. Shuttle Valve Option and Speed Sensor are not used on this model. Refer to machine
parts manual for parts ordering.
5-30
5-31
5-32
5-33
5-34
5-35
5-36
5-37
5-38
5-39
5-40
5-41
5-42
5-43
5-44
Section 6
Mast / Rotary Drive / Pipe Rack
SKS Mast/Rotary Drive/Pipe Rack
6-1
Hoist and Pulldown Cylinder
Fig. 6-1 Lower & Upper Mast Sections

31. Adapter
52. Spacer
53. Chock Bar
Fig. 6-2 Sheave Mounting Bracket

1. Sheave Bracket Mounting Bolts
(4 per side)
2. Upper Cylinder Guide Mounting Bolts (4)
6-2

Removal from Mast Assembly
WARNING:
DO NOT climb on mast, serious injury or death can occur.

BE SURE to relieve pressure on hydraulic or pneumatic
1.
Place mast in horizontal position and remove chock bars (item 53, fig. 6-1) that hold cylinder end
nuts at top and bottom of mast. Raise mast back up to vertical position and lock in place.
2.
Remove drill pipe from top sub-adapter and rack in carousel. Extend auto tool wrench and place
hardwood block on top of tool wrench. Place a steel plate on top of the hardwood block.
3.
Bring rotary head with sub-adapter down on top of steel plate and wood block.
4.
Switch Drill/Propel switch to Drill mode, switch pulldown system switch to Engage pulldown. Set
pulldown system pressure to 4000 psi (275 bar) with pulldown system pressure control. Lower
mast to horizontal position.
NOTE
Be careful not to damage threads on cylinder rod when removing nuts. Record
number of threads showing from top of nut.
5.
With mast in horizontal position and pulldown still engaged, loosen lower cylinder nut using a chain
wrench or a wrench made to fit nut. Nut may have to be broken loose with a sledge hammer. If nut
does not break loose, increase pulldown pressure to 5000 psi (345 bar) and apply heat to nut. Once
lower nut is loose, decrease pulldown pressure and switch pulldown switch to Disengage pulldown.
6.
Run rotary head to top of mast. Secure rotary head to mast crown with chain, so it can not move.
Remove the 8 bolts that hold the sheave mounts to the cylinder - 4 per side (item 1, fig. 6-2). Move
the cylinder so the rods are centered on both ends. This is done to balance the cylinder for safer and
easier removal.
7.
Shut off engine and relieve pressure from system by opening vent on top of hydraulic tank. Remove
the hydraulic hoses and fittings from both ends of the cylinder rods. Plug ports with cap plugs (not
shop rags)
8.
Make a note of how many threads are showing above the cylinder rod nuts. When cylinder is installed, you will need to have the same amount of thread showing as before removal.
9.
Support cylinder barrel (do not lift cylinder by the cylinder rods) with lifting straps and using an
adequate lifting device, place slight tension on the cylinder barrel. Remove the lower and upper
cylinder rod nuts. Remove the two lower cylinder guide bolts and the four upper cylinder guide
mounting bolts (item 2, fig. 6-2).
10. Protect chrome finish on exposed cylinder rods before lifting cylinder out of mast. Gently lift cylinder
and move forward enough to clear the lower mount them move opposite to clear upper mount. Now
carefully move cylinder out from under mast. Repair cylinder in an enclosed shop if possible. Use
caution not to damage threaded ends of cylinder rods or chrome surface of rods.
6-3
Fig. 6-3 Hoist/Pulldown Cylinder (ref. 424739)

1. O Ring (2)
8. Seal (2)
2. Back-up Ring (2)
9. Contamination Ring (2)
3. Wiper (2)
10. jWear Ring (4)
4. Seal (1)
11. Wear Ring (4)
5. Back-up Ring (4)
12. Seal Kit - includes item s 1-11
6. Seal 2)
13. Setscrew (2)
7. Back-up Ring (2)
14.
15.
16.
17.
18.
19.
Port Plug (2)

Tube Assembly (1)
Rod assembly (1)
Rod Assembly (1)
Head (2)
Head Cap (2)
20. Nut (2)

21. Capscrew (14)
6-4

Repair
Refer to parts manual for specific cylinder and repair part numbers. Refer to cylinder repair information in section 7 of this manual for type of cylinder on machine. Follow the instructions on the "General
Information" page, then follow the detailed instructions for the type of head and type of piston that matches
what is in the cylinder. For this particular cylinder, follow the procedures for "N" Type Head and "Z" Type
Piston. This cylinder is somewhat different, due to the double ended rod. Pay particular attention to the
notes and differences on the drawing (fig. 6-3).
Installation
1.
Protect the chrome surface of the exposed cylinder rods by wrapping with cloth or several layers of
paper. Wrap the threaded ends of the cylinder rods with tape to protect threads from damage. With
cylinder rods centered (equal length of rod exposed on both ends of cylinder body), lift cylinder
barrel (do not lift by the cylinder rods) and position under mast with the lower cylinder guide mounts
toward bottom of mast (fig. 6-3a).
2.
Position lower rod end through hole in mast base, then position upper rod end through hole in crown
block. Install spacers (item 52, fig. 6-1) and thread nut on rod ends so same length of rod extends
beyond nut as before removal.
3.
Install lower nut and tighten with chain wrench or special made wrench and a "cheater" pipe.
4.
Remove cap plugs from rod ends and install fittings and hoses (fig. 6-3b).
Fig. 6-3a Hoist/Pulldown Cylinder - lower end

1. Mast Base
2. Lower Cylinder Guide Mount
Fig. 6-3b Hoist/Pulldown Cylinder - lower end

1. Spacer
2. Nut
3. Hydraulic Fitting
6-5

Installation (continued)
5.
Install the four upper and two lower guide mounts and bolts on cylinder (fig's. 6-3c & 6-3d).
6.
Start engine and using pulldown control lever, move cylinder to align bolt holes with sheave mounting
brackets. Install 8 bolts using loctite on threads.
7.
Remove chain from rotary head and mast crown.
8.
Raise mast and run rotary head up and down mast ten to twelve times to work air out of the cylinder.
9.
Place hardwood block and steel plate used previously on auto tool wrench jaw. Bring rotary head
sub down against steel plate and block. Switch drill/propel switch to Drill mode and pulldown switch
to Engage pulldown. Set pulldown pressure to 4000 psi (275 bar) using pulldown system pressure
control.
10. Lower mast with pulldown pressure still at 4000 psi (275 bar), tighten lower hoist/pulldown cylinder
nut using chain wrench or special wrench and cheater pipe. Tighten nut as much as possible. Decrease pulldown pressure and switch pulldown switch to Disengage pulldown.
11. Weld chock bars back in place against hoist/pulldown cylinder nut on top and bottom of mast.
12. Raise mast and install bit sub, table bushing and bit. Install drill pipe.
13. Shut machine down and check the fluid level in the hydraulic reservoir and add as required.
Fig. 6-3c Hoist/Pulldown Cylinder Mounts

1. Upper Mounts (4)
2. Lower Mounts (2)
6-6
Fig. 6-3d Hoist/Pulldown Cylinder Mount Detail

45. Guide Pad (6)
46. Guide Pad Retainer (6)
47. Spacer (6)
48. Mounting Plate (3)
50. Capscrew (6)
51. Flat Washer (6)

WARNING:
Hoist / Pulldown Cable Adjustment
The following procedure is used to adjust the tension in the hoist/pulldown cable system. Frequency
of adjustment varies according to drilling methods and operational requirements.
Proper and equal cable tension is required to prevent misalignment of the rotary head, as well as,
limiting any undesired stress forces in the mast assembly.
1.
With one (1) piece of drill pipe in the rotary head, raise the rotary head to the top of the mast. Extend
the automatic tool wrench, and engage the jaw over the bit sub slats.
2.
Using the high-speed pulldown lever (or automatic feed switch if so equipped), apply 3000 PSI of
hydraulic pressure down on the breakout jaw. Lower the mast back down to the headache rack, as
in the tramming position.
3.
Tighten the top cable adjustment nuts (fig.6-4, item 24) until no sag is visible in the cables. Release
the hydraulic pressure on the system. The cables are now adjusted.
NOTE Over time, as the cables are adjusted, it will be noticed that the rotary head does
not travel all the way to the bottom of the mast, potentially causing non-engagement of the breakout wrench on the flats of the drill stem. At this point it will be
necessary to loosen the top cable adjustment nuts and then tighten the lower cable
adjustment nuts. Be sure to do this in equal amounts, i.e. one turn at the top for one
turn at the bottom. Once this is done, the normal cable adjustment procedure is to
be followed.
Fig. 6-4 Lower & Upper Mast Sections

24. Hex Nut (8)
25. Flat Washer (4)
31. Adapter
52. Spacer
53. Chock Bar
6-7
Hoist/Pulldown Cable Replacement

HOIST CABLE ADJUSTMENT
CROWN SHEAVE
HOIST CABLE
PULLDOWN CABLE
GUIDE ASSEMBLY
HOIST CABLES
PULLDOWN CABLES
PULLDOWN CABLE
ADJUSTMENT
MAST BASE SHEAVE
Fig. 6-5 Hoist/Pulldown Cables (ref. 427404)

6-8
Hoist/Pulldown Cable Replacement

WARNING:
Hoist / Pulldown Cable Replacement

1.
With one (1) piece of drill pipe in the rotary head, raise the rotary head to the top of the mast.
Extend the automatic tool wrench, and engage the jaw over the bit sub slats.
2.
Using the high-speed pulldown lever (or automatic feed switch if so equipped), apply 3000 PSI of
hydraulic pressure down on the breakout jaw. Lower mast to horizontal position, resting on mast
rest.
3.
If you are replacing the hoist cables, apply pressure downward, this will put some slack in the
hoist cables, so you can loosen the nuts.
If you are replacing the pulldown cables, apply pressure upward, this will put some slack in
the pulldown cables, so you can loosen the nuts.
Loosen the jam nuts and adjusting nuts until there is no tension on the cable.
NOTE Always replace cables in sets. Do not install a new cable on one side and a used
one on the other side.
4. Remove all sheaves that the cable passes through. Check all sheave bearings and seals and replace if necessary. Remove cable.
5.
Install new cable. Attach clevis to rotary head first, then install threaded end to mast. Grease and
install sheaves.
6.
Install adjusting nuts and tighten until cable feels tight enough to be tested.
7.
Follow procedure for hoist/pulldown cable adjustment.
6-9
Rotary Head Guide Alignment
Fig. 6-6 Rotary Drive Assembly (ref. 425073)

1. Rotary Gearbox
14. Capscrew, Drilled (12)
3. L.H. Rotary Guide
15. Flat Washer (12)
4. R.H. Rotary Guide
16. Capscrew, Brass (8)
5. Wear Pad (8)
30. Tie Wire
6. Shim, Wear Pad (8)
31. Chock Bar (6)
6-10
32. Chock Bar (2)

34. Wear Pad- 18" (4)
Rotary Head Guide Alignment

The following method is used to align the rotary head in relationship to the travel rails in the mast
assembly:
Spot and level the machine and raise the mast as in preparation for normal drilling operations.
Before drilling the hole, check to be sure pipe is plumb with a level on the pipe. Check this reading against
level in cab to be sure they are the same. Drill one pipe into the ground. At the completion of this pass,
raise the rotary head just enough to suspend the drill pipe in the hole, approximately 2 ft.
Check alignment of the pipe in the drill bushing. It should be hanging in the center without touching
the sides of the bushing. If it is touching, loosen the hex head screws attaching the wear pads to the
rotary guide assembly (fig. 6-6).
If shimming of the rotary head guide is necessary, add or subtract the necessary amount of shims
between the pads and guides until the drill stem hangs freely within the drill bushing. Retighten the guide
/ pad screws.
Follow the sequence below:
1.
Shim the inside wearpad first.
2.
Shim the front wearpad (towards the radiator end of the machine).
3.
Shim the rear wearpad (cab end of machine).
6-11
Rotary Drive Assembly
Fig. 6-6 Rotary Drive Assembly (ref. 425073)

1. Rotary Gearbox
14. Capscrew, Drilled (12)
3. L.H. Rotary Guide
4. R.H. Rotary Guide
5. Wear Pad (8)
30. Tie Wire
31. Chock Bar (6)
6-12
32. Chock Bar (2)

34. Wear Pad- 18" (4)
Rotary Drive Assembly

Rotary Drive - Removal from Mast
WARNING:

1.
Remove pipe from sub-adapter and lower mast to horizontal position. Be sure machine is on level
ground and position rotary head in an accessible working position. Grind the weld from the two
chock bars that secure the sub-adapter to the rotary drive shaft and remove sub-adapter.
2.
Remove air hose from swivel.
3.
Remove the two hydraulic motors and suspend with wire. Do not let motors hang by their hoses.
NOTE You must remove the center gearbox cover bolt on each outer edge of the gearbox, so it will clear the upper stop blocks when lifting out.
4.
Grind the welds from the two chock bars on the bottom of the rotary gearbox so you can lift the
gearbox out of the mast.
5.
Support rotary gearbox with suitable lifting device in two places. Cut tie wires (30) and remove
capscrews (14) that hold gearbox to guides (3 & 4). Carefully slide gearbox up and out of the
mast and take to shop for repair.
Rotary Drive - Installation

1.
Hoist rotary drive into position with suitable lifting device. Align unit between upper and lower stop
blocks and slide into guides (3 & 4). Align the six bolt holes in the rotary drive with the holes in the
right and left guides.
2.
Install the six capscrews and washers (14 & 15) on each side and torque to 282 ft. lbs. (384
Nm). Install lock wires as shown in fig. 6-6. Order lock wire from parts book, or use 16 ga. stainless steel wire, type 304.
WARNING:
BE SURE to install lock wires correctly, as per drawing.

NEVER reuse lock wires.
INSPECT lock wires daily to be sure none are broken or missing.
3.
Set main shaft bearing preload per procedure on page 6-16.
4.
Install seal housing, air swivel and rotation motors along with all hoses and any other connections
that were removed, don't forget the two gearbox cover bolts at the outer edges.
5.
Start machine and check that rotary drive functions properly and there are no leaks. Shut down
machine and install sub adapter or shock sub and tighten joint. Weld new chock bars in place on
the sub-adapter according to fig. 6-6. Also weld new chock bars in place under gearbox that were
removed earlier.
6-13
Rotary Drive Gearbox (built in air swivel)
Fig. 6-7a Rotary Drive Gearbox - with built in air swivel (ref. 424913)
NOTES:
6-14
1.
Set preload to 0.002 to 0.004 by placing an 8 X 8 wood block under rotary head and load pulldown to 1500
o
PSI (103 bar). Turn locknut (11) until it contacts bearing cone (26), then turn locknut another 15 . Tighten
setscrews (50) in locknut to 50 ft.lb. min. Tighten screws evenly and opposite to one another, gradually
increasing the torque. Do Not tighten screws prior to assembling locknut to shaft.
2.
Install silicone rubber sealant at all split lines unless shim or gasket is used.

Rotary Drive Gearbox (built in air swivel) - Item Listing
ITEM
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
ADAPTER-SPLINE
KEY
SHAFT
SHAFT, 24T
GEAR, 84T
SHAFT, 24T
GEAR, 110T
COVER, END
SPACER
SPACER
LOCK NUT
PLATE, SEAL
CARRIER, BEARING
HOUSING, SEAL
CASE
COVER
CAPSCREW, HEX HEAD
CAPSCREW, HEX HEAD
CAPSCREW, HEX HEAD
CAPSCREW, SOCKET HEAD
WASHER, LOCK
WASHER, LOCK
WASHER, LOCK
BEARING, CONE
BEARING, CUP
BEARING, CONE
BEARING, CUP
BEARING, CONE
BEARING, BALL
PIN, ROLL
PIN, DOWEL
BUSHING
PLUG, MAGNETIC
PLUG, PIPE, CSK
PLUG, O RING
PLUG, MAGNETIC
RING, RETAINING
RING, RETAINING
RING, RETAINING
RING, RETAINING
QTY.
2
2
1
2
2
2
1
2
1
1
1
1
1
1
1
1
14
13
8
6
14
19
8
4
4
1
2
1
4
1
2
1
1
2
1
1
2
2
2
1
ITEM
42
43
44
48
49
50
51
52
53
54
55
57
58
59
60
61
62
DESCRIPTION
SEAL
NAMEPLATE
WINDOW, OIL LEVEL
FITTING, BREATHER
SHIM SET
SET SCREW
PLUG, SQ HEAD
HOUSING, SEAL
SHIM, .005"
SHIM, .007"
SHIM, .020"
RING, PACKING
BUSHING, WEAR
SEAL
CAPSCREW, HEX HEAD
FITTING, GREASE
SHIELD
QTY.
1
1
1
1
2
4
1
1
3
3
1
2
1
2
6
1
1
Fig. 6-7b Rotary Drive Gearbox \with built in air swivel (ref. 424913)
6-15

Rotary Drive Gearbox - Repair
(Refer to Figure 6-7A.)
1.
Repair of the gearbox is limited to the replacement of damaged or worn parts.
2.
Inspect gear teeth for galling or heat discoloration and replace as necessary.
3.
Inspect gear teeth for uneven wear patterns.
4.
Inspect bearings and replace as necessary.
5.
Replace seals and gaskets.
NOTE
Refer to parts manual for specific gearbox and part numbers.
Main Shaft Bearing Preload
After repairs are made to rotary drive gearbox, the main shaft bearing preload of .002" to .004"
must be set as follows:
1. Do not install seal housing (14) until after setting main shaft bearing preload.
6-16
2.
With rotary gearbox installed on the mast, place an 8 X 8 wood block on top of the deck wrench
and lower rotary gearbox so it is against the block.
3.
Apply 1500 PSI (103 bar) pulldown pressure.
4.
Tighten locknut (11) by hand until it contacts the upper bearing cone (26), then turn (tighten)
o
locknut another 15 .
5.
On earlier models with external air swivel (fig. 6-7), tighten the four setscrews (50) in the locknut
evenly and opposite one another, gradually increasing torque to 50 FT.LBS. (68 Nm) minimum.
Later models with built in air swivel (fig. 6-7a), tighten the four capscrews (50) in the locknut
evenly and opposite one another, gradually increasing torque to 100 FT.LBS. (136 Nm) minimum.
6.
After correct setting of main shaft bearing preload, install the seal housing (14), air swivel (if
equipped), hydraulic motors and all connections that were removed.
Rotary Drive Gearbox

Seal Installation
In order to get maximum service life out of heavy duty face seals, they must be seated in their
housings symmetrically, resulting in a stable running position. If the seal halves are not installed accurately, misalignment or cocking of the seal set can occur during the assembly procedure, resulting in nonuniform face loading and wobbling of the seals in their housings. This is the leading cause of leakage and
premature failure. To avoid this, always follow these instructions.
1.
Clean all sealing components, seal rings (metal rings), load rings (bellevilles) and the housings with
denatured alcohol. Check to make sure that there is no nicks or burrs in the housing area that
could damage the load ring during installation.
2.
After components have dried, the load rings should be placed back on the seal rings in their
proper position. Make sure that the load rings are seated completely and tightly on the seal ring.
WARNING:
Do not place the seal rings face down on any hard or

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

cause leakage or premature failure.
6.
The seal may be adjusted by gently pushing the load ring into position with your fingers from the
outside.
WARNING:
Never use sharp instruments such as screwdrivers. They

can cause permanent damage to the load ring and/or
seal ring, which may lead to rapid failure.
Also, the seal ring may need to be adjusted in the load ring. This can also be done with your
fingers. For twists or obvious bulges in the load ring or if the seal ring is "riding up" on the load ring
can not be adjusted, remove the seal half and repeat the procedure, beginning with the cleaning
process.
6-17

7.
After successful installation in housings, wait a few minutes for the alcohol to completely evaporate, before assembling. The alcohol is necessary as a lubricant during the installation process,
but for assembly the area must be clean and dry in order for the load ring to properly "crush" into
its final position.
WARNING:
Never install seals with oil, grease or any solvent that can
leave a residue.
Assembly Instructions
1.
After both seal halves have been installed in the case and seal plate housings and just prior to
assembly, thoroughly clean the faces with denatured alcohol. Apply a thin film of oil (the same oil
that will be used in the drive unit) to the faces of the seal rings with a clean lint free cloth. Be
careful not to get oil on the load rings.
2.
Pick up the seal plate (with the half seal installed) with both hands and turn it over using your
fingers to hold the seal ring in place, while it is inverted. Line the plate up over the shaft and slide
on until the case seal face come in contact with your fingers. Slowly slide your fingers out at the
gap and let the faces come together.
3.
Place both hands on the seal plate and apply even pressure to the top of it to make sure that the
seal is completely seated in the housings. Turn the plate slightly in both directions while applying
pressure. At this time it is not important to line up the bolt holes.
4.
Visually inspect the gap between the plate and the case to see that it is the same size all of the
way around the circumference. If it is not, repeat step 3. If further adjustments are necessary,
remove the seal plate and the seal halves from their housings and repeat the installation procedure again starting with step 1 (cleaning process).
5.
Line up the bolt holes, and slowly and evenly draw the plate down to the case using the specified
torque.
Run-In Period
The run-in period is the amount of running time necessary for the faces to mate to each other to
form a perfect seal. One hour in each direction is normally sufficient. It is common for seals to
"weep" a little during this period. Continuous dripping and/or running oil is a signal that something
is wrong.
Maintenance
For trouble free function of the seal, adequate lubrication of the sealing faces is necessary at all
times. A small amount of oil may be visible on the outer diameter of the seal when it is working.
This is not a leak, but only the seal faces being properly lubricated. If a seal is removed or the
faces are separated after it has been run-in, it should be replaced with a new set.
6-18

Repair
1.
Repair of the gearbox is limited to the replacement of damaged or worn parts.
2.
Inspect gear teeth for galling or heat discoloration and replace as necessary.
3.
Inspect gear teeth for uneven wear patterns.
4.
Inspect bearings and replace as necessary.
5.
Replace seals and gaskets.
If further disassembly and repair are necessary, refer to the following Cotta TM2116-7 Repair Manual.
Refer to parts manual for specific gearbox and part numbers.
Main Shaft Bearing Preload

After repairs are made to rotary drive gearbox, the main shaft bearing preload of 0.002 to 0.004 in.
must be set as follows:
1.
Do not install seal housing until after setting main shaft bearing preload.
2.
With rotary gearbox installed on the mast, place an 8 X 8 wood block on top of the deck wrench
and lower rotary gearbox so it is against the block.
3.
Apply 3000 PSI (207 bar) pulldown pressure.
4.
Tighten locknut by hand enough to achieve 0.000 end play, then tighten 1/64 to 1/32 turn (5o to
11o).
5.
Tighten the setscrews in the locknut evenly and opposite one another, gradually increasing torque
to 50 ft. lbs. (68 Nm) minimum.
6.
Do not tighten screws prior to assembling locknut to shaft. Apply Loctite 242 to setscrews.
7.
After correct setting of main shaft bearing preload, install the seal housing, air swivel (if equipped),
hydraulic motors and all connections that were removed.
Rotary Head Bull Shaft Bearing Nut
NOTE:
Locknut is Left hand thread
6-19
Notes
6-20
6-21
Rotary Drive Gearbox Repair
6-22
6-23
6-24
6-25
6-26
6-27
6-28
6-29
6-30
6-31
6-32
6-33
6-34
6-35
6-36
6-37
6-38
6-39
6-40
6-41
6-42
6-43
6-44
6-45
6-46
6-47
6-48
6-49
6-50
6-51
6-52
6-53
6-54
6-55
6-56
6-57
6-58
6-59
6-60
6-61
Notes
6-62
Rotary Drive Gearbox Motor

Rotary Drive Gearbox Motor - Repair
Repair of hydraulic piston motors and pumps in this manual is limited to external controls (Refer to
Section 7) and shaft seal replacement. Normally when a piston motor or pump is worn out or damaged
internally it is more cost effective to replace it with a new or rebuilt unit.
Shaft Seal Replacement
Removal - Refer to fig. 6-8 on next page.

1.
Remove four screws (33), gaskets (32), seal retainer (31), and o-ring (29).
2.
Remove shaft seal (30) from shaft (27).
3.
Remove screw (26) that secures cam (23) to housing.
4.
Remove shaft and bearing assembly and cam (23) by grasping shaft and pulling out of housing
from end of unit opposite mounting flange.
CAUTION:
When removing shaft from cam, use extreme care not to

damage seal surface of shaft. Any scratches or marks on this
surface will cause leaks around shaft seal.
5.
Carefully remove shaft and bearing assembly from cam.
NOTE Do not remove bearing (18) from housing, unless damaged or worn.
Installation - Refer to fig. 6-8 on next page.

1.
Insert barrel stop (14) into the spring assembly (15) through the shaft seal end of motor.
2.
Insert the small end of drive shaft (27) and bearing through the bore of housing, bore of cam, and
into the barrel spline until shaft rests against the springs (15) in the barrel.
3.
Install o-rings (29) into counterbore of housing.
4.
Press shaft seal (30) into seal retainer (31). Grease seal lips.
5.
Install screws (33) through retainer (31). Install o-ring (32) over screw end protruding through
retainer. O-ring to be trapped in retainer recess.
6.
Install shaft seal (30) onto shaft using shaft seal assembly tool (see fig. 8a).
Use care not to scratch seal surface of shaft. Scratches will cause leakage around
the seal.
Slide seal retainer over shaft and into housing, letting bolts go through housing to cam. Engage
each screw 1-2 turns into cam.
NOTE
7.
8.
Tighten each screw by no more than 1/4" in sequence so that each screw is advanced equally.
Failure to do this may damage o-ring (32).
9.
Pull screws down tight and torque evenly to 50 ft. lbs. (68 Nm).
6-63
Fig. 6-8 Rotary Gearbox Rotation Motor (ref. 95176)
6-64

Fig. 6-8 Rotary Gearbox Motor - Parts List
1. Plug, Hex Soc. (2)
14. Barrel Stop (10
2. O Ring (2)
15. Disc Spring (12)
3. Screw, Hex Hd. Cap (4)
16. Thrust Washer (12)
4. Port Block w/Shuttle (1)
17. Cylinder Barrel (1)
5. Gasket (1)
18. Barrel Bushing (1)
6. Port Plate, CW (1)
19. Retaining Ring (1)
7. Face Plate (1)
8. Pin, Face Plate (5)
21. Piston, Shoes & Retainer (1)
9. O Ring (3)
22. Creep Plate (1)
10. Shuttle Valve (1)
23. Cam (1)
11. Screw, Hex Hd. (3)
24. Dowel Pin (2)
12. Retaining Ring (1)
25. Housing (1)
13. Spring Retainer (1)
26. Screw, Soc. Hd. Cap (1)

27. Shaft, Spined (1)
28. Bearing Assembly (1)
29. O Ring (1)
30. Shaft Seal (1)
31. Seal Retainer (1)
32. Gasket (4)
33. Screw, Hex Hd. Cap (4)
34. O Ring (1)
35. Plug, Hex Soc. (1)
Fig. 6-8a Shaft Seal Installation Tool
6-65

Trouble Shooting
Component problems and circuit problems are often interrelated. An improper circuit may operate
with apparent success but will cause failure of a particular component within it. The component failure is the
effect, not the cause of the problem. This general guide is offered to help in locating and eliminating the
cause of the problems by studying their effects.
6-66
Effect of Trouble
Possible Cause
Fault Which Needs Remedy
Noisy pump / motor
Air in Fluid
Leak in suction line

Leak at shaft seal
Low fluid level
Turbulent fluid
Return lines above fluid level
Gas leak from accumulator
Excessive pressure drop in the inlet
line from a pressurized reservoir
Suction line strainer acting as air trap
Cavitation in rotating group
Fluid too cold

Fluid too viscous
Fluid too heavy
Shaft speed too high
Suction line too small
Suction line collapsed
Suction strainer too small
Suction strainer too dirty
Operating altitude too high
Boost or replenishment pressure too low
Replenishment flow too small for
for dynamic conditions
Misaligned shaft
Faulty installation
Distortion in mounting
Axial interference
Faulty coupling
Excessive overhung loads
Mechanical fault in motor
Piston and shoe looseness or failure

Bearing Failure
Erosion on barrel ports

and port plate
Air in fluid
Cavitation
See Above
See Above
High wear in motor
Excessive loads
Reduce pressure settings

Reduce speeds
Contaminant particles
Improper filter maintenance

Filters too coarse
Introduction of dirty fluid into system
Reservoir openings
Reservoir breather
Improper line replacement

Trouble Shooting (continued)
Effect of Trouble
Possible Cause
Fault Which Needs Remedy
High wear
Improper fluid
Fluid too thin or thick for operating

temperature range
Breakdown of fluid with time/
temperature/shearing effects
Incorrect additives in new fluid
Destruction of additive effectiveness
with chemical aging
Improper repair
Incorrect parts
Incorrect procedures, dimensions, finishes
Unwanted water in fluid
Condensation
Faulty breather / strainer
Heat exchanger leakage
Faulty cleanup, practice
Water in make-up fluid
Cogging load
Mechanical considerations
Worn relief valve
Needed repairs
Slow response in check valves
Replace or relocate
Excessive decompression
energy rates
Improve decompression controls
Excessive line capacitance

(line volume, line stretch,
accumulator effects)
Reduce line size or lengths. Eliminate hose

Bleed air
Barrel blow-off
Recheck hold-down rotating group,

drain pressure
Excessive motor leakage
Recheck case drain flow and repair

required
Fluid too thin
Improper shaft assembly, port timing
Reservoir
Too little fluid

Entrained air in fluid
Improper baffles
Insulating air blanket that prevents
heat rejection
Heat pickup from adjacent equipment
Pressure shocks
Heating of fluid
6-67
Winch Assembly
Precautions on the Use of Winches
WARNING:
Winch brakes may slip or not function if operated in cold

weather before proper warm-up.
ALWAYS maintain a minimum five (5) wraps of wire rope on
the drum.
Before operating any winch, be absolutely sure that the drill hydraulic system is properly warmed up
to 100oF (38oC). After proper hydraulic system warm-up "exercise" the winch without load for several up
and down cycles to allow warm hydraulic fluid to circulate in the winch.
Wire Rope
Regular wire rope inspection, maintenance and replacement is necessary on all drill rigs. Environmental drills may have five or more different winches; each with a different wire rope size, length, operating condition and load factor. Wear can occur rapidly on one winch and be negligible on another on the
same drill rig.
The point at which to discard a wire rope is after receiving maximum service but without sacrificing
safety. This is achieved by visual inspection of the outside condition of the wire rope. Deterioration of wire
rope occurs both internally and externally from abuse, wear and corrosion. Research by wire rope manufacturers has shown that internal failures are followed by external failures visible to an inspector. On this
basis, careful examination of the outside of the wire rope is a satisfactory means of determining the
condition of the rope.
Since safety is dependent on the proper operation of the wire ropes in all operations, a visual
inspection of the wire rope should be performed daily by appointed personnel by running the block to its
lowest usable point, and slowly running the block up as all parts of the cable are observed for signs of
wear and damage:
A.
Kinks or severe twists
B.
Broken wires and nicks
C.
Deformed, worn or flattened wires
D.
Corroded or pitted surfaces
E.
Shortened or lengthened rope lays
Fig. 6-11 Wire Rope

6-68
Winch Assembly
Wire Rope (continued)
In addition, the following more detailed inspection should be performed monthly or at more frequent
intervals dependent upon operating conditions and usage:
WARNING:
When running out the wire rope, exercise care that the drum
stops at the end of the rope run-out and does not begin rewinding in the reverse direction. Stop run-out before you
reach the dead lays on the drum.
1.
Run out wire rope completely and note conditions such as the number of broken wires in one lay,
the reduction in rope diameter, corrosion, shortening of the lay and lubrication.
2.
Run a soft cloth (preferably cotton) over the entire length of wire rope and examine rope lays which
pick up threads of cloth. Determine the extent of damage due to broken wires or nicks.
3.
Examine sheaves and drums for abnormal wear, breakage or deterioration. Replace any sheave or
drum contributing to rope wear.
4.
Examine the wire rope closely at the equalizer sheave location. Where wear is noted, the rope can
be shortened from the dead end to change the point of wear. (However, two dead wraps must be
maintained on the drum and required lift or operating range not reduced.)
5.
Examine socketed fittings; if one broken wire is noted adjacent to the socket, resocket the wire
rope.
The length and type of service and the severity of operation must be taken into consideration before
determining the disposition of a wire rope which shows signs of damage. Where failure might endanger life
of equipment, the rope must be condemned and replaced if any of the following conditions are discovered:
1.
Six wires broken in one rope lay.
2.
Three wires broken in one strand in one rope lay
3.
Wear of 1/3 the original diameter of outside individual wires.
4.
Rope severely kinked, crushed, cut, or unstranded, or any other damage resulting in distortion of
rope structure.
5.
Considerable corrosion in the valleys between strands.
6.
Reduction from nominal rope diameter of more than 1/64" (0.3mm) for diameters up to and including 5/16" (3.1 mm); 1/32" (0.7mm) for diameters of 3/8" through 1/2" (9.5-12.7 mm); 3/64" (1.2
mm) for diameters of 9/16" through 3/4" (14.2-19.1 mm); 1/16" (1.6mm) for diameters of 7/8"
through 1-1/8" (22.2-28.6mm); and 3/32" (2.4mm) for diameters of 1-1/4" through 1-1/2" (31.838.1mm).
When any of the above conditions exist, the wire rope must be condemned and replaced.
6-69
Winch Assembly
Wire Rope (continued)
Lubrication is also important in the life of wire ropes, and can be accomplished with little trouble and
expense. Regular, frequent applications of lubricant are preferred to infrequent heavy applications. Brush,
spray, or dip the wire rope with cable lubricant M-2C-10 as required, depending on service conditions. The
lubricant must be applied properly to coat the entire cable, not just the portion in most frequent use. Wire
rope subjected to high operating temperatures or corrosive atmosphere should be lubricated semi-monthly.
Keep all wire ropes, including those infrequently used or those in storage, free of contaminants and
well protected with lubricant. Dirty cables should be cleaned and flushed with M-99C30 penetrating oil;
after one week, the entire surface should be brushed to remove all excess grease, accumulated dirt,
metal rust, or other harmful contaminants.
NOTE
NEVER subject a wire rope to shock loads or loads exceeding the safe load rating.
Wire Rope Clips

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

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

clips to the recommended torque will reduce the wire lines load
rating, thus creating a hazardous condition.
6-70
Winch Assembly
How to Apply Wire Rope Clips (continued)
A termination made in accordance with the above instructions, and using the number of clips shown
has an approximate 80% efficiency rating. This rating is based upon the catalog breaking strength of wire
rope. If a pulley is used in place of a thimble for turning back the rope, add one additional clip.
The number of clips shown is based upon using right regular or long lay wire rope, 6 x 19 class, or 6
x 37 class, fiber core or IWRC, IPS, or XIPS. If Seale construction or similar large outer wire type construction in the 6 x 19 class is to be used for sized 1" (25.4 mm) and larger, add one additional clip. The number
of clips shown also applies to right regular lay wire rope, 8 x 19 class, fiber core, IPS, sizes 1-1/2" (38.1mm)
and smaller; and right regular lay wire rope, 18 x 7 class, fiber core, IPS or XIPS, sizes 1-3/4" (44.5mm) and
smaller.
For other classes of wire rope not mentioned above, it may be necessary to add additional clips to the
number shown. If a greater number of clips is used than shown in the table, the amount of rope turn-back
should be increased proportionately.
Fig. 6-12 Wire Rope Clip Styles
Fig. 6-13 U-Bolt Wire Rope Clip Dimensions
6-71
Winch Assembly
Fig.6-14 Fist Grip Wire Rope Clip Dimensions
6-72
Winch Assembly
How to Apply Wire Rope Clips (continued)
1.
Fist Grip Clips

Turn back the specified amount of rope from the thimble. Apply the fist clip one base width from the
dead end of the wire rope. Tighten nuts evenly to recommended torque.
2.
Apply the next clip as near the loop as possible. Turn on nuts firmly, but do not tighten.
3.
Space additional clips if required equally between the first two. Turn on nuts, take up rope slack,
and tighten all nuts evenly on all clips to recommended torque.
WARNING:
Apply the initial load and retighten nuts to the recommended torque. New rope, in particular, and used rope will
stretch and shrink in diameter when loads are applied.
Inspect periodically and retighten.
A termination made in accordance with the above instructions, and using the number of clips shown,
has an approximate 80% efficiency rating. This rating is based upon the catalog breaking strength of wire
rope. If a pulley is used in place of a thimble for turning back the rope, add one additional clip.
The number of clips shown is based upon using right regular or long lay wire rope, 6 x 19 class, or 6
x 37 class, fiber core or IWRC, IPS, or XIPS. If Seale construction or similar large outer wire type construction in the 6 x 19 class is to be used for sized 1" (25.4 mm) and larger, add one additional clip. The number
of clips shown also applies to right regular lay wire rope, 8 x 19 class, fiber core, IPS, sizes 1-1/2" (38.1mm)
and smaller; and right regular lay wire rope, 18 x 7 class, fiber core, IPS or XIPS, sizes 1-1/2" (38.1mm) and
smaller.
For other classes of wire rope not mentioned above, it may be necessary to add additional clips to the
number shown. If a greater number of clips is used than shown in the table, the amount of rope turn-back
should be increased proportionately. The above is based on use of Fist Grip Clips on new wire rope.
WARNING:
Failure to make proper terminations or to periodically retighten

clips to the recommended torque will reduce the wire lines load
rating, thus creating a hazardous condition.
6-73
Winch Assembly
Wedge Sockets
One of the more popular end attachments for wire rope is the wedge socket. For field, or on-the-job
attachment, it is easily installed and quickly dismantled.
1.
Inspect the wedge and socket; all rough edges or burrs, that might damage the rope, should be
removed.
2.
If the rope is welded, the welded end should be cut off. This will allow the distortions of the ropes
strands, caused by the sharp bend around the wedge, to adjust themselves at the end of the line. If
the weld is not cut off, the distortions will be forced up the working line. This may result in the
development of high strands of wavy rope.
3.
Place the socket in an upright position and bring the rope around in a large, easy to handle loop.
Care must be taken to make certain that the live-loaded side of the rope is in line with the ears.
4.
The dead end of the rope should extend from the socket for a distance approximately nine times the
rope diameter. The wedge is now placed in the socket, and a wire rope clip is placed around the
dead end by clamping a short, extra piece or rope to the tail. (DO NOT clamp to the live part.) The
U-bolt should bear against the tail; the saddle of the clip should bear against the short extra piece.
5.
Secure the ears of the socket to a sturdy support and carefully take a strain on the live side of the
rope. Full the wedge and rope into position with tension sufficiently tight to hold them in place.
6.
After final pin connections are made, increase the loads gradually until the wedge is properly
seated. Avoid sudden shock loads.
The foregoing is the recommended procedure. If variations are made to suit special conditions, they
should be carefully evaluated beforehand.
Fig. 6-15
6-74
Winch Assembly
Grooved Drums
With grooved drums, the winding conditions should be closely supervised to assure adherence to
the following recommended procedures.
1.
The end of the rope must be secure to the drum by such means as will give the end attachment
at least as much strength as is specified by the equipment manufacturer.
2.
Adequate tension must be maintained on the rope while it is being wound so that the winding
proceeds under continuous tension.
3.
The rope must follow the groove.
4.
There should be at least three dead turns remaining on the drum when the rope is unwound during
normal operation. Two dead turns are a mandatory requirement in many codes and standards.
If the sire rope is carelessly wound, and, as a result, jumps the grooves, it will be crushed and cut
where it crosses from one groove to the other. Another, almost unavoidable problem is created at the
drum flange; as the rope climbs to a second layer there is further crushing and the wires receive excessive abrasion. Riser and filler strips may help remedy this condition.
Plain (Smooth) Drums

Installation of a wire rope on a smooth face drum requires a great deal of care. The starting position
should be at the drum end so that each turn of the rope will wind tightly against the preceding turn. Here
too, close supervision should be maintained during installation. This will help make certain that:
1.
the rope is properly attached to the drum;
2.
appropriate tension on the rope is maintained as it is wound on the drum;
3.
each turn is guided as close to the preceding turn as possible, so that there are no gaps between
turns; and
4.
there are at least two dead turns on the drum when the rope is fully unwound during normal
operating cycles.
Loose and uneven winding on a smooth drum can, and usually does, create excessive wear, crushing and distortion of the rope. The results of such abuse are lower operating performance, and a reduction in the rope's effective strength. Also, for an operation that is sensitive in terms of moving and spotting
a load, the operator will encounter control difficulties as the rope will pile up, pull into the pile and fall from
the pile to the drum surface. The ensuing shock can break or otherwise damage the rope.
6-75
Winch Assembly
Fig. 6-16 Wire Rope Cross-Over
Fig. 6-17 Diagram showing how to determine wire rope "lay"
6-76
Winch Assembly
Plain (Smooth) Drums (continued)
The proper direction of winding the first layer on a smooth drum can be determined by standing
behind the drum and looking along the path the rope travels, and then following one of the procedures
illustrated. The diagrams (Figs 6-16 and 6-17) show: the correct relationship that should be maintained
between the direction of lay rope (right or left), the direction of rotation of the drum (overwind or underwind),
winding from left to right, or right to left.
Drums - Multiple Layers

Many installations are designed with requirements for winding more than one layer of wire rope on a
drum, winding multiple layers presents some further problems.
The first layer should wind in a smooth, tight helix which, if the drum is grooved, is all ready established. The grooves allow the operator to work off the face of the drum, and permit the minimum number
of dead turns.
A smooth drum presents an additional problem, initially, as the wire rope must be wound in such a
manner that the first layer will be smooth and uniform, and will provide a firm foundation for the layers of
rope that will be wound over it. The first layer of rope on the smooth drum should be wound with tension
sufficient to assure a close helix, each turn being wound as close as possible to the preceding turn, and
most, if not all, of the entire layer being used as dead turns. The first layer then acts as a helical groove
which will guide the successive layers. Unlike wire ropes operating on groove drums, the first layer should
not be unwound from a smooth-faced drum with multiple layers.
After the rope has wound completely across the face of the drum (either smooth or grooved), it is
forced up to a second layer at the flange. The rope then winds back across the drum in the opposite
direction, lying in the depression between the turns of the rope on the first layer. Advancing across the
drum on the second layer, the rope, following the "grooves" formed by the second layer, the rope, following the "grooves" formed by the rope on the first layer, actually winds back one turn in each revolution of
the drum. The rope must then cross two rope "grooves" in order to advance across the drum for each
turn. The point at which this occurs is known as the cross-over. Cross-over is unavoidable on the second,
and all succeeding layers.
At these cross-over points, the rope is subjected to severe abrasion and crushing as it is pushed
over the two rope "grooves" and rides across the crown of the first rope layer. The scrubbing of the rope,
as this is happening, can easily be heard. There is, however, a special drum grooving available that will
greatly minimize the damage that can occur at crossover points. Severe abrasion can also be reduced
by applying the rule for the correct rope lay (right or left-lay) to the second layer rather than to the first
layer. It is for this reason that the first layer of a smooth drum should be wound tight and used as dead
turns.
Winch Assembly Service

Refer to the following Braden manual covering Model BG8A for service of the winch assembly.
6-77
Notes
6-78
6-79
Notes
6-80
6-81
6-82
6-83
6-84
6-85
6-86
6-87
6-88
6-89
6-90
6-91
6-92
6-93
6-94
6-95
6-96
6-97
6-98
6-99
6-100
6-101
6-102
6-103
6-104
6-105
6-106
6-107
6-108
H.O.B.O. Wrench
WARNING:

Service procedures for the Hydraulically Operated Break Out (H.O.B.O.) Wrench are limited to replacing or repairing cylinders, and replacing the tong dies and holders. Refer to parts manual for specific
repair part numbers, detailed drawings and cylinder repair kits.
Refer to Section 3 of this manual for repair procedures on Texas Hydraulics cylinders. When
repairing hydraulic cylinders follow the "General Information" instructions, then follow the specific
instructions for the type of head and piston the cylinder you are working on has.
Refer to Section 7 of this manual for pressure relief valve settings, sequence valve adjustment
and hydraulic schematic and piping diagrams.
Fig. 6-18 Hydraulically Operated

1. Swing Cylinder
2. Telescoping Cylinder
3. Rotate Cylinder
4. Clamp Cylinder
Break Out (H.O.B.O.) Wrench

5. Counterbalance Valve for Swing Cylinder
6. Sequence Valves for Clamp and Rotate Cylinders
7. Cylinder Lock/Float Valve for Telescoping Cylinder
6-109
Pipe Positioner
WARNING:

Service procedures for the pipe positioner are limited to replacing or repairing cylinders, and replacing pins and bushings. Refer to parts manual for specific repair part numbers, detailed drawings and
cylinder repair kits.
Refer to Section 3 of this manual for repair procedures on Texas Hydraulics cylinders. When
repairing hydraulic cylinders follow the "General Information" instructions, then follow the specific
instructions for the type of head and piston the cylinder you are working on has.
Refer to Section 7 of this manual for sequence valve adjustment and hydraulic schematic and
piping diagrams.
Fig. 6-19 Pipe Positioner

1. Swing Cylinder
2. Clamp Cylinder
3. Sequence Valves
6-110
Carousel Pipe Rack

Major Components
Fig. 6-20 Lower Pipe Rack

1. Pipe Rack Support
2. Carousel Pipe
3. Bearing Cap - Lower Pipe Rack Support
7. Thrust Washer - Lower Pipe Rack Support
45. Swing Cylinder - Lower
61. Index Cylinder
Fig. 6-21 Mid-Section of Pipe Rack

24. Mid-Support - 2 places
Fig. 6-22 Upper Pipe Rack

3. Bearing Cap - Upper Pipe Rack Support
4. Bearing Cap - Carousel
45. Swing Cylinder - Upper
6-111
Fig. 6-23 Pipe Rack Assembly (ref. 411495)

6. Bearing, Journal
2. Carousel Weldment
3. Bearing Cap, Support (2)
24. Mid-Support (2)
4. Bearing Cap, Carousel
25. Capscrew (12)
5. Bearing, Journal (4)
26. Nut, Hex (12)
27. Washer, Flat (24)

30. Bushing (2)
31. Nut, Elastic Stop (4)
33. Capscrew (4)

47. Shim Kit
57. Index Plate
60. End Cap
61. Cylinder, Index
Carousel Pipe Rack
6-112
Carousel Pipe Rack

General Information
Service to the pipe rack assembly primarily consists of replacement of the hydraulic cylinders,
replacement of the pipe rack support bearings, carousel bearings and pipe rack support roller.
Replacement of hydraulic cylinders is a straightforward procedure that requires no detailed steps.
Be sure the item is secure from movement before removing that cylinder. Be sure that lines are not
pressurized before disconnecting fittings. Study the detail drawings of that cylinder in this manual or in the
parts manual for removal and installation. Repair information for hydraulic cylinders is found in section 3
of this manual.
Pipe Rack Bearings - Removal

If bearings are worn, it is best to replace both upper and lower bearings at the same time to avoid
extra down time. Refer to photo's (fig's. 6-20 to 6-22) and drawings (fig's. 6-23 to 6-27) for disassembly
and assembly. Read through entire procedure before starting and be sure you have all parts required on
hand.
1. Remove pipe sections from carousel. Be sure machine is on level and stable ground. Lower mast
to horizontal position, resting on mast rest. Pipe rack must be fully retracted and resting against
the stop plate (item 35, fig. 6-27). Retract the index lock cylinders (8), so carousel is not locked.
Extend index cylinder (61) so carousel is rotated counterclockwise all the way (as viewed from
bottom).
2.
Remove pin (58) from index cylinder rod end. Retract cylinder and shut down machine.
3.
Support pipe rack be means of chain or sling and a suitable lifting device. Place chain or sling
around upper and lower portions of pipe rack support (1) and carousel weldment (2).
4.
Remove the pins (53) from the upper and lower pipe rack swing cylinders (45).
Fig. 6-24 Pipe Rack Swing Cylinder Assembly

13. Washer, Flat 3/8 (2)
50. Capscrew, 1/2 (4)
34. Grease Fitting
51. Washer, Flat 1/2 (4)
45. Cylinder, Swing
52. Bushing (4)
49. Pin, Bolt Retained (2)
54. Capscrew, 3/8 (2)

55. Bushing
56. Bushing
6-113
Fig. 6-23 Pipe Rack Assembly (ref. 411495)

6. Bearing, Journal
3. Bearing Cap, Support (2)
24. Mid-Support (2)
4. Bearing Cap, Carousel
25. Capscrew (12)
26. Nut, Hex (12)

30. Bushing (2)
31. Nut, Elastic Stop (4)
33. Capscrew (4)

47. Shim Kit
57. Index Plate
60. End Cap
61. Cylinder, Index
Carousel Pipe Rack
6-114
Carousel Pipe Rack

Pipe Rack Bearings - Removal continued
5.
See fig. 6-23. Remove the four capscrews (25) from the upper bearing caps (3 & 4) and lower
bearing cap (3).
6.
Remove the caps from the mid-supports (24), by removing the four capscrews (33).
7.
The pipe rack assembly is now free to move. Use caution and watch hoses to be sure they don't get
stretched. Move pipe rack assembly far enough to remove bearing caps (3 & 4) and to gain access
to the capscrews (62) that hold the end cap (60) to the bottom of the carousel.
8.
See fig's. 6-23 & 6-25. Remove the eight capscrews (62) that hold the end cap (60) to the bottom
of the carousel (2). Be careful not to lose the shims (47) under the cap.
Some units may not have any shims under the cap. They are only used if there is
insufficient clearance between the outer flange of the end cap and base of carousel. There needs to be about .030" (.76mm) clearance so carousel will not bind
when it is rotated.
Disconnect the index cylinder (61) from the index plate (57) and remove hoses from the index
lock cylinder (8). Cap or plug all open hydraulic fittings and hose ends.
NOTE
9.
10. Support the index plate (57) so it cannot fall when carousel pipe is removed. Slide the carousel
pipe (2) out of the index plate (57) and carousel support (1).
11. See fig. 6-26. Using a suitable lifting device, remove the index plate (57) to a convenient working
area.
Fig. 6-25 Lower Pipe Rack Assembly (ref. 411495)

8. Hydraulic Cylinder, Index Lock (2)
34. Grease Fitting
9. Pin, Carousel Lock
44. Bushing (2)
10. Insert, Pin
47. Shim Kit
11. Pin, Dowel
51. Washer, Flat 1/2
12. Capscrew 3/8
57. Index Plate
59.
60.
61.
62.
63.
End Cap, Cylinder (2)

End Cap, Carousel
Hydraulic Cylinder, Index
Capscrew 1/2 (8)
Capscrew 1/2 (8)
6-115
Carousel Pipe Rack

Pipe Rack Components - Inspection
1.
Inspect journal bearings (5 & 6) for wear. The I.D. for a new pipe rack support or carousel base
bearings (5) is 8.025" - 8.030" (203.8 - 204mm). The I.D. for a new upper carousel bearing (6) is
6.025" - 6.030" (153 - 153.2mm).
2.
Inspect the two mid-point support bushings (30) for wear. These are split bushings, the I.D. should
be 6.00" (152mm).
3.
Inspect the two nylon thrust washers (7) for wear. Original thickness is 1/2" (12.7mm). Replace if
wear is noticeable.
4.
Inspect all weld areas for cracking. Check for damaged, misaligned or worn components. Repair
any damage before reassembly of pipe rack.
5.
Replace damaged or leaking hoses, repair leaking cylinders.
6.
Inspect pipe rack roller (15) for wear. See separate repair instructions in this section.
Fig. 6-26 Lower Carousel Cross Section

15. Pipe Rack Roller
44. Bushing (2)
7. Thrust Washer
47. Shim Kit
8. Index Lock Cylinder (2)
12. Capscrew 3/8
57. Index Plate
6-116

59. End Cap, Cylinder (2)
60. End Cap, Carousel
61. Hydraulic Cylinder, Index
62. Capscrew 1/2 (8)
63. Capscrew 1/2 (8)
Carousel Pipe Rack

Pipe Rack - Assembly and Installation
NOTE Be sure to install the bearings so the grease groove is aligned with the grease
fitting.
1. The journal bearings (5 & 6) are a slight press fit. Be sure to install the bearings so the grease groove
is aligned with the grease fitting. Chill the bearings in a freezer for about 30 minutes before installing
and they should drop right in. Clean old grease from tube ends, coat journal bearings with new
grease.
2.
See fig. 6-26. Install thrust washer (7) onto lower carousel pipe. Install other thrust washer (7) onto
pipe rack support tube (1). Install lower carousel into bottom plate of pipe rack support (1). Install
index plate (57) onto end of carousel tube.
3.
See fig. 6-26. Install shims (47) and end cap (60) to bottom of carousel (2). Install 8 capscrews (62)
and washers (51). Tighten capscrews and check for correct clearance between end cap and bottom of carousel pipe. You should have about .003" (.08mm). Add or subtract shims to get correct
clearance.
4.
See fig. 6-23. Grease and install the upper and lower pipe rack support bearing caps (3) onto the
pipe rack support. Grease and install the upper carousel bearing cap (4) onto the upper carousel
pipe. Grease mid-point support bushings (30). Install new bushings if required.
5.
Hoist pipe rack assembly into position. Line up bearing cap bolt holes and install bearing cap bolts,
nuts and washers (25, 26 & 27, fig. 6-23). Line up swing cylinder rod ends with clevises and install
pins (53, fig. 6-24) and retaining bolts and washers (13 & 54). Tighten bearing cap bolts.
6.
Grease and install mid-point support caps and bushings (30). Fasten with capscrews, washers and
locknuts (33, 32, 31)
7.
Line up index cylinder (61) with index plate clevis and install pin (58) and retaining bolt and washer
(12 & 13).
8.
Install hydraulic hoses to index lock cylinders (8).
9.
Check all connections and all bolts for proper torque. Apply grease to all fittings at all pivot points.
Start machine and check to see that pipe rack carousel functions correctly and there are no leaks.
Fig. 6-27 Pipe Rack Top View

13. Flat Washer
34. Grease Fitting
35. Stop Plate
45. Swing Cylinder (2)
50. Capscrew
51. Flat Washer
54. Capscrew
6-117
Carousel Pipe Rack

Pipe Rack Roller Remove and Replace
1.
Lower mast to horizontal position, resting on mast

rest.
2.
Remove pipe rack roller from lower pipe rack

support, by removing the two capscrews that hold
the pipe rack roller shaft retainer plate (fig. 6-28).
Then remove the retainer plate.
3.
Remove grease fitting from end of roller shaft,

and use a port-a-power to drive shaft out of lower
pipe rack support. Repair or replace roller assembly.
4.
Install roller shaft into bore far enough so retainer 1. Capscrew (2)
plate will fit into the slot.
2. Retainer Plate, Pipe Rack Roller Shaft
Fig. 6-28 Pipe Rack Roller
5.
Install the two capscrews and lockwashers and 3. Shaft, Pipe Rack Roller
tighten.
6.
Grease bearings through grease fitting at end of

shaft. Grease once each shift.
Fig. 6-29 Pipe Rack Roller (viewed from mast pivot end)
4. Roller, Pipe Rack
5. Stop, Roller
6-118
Carousel Pipe Rack

Pipe Rack Roller Disassembly and Assembly
1.
Remove the two capscrews from the retainer

plate (fig. 6-30) and remove retainer plate.
Fig. 6-30 Pipe Rack Roller Retainer Plate.
2.
Turn roller over and remove the inner retaining

ring as shown in fig. 6-31
Fig. 6-31 Pipe Rack Roller Inner Retaining Ring.
3.
Remove seal retainer (fig. 6-32) by pressing out

shaft from opposite end using an arbor press. The
inner bearing cup will come out with the seal retainer.
Fig. 6-32 Pipe Rack Roller Seal Retainer.

6-119
Carousel Pipe Rack

Pipe Rack Roller Disassembly and Assembly
4.
Remove the outer retaining ring and outer bearing cup (fig. 6-33).
5.
Clean and inspect inner and outer surfaces of

roller. The I.D of the roller is 4.438" to 4.439".
Check O.D. for any flat spots or cracks. Check
roller shaft for damage and wear. The O.D. of the
shaft on the bearing side is 2.438" .001". The
O.D. of the shaft on the slot side is 2.498" + .002",
-.000". Check to be sure the grease passage is
not blocked.
6.
Install outer bearing cup (fig. 6-33) so it is past Fig. 6-33 Outer Bearing Cup and Retaining Ring.
the retaining ring groove.
7.
Install outer retaining ring and seat outer bearing

cup against retaining ring.
8.
Pack dual bearing cone with grease and press

onto roller shaft. Be sure bearing seats against
shoulder of shaft. Install shaft into roller (fig. 634).
9.
Press inner bearing cup (fig. 6-35) in place. Seat

bearing cup against bearing cone. Be sure shaft
rotates freely, but no excessive end play.
Fig. 6-34 Install Roller Shaft/Bearing Assembly into roller.
10. Install seal retainer (fig. 6-32) and seat below retaining ring groove. Install inner retaining ring (fig.
6-32).
11. Turn roller over and install retaining plate (fig. 630) with two capscrews and washers.
12. Install grease fitting into end of shaft and pump
full of grease until grease comes out of bearings.
Fig. 6-35 Install Inner Bearing Cup.

6-120
Section 7
Hydraulic Systems
SKS Hydraulic Systems
7-1
Notes
7-2
Hydraulic System
Hydraulic Reservoir and Return Filters
The hydraulic system consists of a hydraulic reservoir (tank) that supplies oil to hydraulic pumps. These
hydraulic pumps provide hydraulic pressure to operate all machine functions outside of the electrical and
compressed air circuits. From the pumps, oil is supplied to the levers and control valves which operate
hydraulic motors or cylinders. Another important feature of hydraulic systems is the filters.
All the oil returning to the tank flows through either the return manifold, the drain manifold, or the
case manifold. Oil returning from the return manifold must pass through the return filter before entering
the tank. Oil returning from the drain and case manifolds is first teed together before passing through the
case return filter. Both these filters have by-pass check valves in case the filters become blocked.
NOTE
It is important to remember that the pressure in the return, drain, and case manifolds is different. The pressure in the return manifold is around 20+ psi, and in the
drain and case manifolds is only <7 psi. This is particularly important when connecting case drains from motors or pumps. If they are connected to the return manifold
the increased pressure will prevent the case drain from draining, which will result in
too much oil in the case and blowing out the shaft / oil seal.
Fig. 7-1 SKS An important part of the hydraulic system is the filters.
Hydraulic Reservoir Assembly
1. Main Return Filter
2. Case Drain Filter
3. Air Filter
4. Service Valve (open to relieve pressure after machine is shut down)
5. Hydraulic Pressure Test Station (optional)
7-3
Pressure Setting Sequence

Pressure Setting Sequence
The following sequence is recommended for checking and setting pressures. Be sure to relieve all
pressure in system prior to installing gauges. If machine is equipped with a hydraulic pressure test station
(see fig's.7-2, & 7-2a) it will not be necessary to install gauges. The pressure setting procedures and locations are described fully in this section.
FUNCTION
PRESSURE
PAGE
5500 PSI (380 bar)
7-27
HYDRAULIC SYSTEM
1.
Crossover Relief
(High Pressure)
2.
RH Tram & LH Tram/Rotation

Pressure Override (P.O.R.)
5000 PSI (345 bar)
7-27
3.
Charge Pressure
450 PSI (31 bar)
7-29
4.
Mast Control Valves
2250 PSI (155 bar)
7-34
5.
Main Control Valves
2700 PSI (190 bar)
7-44
6.
Cooler Fan Speed (single)

Cooler Fan Speed (dual)
2400 PSI (166 bar)

2000 PSI (138 bar)
7-56
7-56
Fig. 7-2 Hydraulic Pressure Test Station (ref. 426487) - optional - mounted on hydraulic tank
7-4
Hydraulic Pressure Test Station Circuit
Fig. 7-2a Hydraulic Pressure Test Station Circuit (ref. 426487)

7-5
Hydraulic System
Drill Tooling Circuit
CAUTION:
Relieve pressure on hydraulic and pneumatic systems before loosening connections or parts.
NOTE
When checking and setting relief

valves, the engine should be operated at full governed RPM.
Open Service Valve on top of hydraulic tank

to relieve any residual pressure in system. Open
valve for about 30 seconds to let all air escape
from tank, then close valve. Install a 3000 PSI
(207 bar) test gauge in the inlet port or a work
port of the valve.
Start machine and engage one of the valve
functions on the mast valve to deadhead the pressure.
Correct relief valve pressure is 2250 PSI
(155 bar). This indicates that the relief valve is set Fig. 7-1 Hydraulic Tank
properly and that the pump will build pressure. To 1. Service Valve - open to relieve pressure after system is
adjust the relief valve, loosen the jam nut using a shut down.
13mm wrench. Use a 4mm allen wrench to adjust
relief valve adjusting screw.
With the pressure deadheaded, turn the adjusting screw clockwise to increase relief pressure,
or counter-clockwise to decrease the pressure.
Tighten the jam nut while holding the adjusting
screw. Recheck the pressure setting after the jam
nut is tightened, to be sure 2250 PSI (155 bar) is
showing on the gauge.
Fig. 7-3 Mast Valve Assembly (422873)

Located above HOBO wrench, on left side of mast.
7-6
Hydraulic System
Open Loop System (Low Pressure)
The open loop system consists of the necessary pumps, cylinders and controls to
prepare and position the drill rig for operations:
30 / 17 GPM Tandem Gear Pump
36 GPM Gear Pump
Carousel Swing & Rotation Cylinders
Pipe Positioning Cylinder
Tool Wrench Devices
Mast Locks
Dust Control System
Cooling Fan Circuits
Service Winch
Filtration
Pilot Pressure is initially filtered through one closed loop charge filter.
Fig. 7-3a Left Hand Pump
Fig. 7-4 Right Hand Pump
Return system pressure is filtered at the reservoir.
7-7
Hydraulic System
Open Loop System (Low Pressure)
NOTE
When checking and setting relief valves, engine should be operated at full governed
RPM.
The valve bodies are located on the hydraulic tank in front of the operator's cab (fig. 7-5).
Before checking pump and relief valve settings, ensure that the dust collector / water injection pump
control switch is in the neutral position.
Completely extend or retract the leveling jack cylinders. 2750 PSI (190 bar) should be shown on the
hydraulic system pressure gauge in the cab. This indicates that the hydraulic pump is building pressure and
the relief valves are set correctly. If not, adjust the relief valves as described below.
Adjustment Procedure
1.
This procedure is best done with two people. With machine running, have a helper in the cab hold one
of the valve functions on the upper (5 bank) valve in the open or closed position to deadhead the flow.
Adjust the relief valve on the upper (5 bank) valve until pressure on the hydraulic gauge in the cab
reads 2750 PSI (190 bar).
2.
Repeat this procedure in step 1 for the lower (4 bank) valve. You may have to back out the relief valve
on the lower (4 bank) valve a couple of turns so the pressure will be lower than 2750 PSI (190 bar).
If not, the pressure will relieve at the upper (5 bank) valve setting. Turn adjustment screw in until pressure on the hydraulic gauge in the cab reads 2750 PSI (190 bar).
Fig. 7-5 Deck Valve Assembly

1. Relief Valve Adjustment Screw
7-8
Hydraulic System
Closed Loop System
(High Pressure)
The closed loop system consists of two

AA4VG180 piston pumps, controlling the
tram and drill circuit.
Two AA4VG180 Piston Pumps
Hoist / Pulldown Cylinder
Rotary Drive Motor
Propel Motors
Pilot Control Valves
Fig. 7-6 Closed Loop Portion of Hydraulic Schematic (ref. 426661)

7-9
Main Hydraulic Pumps

NOTE
The main hydraulic pumps discussed as follows are Rexroth pumps. Some SKS series
of drills use Linde main pumps. Refer to the parts manuals for your machine and if
Linde equipped, refer to the Linde Pump Supplement at the end of this section.
Description
The main hydraulic pumps used on the SKS are the Rextroth AA4VG180 variable displacement pump
with built in charge pump. There are two types of pump controllers used, these are:
1. Electric Control (EP) - EP1 is 12VDC and EP2 is 24VDC. TEREX-Reedrill machines use 24VDC controllers.
2.
Hydraulic Pilot Control (HD).

These control options are described below.
AA4VG EP2 (electric control) Main Hydraulic Pumps

The two main pumps are AA4VG180EP2 Rexroth variable piston pumps. The left main pump
supplies pressure to the left hand tram circuit and the rotation circuit. The right main pump supplies pressure to the right hand tram circuit and the pulldown (feed) circuit. The circuits are closed loop circuits.
The internal charge pumps built into the back of each pump discharge through the Fe ports from which
the oil is directed through a charge filter for each pump then back into the Fa ports to supply charge pressure
to the piston pumps. The two charge circuits are teed together after the charge filter and pressure (450
psi) is controlled by a common charge relief. G ports are also looped together. Joining the charge circuit
enables one side to assist the other so preventing dips in the charge pressure which can cause cavitation
and reduced pump life. The charge pressure is used as pilot pressure on the servo piston to stroke the pump
as well as boosting the piston pump inlet. The standard integral charge relief in each pump is replaced by
an orifice plug which allows a small amount of charge oil to flush the pump case, but the volume is reduced
so pump case pressure is reduced and shaft seal life is increased. This particular pump configuration uses
an electric proportional (EP) control to control the pump flow. For a complete description, see following
pages under topic "EP (24VDC) Control".
AA4VG HD (hydraulic control) Main Hydraulic Pumps

The two main pumps are AA4VG180HD Rexroth variable piston pumps. The left main pump
supplies pressure to the left hand tram circuit and the rotation circuit. The right main pump supplies pressure to the right hand tram circuit and the pulldown (feed) circuit. The circuits are closed loop circuits.
The internal charge pumps built into the back of each pump discharge through the Fe ports from which
the oil is directed through a charge filter for each pump then back into the Fa ports to supply charge pressure
to the piston pumps. The two charge circuits are teed together after the charge filter and pressure (450
psi) is controlled by a common charge relief. G ports are also looped together. Joining the charge circuit
enables one side to assist the other so preventing dips in the charge pressure which can cause cavitation
and reduced pump life. The charge pressure is used as pilot pressure on the servo piston to stroke the pump
as well as boosting the piston pump inlet. The standard integral charge relief in each pump is replaced with
a charge cartridgeby an orifice plug which allows a small amount of charge oil to flush the pump case, but
the volume is reduced so pump case pressure is reduced and shaft seal life is increased. Pilot pressure to
control the pump direction and volume via the HD (hydraulic pilot) control is taken from the charge pressure. This pressure is supplied via the Drill/Tram solenoid valve, and then on to the control levers in the cab
before reaching the "Y1" or "Y2" ports to enable the pump to stroke in either direction.
7-10
Main Hydraulic Pumps (HD)
Fig. 7-7 Standard AA4VG Pump Circuit
7-11
Main Hydraulic Pumps - Port Locations
Fig. 7-8 Main Hydraulic Pumps - AAVVG180 Port Locations

Shown without Control
Right Track/Pulldown (Feed), Left Track/Rotation
7-12
Main Hydraulic Pumps - Port Locations
Fig. 7-8a EP Control Option
Fig. 7-8b HD Control Option
7-13
Main Hydraulic Pumps (EP)
Relief
Fig. 7-8c AA4VG Pump with electric controls (EP)
7-14
Charge Pump
Fig. 7-8d AA4VG Pump with electric controls (EP)

7-15
Fig. 7-8e AA4VG Pump with electric controls (EP)

7-16
Main Hydraulic Pump Circuit (EP)
Fig. 7-8f AA4VG Pump Circuit with electric controls (EP)
7-17
Main Hydraulic Pump Circuit (EP)

EP (24VDC) Control
EP stands for Electrical Proportional control. Pump flow is infinitely varied from 0 to 100 percent,
proportional to an electrical current in the range of 200 - 600 mA at 24VDC, supplied to solenoid A or B
(see table 7-1). Electrical energy is converted to a force acting on the control spool. The spool then directs
control oil in and out of the stroking piston to stroke the pump as required. A feedback lever, connected
to the stroking piston, maintains the pump flow for any given current within the control range. The plugs to
the solenoid valves are equipped with a green LED light (fig. 7-9). If the light is on, it indicates it is receiving
power.
Table 7-1 Current vs. Flow

Control Current (24 VDC):
Begin of control:
End of control:
I = 200 - 600 mA
l = 200 mA (Vg0)
l = 600 mA (Vg max)
Fig. 7-9 EP Control 24VDC

Solenoids are receiving power if green LED is on.
7-18

AA4VG Pump - HD Control Module
Fig. 7-9a AA4VG Pump - HD Control Module
Fig. 7-9b AA4VG Pump - HD Control Module

7-19

AA4VG Pump - Flow Diagram
Fig. 7-9c AA4VG Pump Flow Diagram
Fig. 7-9d AA4VG Pump Flow Diagram

7-20

Charge Pump - Flow Diagram
Fig. 7-9e AA4VG Charge Pump Flow Diagram
7-21
Main Hydraulic Pump Circuit (HD)
Fig. 7-10 AA4VG180HD Pump Schematic
7-22

Before Making Pump Adjustments
Before the main pumps can be centered or the pressure relief and pressure cut off settings can be
adjusted, a number of things have to be done;
1.
Disconnect the tram brake release hose at the tee above the track equalizer bar (fig. 7-10c). This will
set the brakes on and enable you to perform all main pump adjustments, and load the pump without
the rig moving.
2.
Disconnect the rotation torque control line (if used) from the left track/rotation pump (port X3, fig.
7-10e) and plug the port.
Fig. 7-10c 1/4" Brake Release Line - located above axle pivot
beam.
Fig. 7-10e AA4VG180EP Left Track & Rotation Pump.

X3 Port for Rotary Torque Control Connection.
Fig. 7-10d 1/4" Brake Release Line at tram motor.
7-23
Main Hydraulic Pumps Adjustments

Mechanical Centering
With tram brakes set as described previously.
1.
Remove plugs at ports X1 and X2, and connect both control chambers with a hydraulic hose, no
less than 1/4".
2.
Disconnect and plug the X3 port for the rotation torque control (if used).
3.
Install a 6000 PSI (414 bar) hydraulic pressure gauge to port MA and MB.
4.
With pump running, adjust zero position so that at blocked drive both gauges indicate the same
pressure. This pressure is approximately 440 PSI (30 bar).
5.
Use a 24mm wrench to loosen locknut. Use an 8mm allen wrench to adjust centering screw. Turn
allen wrench to the right and to the left and note the "dead band" (the area of the spool where no
signal is received on either side, i.e., no pressure change on gauge) of the zero position of the valve
spool.
6.
Tighten locknut, shut off machine, and remove the hose connecting ports X1 and X2 and install the
plugs.
Fig. 7-11 AA4VG180 Hydraulic Pump
7-24
Main Hydraulic Pumps Adjustments

Hydraulic Centering
(Refer to fig. 7-11a for the following procedures)

With tram brakes set as described previously.
1.
Install a 600 PSI (41 bar) hydraulic pressure gauge to ports X1 and X2.
2.
Disconnect and plug the X3 port for the rotation torque control.
3.
Loosen locking screw with a 4mm allen wrench. Turn adjusting screw with a 4mm allen wrench. Adjust zero position with allen wrench with pump in blocked drive so that both gauges read the same
pressure. This pressure is approximately 40 PSI (2.8 bar). Then tighten locking screw.
NOTE
DO NOT turn adjustment more than 90o in either direction. The adjustment screw is
an eccentric, therefore turning more than 90o will have no further effect, and could
damage the eccentric pin.
Fig. 7-11a AA4VG180 Pump (EP Controls shown)
Fig. 7-11 AA4VG180 Hydraulic Pump
7-25
Fig. 7-11b Pressure Cut-off (POR) adjustment.
Fig. 7-11c High Pressure adjustment.
7-26

High Pressure Valves and Pressure Cut-off (POR) Adjustments
1.
HP (high pressure) valves are always adjusted 10% higher than the pressure cut-off. If one setting is
changed, always check both settings.
2.
Make adjustments with system at normal operating temperature.
3.
Install a 6000 PSI (414 bar) hydraulic pressure gauge to ports MA and MB .
WARNING:
BE SURE machine is on level ground and block

tracks before removing brake lines.
NOTE
High pressure valves must be checked in both directions. In order to load both
pumps in both directions. Disconnect brake line to final drives at bulkhead fitting on
the front axle. Plug line and cap fitting. This will prevent the brakes from releasing
and you can now engage the propel levers in forward and reverse to load the pumps.
Pressure Cut-off (POR):

1.
Loosen locknut with a 13mm wrench, and with pump loaded (tram lever in forward or reverse),
turn adjusting screw in with a 4mm allen wrench. Correct pressure reading is 5000 PSI (345 bar).
Mark the setting of the adjusting screw. Then turn adjusting screw in until pressure is higher than
HP valves (5500 PSI [379 bar]). This must be done BEFORE setting the High Pressure Reliefs. Now
place tram lever in opposite direction.. Pressure should be equal on both sides of center.
High Pressure Valves:

1.
Operate tram valve with small pump flow volume (approximately 20%). Just enough to cause the
relief valves to crack, thus preventing all the oil from washing over the relief valve.
2.
Loosen locknut with a17mm wrench, and with pump loaded to 20% of full flow in one direction, turn
adjustment screw in with a 5mm allen wrench. Set high pressure relief valves to 5500 PSI (379
bar). Now repeat procedure in opposite direction of flow.
NOTE
DO NOT take more than 10 seconds with this setting as excessive heat will be generated with fluid flowing over the high pressure relief valves.
Pressure Cut-off (POR):

1.
After checking/adjusting high pressure setting, turn pressure cut-off back to the mark you first
made, or gauge reading of 5000 PSI (345 bar). The pressure cut-off must be 500 PSI (35 bar)
below the high pressure relief setting.
7-27

Stroking Orifices
Fig. 7-11d AA4VG180 Hydraulic Pump Stroking Orifices
7-28

Charge Pressure Circuit
Charge pressure is the pressue supplied to the inlet side of a piston pump. The piston pump needs
a positive charge to the inlet or it will cavitate and pump life will be reduced. The AA4VG180 piston pump
has an internal charge pump.
The charge pump is a fixed displacement gear pump. Oil comes from the tank in through the charge
pump, and out of the Fe port. The oil goes through the charge filter and back into the main piston pump
at the Fa port.
Both of the AA4VG180 piston pumps are tee'd together and the charge circuit is regulated with one
relief valve. This ensures that there is a constant pressure supplied to both the main piston pumps. If there
is a pressure drop on one side, the other side will supply extra oil to compensate for it.
Charge Pressure Adjustment

1.
Install a 600 PSI (41 bar) hydraulic pressure gauge in the test port of relief valve.
2.
Bring system up to normal operating temperature.
3.
Loosen locknut and adjust pressure to 450 PSI (27.6 bar), tighten locknut.
Fig. 7-12 SKS Main Pump Adjustments

1. Charge Pressure Adjustment
2. Relief Valve Test Port (Install gauge for
Charge Pressure here)
3. Relief Valve
4.
5.
6.
7.
High Pressure Adjustment (for. & rev.)

Pressure Cutoff (POR) Adjustment
Mechanical Zero Adjustment
Hydraulic Zero Adjustment
7-29
Main Hydraulic Pumps Specifications
Pressure Cut-Off
The pressure cut-off valve varies the swashplate angle, as required, to limit the maximum pressure at
port A or B. The pressure cut-off valve prevents continuous dumping of excessive flow, at load pressure,
through the cross port relief valves in the pump. This eliminates unnecessary heating of the oil and protects
the pump and motor during rapid acceleration or deceleration, or when the drive stalls, causing the pump
to deadhead.
The pressure peaks that occur with rapid swivel angle changes, and also the maximum system pressure, are further protected by the high pressure relief valves.
The pressure cut-off valve should be set 20-30 bar (290-435 PSI) less than the high pressure relief
valve settings. Standard Adjustment Range: 2175-6500 PSI (150-450 bar).
7-30
HD Pilot Control
7-31
Notes
7-32
EP Electric Pump Control
7-33
Mast Mounted Control Valve (SD8)

NOTE
When checking and setting relief

valves, the engine should be operated at full governed RPM.
Open Service Valve on top of hydraulic tank

to relieve any residual pressure in system. Open
valve for about 30 seconds to let all air escape
from tank, then close valve. Install a 3000 PSI
(207 bar) test gauge in the inlet port or a work
port of the valve.
Start machine and engage one of the valve
functions on the mast valve to deadhead the pressure.
Correct relief valve pressure is 2250 PSI
(155 bar). This indicates that the relief valve is set
properly and that the pump will build pressure. To
adjust the relief valve, loosen the jam nut using a
13mm wrench. Use a 4mm allen wrench to adjust
relief valve adjusting screw.
With the pressure deadheaded, turn the adjusting screw clockwise to increase relief pressure,
or counter-clockwise to decrease the pressure.
Tighten the jam nut while holding the adjusting
screw. Recheck the pressure setting after the jam
nut is tightened, to be sure 2250 PSI (155 bar) is
showing on the gauge.
7-34
Fig. 7-13 Left Side (dust collector) of Mast

1. SD8 Mast Valve Bank
2. Relief Valve Setting
3. Counterbalance Valve - HOBO Swing
4. Sequence Valves (2) - HOBO Clamp/Rotate
5. Float Valve - connects to Telescoping (float) Cylinder

Specifications
Spools
All eight spools on the mast valve are motor spools as shown below:
Fig. 7-14 Mast Valve - Motor Spool Diagram (all 8 sections)
7-35

Parallel Working Sections - Circuit Diagram
Fig. 7-15 Mast Valve - Work Section Diagram
7-36
Fig. 7-16 Mast Valve - Inlet Section with Relief Valve - set at 2250 PSI (155 bar).
7-37

Electro - Hydraulic Kit (24VDC)
Fig. 7-16a Mast Valve - Electro-Hydraulic Circuit
7-38

Electro - Hydraulic Kit (24VDC)
Fig. 7-16b Mast Valve - Electro-Hydraulic Circuit
7-39
Fig. 7-17 SD8 Mast Valve Assembly (ref. 422873)
Fig. 7-17a SD8 Mast Valve Assembly showing Feeder Kit option in gray (ref. 422873)
7-40
Fig. 7-17b SD8 Mast Valve - Inlet Section
Fig. 7-17c SD8 Mast Valve - Outlet Section
Fig. 7-17d SD8 Mast Valve - Work Section (1 - 8)

Parts List for 8 Section Valve Assembly (ref. 422873) - Refer to fig's. 7-17 through 7-17d.
1. Body, Inlet Section
9. Plug
2. Valve, Relief
10. Tie Rod Kit - torque to 37 ft. lbs. (50 Nm)
3. Body, Work Section 1- 8
11. Bracket Kit
4. Spool, Motor
12. Feeder Kit - 8 Section
5. 24 VDC Electro Hydraulic Kit (sections 1 - 8))
13. Seal Kit (includes o-rings for one working section and one
6. Plate, Dust Proof
outlet section. Order 3 kits for complete valve assembly).
7. Plug, Work Port (2 per section)
8. Body, Outlet Section
7-41
Fig. 7-18 SD8 Mast Valve - Torque Specifications
7-42
Fig. 7-18a SD8 Mast Valve - Troubleshooting

7-43
Main Control Valves (SD25 & SD16)

Deck Mounted Control Valves
There are two control valves that control the auxiliary functions (fig. 7-19). The upper (SD16) control
valve is a 5 bank valve. Four sections are solenoid operated, and one section (mast elevate) is hydraulic
pilot operated. The upper valve receives oil from the 30 GPM (114 lpm) gear pump. The power beyond
port feeds excess oil to the lower (SD25) 4 bank control valve. The lower 4 bank valve has 3 hydraulic
pilot operated sections for the jack functions, and one solenoid operated section for the service winch.
The lower valve receives oil from the 17 GPM (64 lpm) gear pump, and from the power beyond port of the
upper 5 bank valve.
1.
This procedure is best done with two people. With machine running, have a helper in the cab hold one
of the valve functions on the upper (5 bank) valve in the open or closed position to deadhead the flow.
Adjust the relief valve on the upper (5 bank) valve until pressure on the hydraulic gauge in the cab
reads 2750 PSI (190 bar).
2.
Repeat this procedure in step 1 for the lower (4 bank) valve. You may have to back out the relief valve
on the lower (4 bank) valve a couple of turns so the pressure will be lower than 2750 PSI (190 bar).
If not, the pressure will relieve at the upper (5 bank) valve setting. Turn adjustment screw in until pressure on the hydraulic gauge in the cab reads 2750 PSI (190 bar).
Fig. 7-19 Main Hydraulic Valves mounted on Hydraulic Tank (ref. 422952)
7-44
4 Section Valve (SD25)

Specifications
Fig. 7-19b Parallel Circuit with Two Sections
7-45
Fig. 7-20 4 Section Valve Assembly (ref. 422875)
Fig. 7-20a Inlet Section (ref. 422875)
Fig. 7-20b Valve Section 1 Assembly (ref. 422875)

7-46
Fig. 7-20c Valve Section 2 - 4 Assembly (ref. 422875)
Fig. 7-20d Outlet Section (ref. 422875)
Fig. 7-20e Feeder Kit - Electro-Hydraulic (ref. 422875)

Parts List for 4 Section Valve Assembly (ref. 422875) - Refer to fig's. 7-20 through 7-20e.
9. Body, Section 2 through 4
2. Valve, Relief
10. Spool, Sections 2 through 4
3. Body, Section 1
11. Hydraulic Spool Control Kit, Sections 2 through 4
4. Spool
5. Plug (2 per work section)
14. Bracket Kit
6. 24 VDC Electro Hydraulic Kit (section 1 only)
8. Feeder Kit (section 1 only)
8a. Plug, Power Beyond
8b. Valve, Backpressure
7-47

Torque Specifications
Fig. 7-21 4 Section Valve (SD25) Torque Specifications
Assembly
1.
Plug all openings to keep dirt out. Be sure all o-rings are in place between each section before
assembly. There are five round o-rings and one square o-ring between each section. Place a little
grease on the o-rings to hold them in place while assembling.
2.
Be sure to assemble valve sections on a flat surface. Install the four tie rods, and be sure the valve
assembly is perfectly flat. Install the four nuts on each end. Tighten nuts gradually in sequence to
37 ft. lbs. (50 Nm.).
3.
DO NOT over-tighten tie rod nuts, as this can cause leakage and valve spool binding or sticking.
7-48

Specifications
Fig. 7-22 Parallel Circuit with Two Sections
7-49
Fig. 7-23 5 Section Valve Assembly (ref. 422874)
Fig. 7-23a Inlet Section (ref. 422874)
Fig. 7-23b Valve Section 1 - 4 Assembly (ref. 422874)
7-50
Fig. 7-23c Valve Section 5 Assembly (ref. 422874)
Fig. 7-23d Outlet Section (ref. 422874)
Fig. 7-23e Feeder Kit - Electro-Hydraulic (ref. 422874)

Parts List for 5 Section Valve Assembly (ref. 422874) - Refer to fig's. 7-23 through 7-23e.
2. Valve, Relief
10. Plug, Sections 1 - 4 (2 per section)
3. Plug, Blanking
11. Body, Work Section 5
4. Plug, G 3/4
12. Spool, Cylinder (Work Section 5)
5. Feeder Kit, 4 Section
13. Spring Kit (not shown) use with Section 5
5a. Plug
5b. Valve, Backpressure
6. Body, Work Sections 1 - 4
16. Mounting Bracket Kit
7. Spool, Motor (Sections 1 - 4)
17. Plug
8. 24 VDC Electro Hydraulic Kit (sections 1 - 4)
7-51

Torque Specifications
Fig. 7-24 5 Section Valve (SD16) Torque Specifications
Assembly
7-52
1.
Plug all openings to keep dirt out. Be sure all o-rings are in place between each section before
assembly. There are five round o-rings and one square o-ring between each section. Place a little
grease on the o-rings to hold them in place while assembling.
2.
Be sure to assemble valve sections on a flat surface. Install the four tie rods, and be sure the valve
assembly is perfectly flat. Install the four nuts on each end. Tighten nuts gradually in sequence to
37 ft. lbs. (50 Nm.).
3.
DO NOT over-tighten tie rod nuts, as this can cause leakage and valve spool binding or sticking.
Counterbalance Valve
Counterbalance Valve Adjustments
CAUTION:
Over adjustment of a counterbalance valve, i.e. turning the

adjusting screw in too far, could result in uncontrolled descent of the mast assembly.
NOTE
Adjustment of the counterbalance valves is directly opposite of relief valves in this

system, in that clockwise adjustment of relief valves increases pressure, whereas
clockwise adjustment of the counterbalance valves decreases pressure. This must be
remembered when performing any adjustments to the system.
Fig. 7-25 Counterbalance Valve
7-53

The hydraulic circuit of the mast elevating cylinders is protected by three counterbalance valves. There
is one valve at the piston end of each cylinder, as well as, one that is tee'd into the rod end of both cylinders.
The single valve on the rod ends is for controlling the mast when it breaks over center during setup. This
is basically acting as a snubber valve to prevent the mast from running away when gravity overcomes the
pivot support balance. The two valves on the piston ends are for controlling the descent of the mast when
lowering back to tram position.
Fig. 7-26 Mast Elevating Circuit (ref. 405555)
Test and Adjustment

1.
2.
To determine if the valves are functioning correctly, the following procedure should be utilized:
Lower the mast approximately one half of the way down to horizontal. Shut down the engine. If mast
will move with engine shut down, then the valve on either or both piston ends is leaking by.
To adjust the valve, raise the mast back up and lock in position. Loosen the jam nut and back out
(counterclockwise) the adjusting screw in 1/4 turn increments. Tighten the jam nut and retest. If no difference is noted by the end of one full turn of the adjusting screw, then the valve must be replaced.
Another indication of a malfunctioning counterbalance valve is the mast assembly bouncing during
the lowering of the assembly. If this is experienced, then the same adjustment procedure as above applies,
except that the adjusting screw would be turned clockwise in 1/4 turn increments. Again, if no difference
is noted by the end of one full turn, then the valve should be replaced.
7-54

1.
The function of the dual counterbalance valves in the jack circuit is two-fold:
To prevent the machine from drifting down after the jacks are set.
2.
To prevent the jacks from drifting down when they are in the retracted position.
1.
2.
To check that the counterbalance valves are functioning properly:

Extend jacks to raise machine off ground. Mark position of jacks, and let machine stand overnight. If
machine has drifted down past mark, then counterbalance valve on rod end of cylinder needs adjustment or replacement.
Retract jacks all the way up. Let machine stand overnight. If rod end of cylinder has drifted down,
the counterbalance valve on piston end of cylinder needs adjustment or replacement.
Fig. 7-27 Leveling Jack Circuit with Dual Counterbalance Valves (ref. 423169)
Adjustment
While the valves are preset at the factory, they may be adjusted if drifting is encountered using the
above test. Loosen the jam nut and back out (counterclockwise) the adjusting screw 1/4 turn increments,
not to exceed one full turn. If drifting is still encountered, the valve must be replaced.
NOTE
If in the above test, the unit does not start lowering, but does so during normal operations, then the jack cylinder most likely is bypassing or leaking internally, and further
diagnostics and repair or replacement will be necessary.
7-55
Cooler Fan Circuit

Setting Cooler Fan Speed
Cooler fan pressure and flow is supplied by a open loop gear pump (fig. 7-27a).
Single Fan System
Single fan speed is factory set at 1550 RPM. This results from the fan pump relief valve being set at
approximately 2400 PSI (166 bar).
Dual Fan System
Dual fan speed is factory set at 1700RPM. This results from the fan pump relief valve being set at
approximately 2000 PSI (138 bar).
If you are operating in a hotter or colder environment, you may need to adjust fan speed accordingly.
You do not want to waste horsepower by operating the fan at a higher speed than necessary.
1. Shutdown machine and relieve standing pressure.
2.
Install a 6000 PSI (414 bar) gauge in gauge port on back side of relief valve, opposite of relief valve
adjustment screw (fig. 7-17). Or, if machine is equipped with a hydraulic pressure test station, turn
the knob to FAN PUMP.
3.
Start machine and allow system to warm up. Loosen lock nut and adjust screw (item 2, fig. 7-17) to
desired pressure for fan R.P.M. Check fan speed with a strobe tachometer. When fan speed is correct, tighten lock nut. Shut down machine, relieve standing pressure, remove gauge and install plug
in gauge port.
Fig. 7-27a Cooler Fan Pump

1. Relief Valve
7-56
Cooler Fan Circuit

Hydraulic oil cooler
Hydraulic oil flows from the fan pump through the hydraulic fan motors then through a thermal by-pass
valve then straight back to tank via the return filter until 140o F (60o C) is reached. The thermostat will then
shift and redirect oil through the cooler pack before going back to tank. If the cooler becomes blocked oil
will be redirected straight back to tank via the by-pass check valve. The by-pass check valve like all check
valves is a differential check valve and opens at 45 psi differential between the secondary and primary lines
. The thermostat by-pass is mounted at the bottom of the cooler pack.
When the engine is shut down, in order to prevent the inertia from the fan draining the motor pressure
line and causing the motor to cavitate, oil is diverted from the cooler discharge (to tank line) back through the
motor via the wind down check valve, therefore ensuring positive charge on the inlet for the fan motor.
Fan motor
There are either one or two hydraulically operated fan motors on the cooling pack depending upon
engine/compressor option. Each motor has a manifold mounted wind down check fitted across A and B
ports. This enables fluid from the return side to circulate back through the motor as it slows down after the
rig is shut down so preventing cavitation.
Fig.7-27b Dual Cooler Fans

1. Manifold
2. Wind Down (Anti-Cavitation) Check Valve
3. Thermal By-Pass Valve
7-57
Cooler Fan Circuit
Fig. 7-27c Dual Fan Circuit (ref. 420107)
7-58
Cooler Fan Circuit

Thermal Bypass Valve Operation
Fig. 7-27d Thermal Bypass Valve
7-59
Hoist/Pulldown Cylinder Counterbalance Valve

The function of the counterbalance valve on the hoist / pulldown cylinder is to prevent the rotary head
from dropping when the control is in neutral. It also stops creeping of the cylinder due to pump leakage
when changing drill steel or tramming.
Fig. 7-28 Hoist Pulldown Cylinder
To determine if the counterbalance is functioning correctly, the following procedure should

be used:
Suspend a length of drill steel from the rotary drive; shut down the engine, and watch for creep over
a period of several minutes. If it creeps down, then the counterbalance valve should be checked. Remove
the acorn nut, loosen the jam nut and back out the adjusting screw in 1/4 turn increments. Do Not exceed
one full turn of adjustment.
NOTE
7-60
Prior to replacement of suspected defective counterbalance valve, the pump controller

should be checked for neutral positioning (engine running). If controller is centered in
neutral while running, and counterbalance valve replacement has no effect, then the
hoist / pulldown cylinder is leaking and the cylinder should be repaired.
Hydraulic Operated Breakout Wrench

Setting of Sequence Valves
Adjustment Screw
To Drain
To Drain
3
Rotate Cylinder - Retract
2
Rotate Cylinder - Extend
B From Mast Valve

to Clamp Cylinder - Retract
B Valve
A From Mast Valve
to Clamp Cylinder - Extend
1
A Valve
Fig. 7-28a Sequence Valves for Breakout Wrench.
1.
Check setting of mast valve bank relief. It should be set at 2250 PSI (155 bar). See adjustment
procedure on facing page.
2.
Position H.O.B.O. wrench in open position.
3.
Loosen and remove cap nut from adjustment screws (fig. 7-28a). Loosen locknut.
4.
Screw both adjustments fully in, but not overly firm.
5.
Operate breakout wrench to undo pipe. Pipe clamp cylinder will operate to full stroke, but rotate
cylinder will not move.
6.
While holding switch to clamp, adjust screw of the "A" (top) valve slowly outward until rotate cylinder
actuates, adjust screw slightly more so that the cylinder operates freely. "A" valve is now correctly
set - lock locknut.
There should be about 200 PSI (14 bar) differential pressure between the clamp and
rotate cylinders. This is to assure the clamp jaws are tight around the pipe before the
rotate cylinder actuates, otherwise the jaws will slip on the pipe.
Operate breakout to retract, clamp cylinder will release pipe but rotate cylinder will not move.
NOTE
7.
8.
While holding switch to retract, adjust screw on "B" (lower) valve slowly outward until actuation occurs. Adjust slightly more to achieve free movement.
9.
Tighten adjustment locknut, install both protection caps.
10. Breakout sequencing now correctly set.

See Figure 7-29 for breakout wrench schematic.
7-61
Fig. 7-29 SKS Hydraulic Operated Breakout Wrench (ref. 426769)
H.O.B.O. Wrench Circuit
7-62
H.O.B.O. Wrench
Operation
1.
First be sure the pipe has been secured with the deck wrench on the flats of the pipe.
2.
Be sure the clamp jaws are all the way open before swinging the wrench in.
3.
The SWING cylinder (1), swings the H.O.B.O. wrench into position on the pipe.
4.
The ROTATE (2) and CLAMP cylinder (3) work together through the sequence valves (fig. 7-28a).
When the clamp cylinder reaches the preset pressure, then the rotate cylinder operates to turn the
pipe and break the joint.
NOTE There should be about 200 PSI (14 bar) differential pressure between the clamp and
rotate cylinders. This is to assure the clamp jaws are tight around the pipe before the
rotate cylinder actuates, otherwise the jaws will slip on the pipe.
Fig. 7-29a Hydraulically Operated Breakout Wrench (H.O.B.O.)

1. Swing Cylinder
2. Rotate Cylinder
3. Clamp Cylinder
7-63
Loop Filters (optional)
Fig. 7-30 Loop Filter Assembly (ref. 402263)

1. Bleed Plug
7. O Ring, Filter Element
2. O-Ring
7A. O Ring, Core Tube
3. Bowl
8. Backup Ring
4. Safety Grip
9. O-Ring
5. Label, Element Change
10. Retaining Ring
6. Filter Element
11. Reverse Flow Valve
6A. Core Tube
24. Bleed Plug
7-64
25.
26.
27.
28.
29.
32.
O-Ring
Differential Pressure Device
O-Ring
O-Ring
Dust Cover
Head

Routine Maintenance
The loop filters do not normally require special attention except for periodic monitoring of the dirty
element warning device. See lubrication section for filter change intervals. Refer to Figure 7-40 for item
numbers.
1.
If external leakage is noted, replace o-ring at leak. For bowl seal leaks, replace o-ring (9) and backup
ring (8), locating backup ring as shown in illustration (away from fluid, toward bowl (3) and the atmosphere). If leakage persists, check sealing surfaces for scratches or cracks; replace any defective
parts.
2.
Differential pressure indicators (26) act as a dirty element warning device and actuate when differential pressure across the element becomes excessive because of plugging by contaminant or
because of high fluid viscosity under cold start conditions. If visual indicator actuates (red button
extends 3/15" or 4.8 mm), reset by pushing button back after system reaches normal operating temperature at normal flow. If button stays in, element is still usable; if button will not stay in,
change element (6).

WARNING:

Failure to depressurize system before proceeding could result in
explosive loss of fluid, damage to equipment, or possible personal injury.
1.
Turn off and depressurize system. Open bleed plug (1 or 24) at top of filter one and one-half turns.
Remove plug (24 or 1) at bottom of filter and drain fluid into suitable container. Reinstall drain plug
and tighten both plugs.
2.
Remove bowl (3). Remove element (6) along with core (6A) and carefully inspect the surface for significant visible contamination. Normally, no dirt should show but visible dirt can be an early warning
of system component breakdown and can indicate potential failure. Discard both the element and
its o-ring, but do not discard the core (6A). The filter element is not cleanable. Any attempt to
clean the filter element can cause degradation of the filter medium and allow contaminated fluid to
pass through the filter.
NOTE Older model filters do not use the separate coreless filter and core assembly. The
corless filter and core assembly can be fitted to the older models as a direct replacement for the filter with core.
Core part number V011138.
Filter Element part number V011136.
The coreless filter elements provide longer service life and the core can be reused at
each filter change.
7-65
Fig. 7-30 Loop Filter Assembly (ref. 402263)

1. Bleed Plug
7. O Ring, Filter Element
2. O-Ring
7A. O Ring, Core Tube
3. Bowl
8. Backup Ring
4. Safety Grip
9. O-Ring
5. Label, Element Change
10. Retaining Ring
6. Filter Element
11. Reverse Flow Valve
6A. Core Tube
24. Bleed Plug
7-66
25.
26.
27.
28.
29.
32.
O-Ring
Differential Pressure Device
O-Ring
O-Ring
Dust Cover
Head

Refer to fig. 7-30
3.
Inspect filter housing and its bypass / reverse flow valve for possible damage or malfunction. Determine whether replacement of any components is necessary. Remove any accumulated dirt from
filter, being careful to prevent contaminant from entering the outlet and washing downstream. Refer
to element change instructions.
CAUTION:
Failure to replace damaged components, and operation without

a properly functioning hydraulic filter can cause components
downstream of the filter to fail or degrade in their performance.
Check that bowl seals; o-ring (9) and backup ring (8)) in head are not damaged. Use replacement filter element part number called for on assembly nameplate. Lubricate threads and sealing surfaces
on bowl (3) and the o-ring (7) in element with clean system fluid.
4.
Push open end of filter element onto the core (6A). Lubricate the core o-ring (7A) and push the core
and filter into the filter head (32). Screw bowl to head until bottomed. O-ring sealing not improved by
overtightening; do not exceed 15 ft-lbs (20 Nm) torque. Bleed system. Reset visual warning device
by pushing in the red button; electrical switch is reset automatically.
5.
Pressurize system fully and check for external leaks; if leaks occur, check o-rings and sealing
surfaces. After system reaches normal operating temperature, check that electrical switch has not
actuated or that visual warning button remains down.
Fig. 7-31 Optional Charge Loop Filters (two per pump)

Mounted adjacent to mast "A" frame, two each side)
7-67
Charge Filters
Fig. 7-32 Charge Filter Assembly (ref. 58495)

2. Plug
3. O-Ring
4. O-Ring
5. Filter Element
6. Filter Bowl
7. Filter Head
7-68
Charge Filters
Routine Maintenance
The charge filters do not normally require special attention except for periodic monitoring of the dirty
element warning device. See lubrication section for filter change intervals. Refer to figure 7-42 for item
numbers.
1.
If external leakage is noted, replace o-ring at leak. For bowl seal leaks, replace o-ring (4). If leakage
persists, check sealing surfaces for scratches or cracks; replace any defective parts.
2.
Differential pressure devices actuate when the element needs changing or because of high fluid viscosity under cold start conditions. If visual indicator actuates (red button extends 3/15" or 4.8 mm),
reset by pushing button back after system reaches normal operating temperature at normal flow. If
button stays in, element is still usable; if button will not stay in, change element (6).

WARNING:

1.
Turn off and depressurize system. Open bleed plug (if fitted) one and one-half turns.
2.
Unscrew and remove filter bole (6) from head assembly (7), counterclockwise when viewed from
below. It may be necessary to use a lever on the "Rotolock Ring" of the filter bowl (6) to loosen the
bowl initially.
3.
Remove filter element (5) along with core, and carefully inspect the surface for visible contamination. Normally no dirt should show, but visible dirt or particles can be an early warning of system
component breakdown and can indicate potential failure. Discard both the filter element and its
o-ring, but do not discard the core. The filter element is not cleanable. Any attempt to clean
the filter element can cause degradation of the filter medium and allow contaminated fluid to pass
through the filter element.
CAUTION:
NOTE
Older model filters do not use the separate coreless filter and core assembly. The
corless filter and core assembly can be fitted to the older models as a direct replacement for the filter with core.
Core part number V011137.
Filter Element part number V011135.
The coreless filter elements provide longer service life and the core can be reused at
each filter change.
7-69
Charge Filter
Fig. 7-33 Charge Filter Assembly - adjacent to pumps

1. Charge Filters (2)
Fig. 7-34 Right Side Charge Filter Assembly
7-70
Charge Filter
4.
DO NOT run the system without a filter element (5) installed. Check that the o-ring (4) on the head
assembly (7) is not damaged. Use replacement filter element part number called for on the element
change label, or refer to the parts manual.
5.
Lubricate element o-ring (4) with clean system fluid and push open end of filter element (5) onto the
core. Lubricate o-ring on core and push core and filter into filter head (7). Clean out filter bowl (6)
interior and lightly lubricate threads of filter bowl with clean system fluid. Screw filter bowl onto head
assembly until it bottoms. O-ring sealing in not improved by overtightening.
CAUTION:
DO NOT use pipe wrench, hammer, or any other tool to tighten

bowl.
6. Bleed the system and check for leaks. To bleed filter, open bleed plug, if fitted, one and one
half turns. Jog system and fill filter until all air bleeds through plug, then tighten plug. Pressurize
system fully and check for leaks; if leaks occur, check o-rings and sealing surfaces.
7.
After element change, ensure differential pressure device is reset by pushing in the button; electrical switches reset automatically. When system reaches normal operating temperature, check that
the electrical switch has not actuated and/or the visual warning button has remained depressed. If
visual indicator rises due to a cold start condition, reset again as outlined in "Routine Maintenance".
7-71
Main Return and Case Drain Filter
Fig. 7-35 Main Return and Case Drain Filter

1. Head
2. Cover Assembly
3. Shell
4. Upper Cover O-Ring
5. Lower Cover O-Ring
6. Head to Reservoir O-Ring
7. Filter Element
8. Element O-Ring
9. Indicator
10. Indicator O-Ring
11. Indicator O-Ring
12. Anti-Backflow Assembly
13. Weldable Adapter Flange
7-72

Routine Maintenance
Main Return and Case Drain filters do not normally require special attention except for periodic monitoring of the differential pressure warning device. Schedule replacement of filter element every six months
or sooner, and have ample supply of spare elements available.
1.
If external leaking is noted, replace o-ring at leak. For cover seal (4) and reservoir to head seal (6)
leaks, replace o-rings. If leakage persists, check sealing surfaces for scratches or cracks; replace
any defective parts.
2.
Differential pressure devices actuate when the element needs changing or because of high fluid
viscosity in "cold start" conditions. If visual indicator is fitted and actuates during "cold start", reset
by depressing the rubber button when the normal operating temperature is reached. If indicator
actuates after resetting, replace element.

WARNING:

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

NOTE The 'O' ring (item 5) is very easily dislodged. The filter will bypass if assembled without
the Oring. It is therefore imperative that the 'O' ring is checked every time the filter
is removed.
It is recommended that the 'O' ring be replaced every time the filter is changed.
7-73
Fig. 7-36 Main Return and Case Drain Filter Assembly

1. Main Return Filter
2. Case Drain Filter
3. Air Filter
4. Service Valve (open to relieve pressure after machine is shut down)
Fig.7-37
7-74
Main Return and Case Drain Filters

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

bowl.
6.
Bleed the system and check for leaks. To bleed filter, open bleed plug, if fitted, one and one half
turns. Jog system and fill filter until all air bleeds through plug, then tighten plug. Pressurize system
fully and check for leaks; if leaks occur, check o-rings and sealing surfaces.
7.
After element change, ensure differential pressure device is reset by pushing in the button; electrical switches reset automatically. When system reaches normal operating temperature, check that
the electrical switch has not actuated and/or the visual warning button has remained depressed. If
visual indicator rises due to a cold start condition, reset again as outlined in "Routine Maintenance".
7-75
Hydraulic Cylinder Repair

WARNING:
RELIEVE all pressure before attempting service or maintenance

procedures to this machine.
RELIEVE pressure in both hydraulic and pneumatic systems
before loosening any connections or parts.
The following pages provide information on hydraulic cylinder repair.
Refer to your parts manual to identify and order replacement parts for the cylinder you are working on.
Identify the specific type of head and piston in the cylinder and then follow the steps as outlined below:
7-76
1.
Follow the General Information steps on the following pages.
2.
Follow the Teardown steps.
3.
Follow the Inspection steps.
4.
Follow the specific Rebuild steps for head and piston type you are working on.
7-77
7-78
7-79
7-80
7-81
7-82
7-83
7-84
7-85
7-86
7-87
7-88
7-89
7-90
7-91
7-92
Hydraulic SchematicSKS-W (Linde Pumps)

DRN-9
HOBO
PIPE POSITIONER
DRN-8
RET-9
CLAMP
3
2
SWING
3
2
DRN-3
V1
C1
PIPE RACK SWING
HOBO
3
2
RET-6
R.H. FRONT
CLAMP
C2
V2
EF
C2
CF
PIPE RACK SWING
V2
MAST LOCK
P
V1
C1
3
1
V1
WINCH
BRAKE
L.H. FRONT
3
C2
C1
1
C2
HOBO SWING
WINCH ASSEMBLY
W/BRAKE VALVE
& STATIC BRAKE
V2
DR
V1
C1
C2
3
1
PIPE POSITIONER
(2250 PSI)
C1
V1
C1
MAST LOCK
RET-8
MAIN AIR
ROTATE
L.H. REAR
MAST ELEVATE
WATER PUMP MOTOR
(2250 PSI)
3
1
VIEWING HATCH
RET-12
BR
V2
V1
C1
3
1
BRAKE
VALVE
PIPE RACK LOCK
3
1
DUST CURTAIN
V2
V1
C1
V1
C2
C2
V2
V2
3
PIPE RACK ROTATE
PIPE RACK LOCK
C2
DUST CURTAIN
V2
AUTO TOOL
RET-3
RET-4
L
V
RET-11
25 bar
|A 1
25 bar
362 psi
8 bar
T
25 bar
362 psi
P
P
R.H. REAR
175 bar
2800 psi
DUST
CURTAIN
MAST
LOCK
WATER
INJECTION
MAIN
AIR
VIEWING
HATCH
C
RET-7
175 bar
2800psi
MAST
ELEVATE
WINCH
L.H.
REAR
JACK
FRONT
JACKS
R.H.
REAR
JACK
175 bar
2800 psi
TO GAUGE
IN CAB
HOBO
SWING
AUTO
TOOL
HOBO
CLAMP
SPARE
PIPE
PIPE
RACK
LOCK
POSITIONER
PIPE
RACK
SWING
PIPE
RACK
ROTATE
DRN-10
50 PSI
RET-5
P
A
45 PSI
DRAIN
1600
MANIFOLD
OIL
COOLER
B
A
DRAIN
1600
MANIFOLD
RPM
L.H. REAR JACK
MAST ELEVATE
FRONT JACKS
R.H. REAR JACK
438977
THERMO VALVE
ROTATION MOTORS
DRN-7
SET ABOVE 5000 PSI
RPM
DRN-6
ROTATION TORQUE CONTROL
600 PSI
A
C
B
P
CAB
407730
350 PSI
B2
B1
437842
50 PSI
BYPASS
RET-1
RET-12
Z1
2100 RPM
5510
PSI
100
GPM
5510
PSI
TP
1.0
mm
438004
L.H. TRAM
PST
CH
435433
MZ
RETURN
MANIFOLD
RET-4
B1
DRN-2
GCH
5000
PSI
RET-8
A2
B2
DR
RET-5
RET-7
RET-6
DRILL/PROPEL
VALVE
DRN-3
MY
5000
PSI
RET-9
DRN-11
A1
TP
RET-2
RET-3
GB
RET-10
DRN-1
ROTATION TORQUE X PORT RELIEF
24.4
GPM
60 GPM
RET-11
RET-1
A2
A1
Y1
A
GA
MAIN RETURN FILTER
TO GAUGE
IN CAB
DRN-1
DRN-2
DRN-3
DRN-10
A
350 PSI
50 PSI
BYPASS
DRN-4
RET-2
Y1
17
GPM
30
GPM
HOIST/PULLDOWN CYLINDER
T
B
Z1
DRN-4
200 PSI
DRN-12
100
GPM
5510
PSI
GB
24.4
GPM
438004
Z
Y
MZ
5000
PSI
DRN-7
DRN-11
R.H. TRAM
DRN-12
PST
A
DR
DRN-5
A
GA
MY
DRN-8
BACK-UP ALARM
PRESSURE SWITCH
GCH
CH
TP
P
B
B1
A1
DRN-9
A2
B2
B
1.0
mm
TP
DRN-6
3
5510
PSI
2100 RPM
435433
DRN-5
FLUSHING SHUTTLE VALVE
DRAIN
MANIFOLD
TOP
CASE DRAIN FILTER
5000
PSI
TO GAUGE
IN CAB
PULLDOWN FORCE CONTROL

SET ABOVE 5000 PSI
600 PSI
DRN-6
407730
Hydraulic Systems
DRN-7
A
C
B
P
CAB
Ref. 1526393
437842
7-93
Hydraulic SchematicSKS-W (Rexroth Pumps)

FLOAT/LOCK
CLAMP
SWING
3
2
V1
C1
(2250 PSI)
2
3
1
ROTATE
V1
C1
EF
CLAMP
(2250 PSI)
C2
V2
C2
CF
V2
3
1
V2
L.H. FRONT
2
V2
V1
V1
C1
V1
V2
C2
V1
C2
C1
C2
C2
C1
R.H. FRONT
V1
C1
C1
C2
L.H. REAR
V1
C1
V2
V2
3
1
R.H. REAR
C2
V2
A
25 bar
|A 1
25 bar
362 psi
8 bar
T
25 bar
362 psi
C
P
C
175 bar
2538 psi
DUST CURTAIN
WATER INJECTION
MAST LOCK
MAST ELEVATE
MAIN AIR
175 bar
2538 psi
WINCH
L.H. REAR JACK
FRONT JACKS
R.H. REAR JACK
175 bar
2538 psi
AUTO TOOL
HOBO CLAMP
HOBO SWING
PIPE POSITIONER
PIPE RACK LOCK PIPE RACK SWING
SPARE
PIPE RACK ROTATE
MAST ELEVATE
FRONT JACKS
R.H. REAR JACK
THERMO VALVE
B
45 PSI
1700
RPM
L.H. REAR JACK
B
A
1700
RPM
CHARGE
450 PSI
BACK-UP ALARM
TO COOLER
FAN MOTOR
2000 PSI
B2
A2
50 PSI
R
T1 T2
PS
Fa
Fa1
TO BACK-UP ALARM
P
B
MB
Fe
L
B1
L.H. TRAM
A1
6.3 CU/IN
6.3 CU/IN
PST
RH
DR
1.6mm
(.063")
A
X1 X3
X4 X2
MH
Fs
MA
ROTATION AND L.H.

TRACK PUMP
B2
A2
50 PSI
R
T1 T2
PS
Fa
Fa1
P
B
MB
Fe
B1
R.H. TRAM
A1
PULLDOWN VALVE
17
GPM
30
GPM
PST
RH
DR
1.6mm
(.063")
A
X1
X3
X4
X2
MH
Fs
MA
FEED AND R.H.

TRACK PUMP
Ref. 429871)
7-94
Hydraulic Systems
LOWER VALVE
14
AIR GAUGE
SHUTTLE VALVE
LEFT LOOP FILTER
SHUTTLE VALVE
LOOP FILTER
15
TO MS PORT
PULLDOWN PUMP
12
BRAKE
DRAIN
PRESSURE FROM
RH PUMP
CHARGE FILTER
HYDRAULIC PLUMBING
PRESSURE FROM "B" PORT

OF DRILL/PROPELL VALVE
LOCATED OUTSTDE
Hydraulic Plumbing CabSKS-W
13
11
CAB WALL
DRILL/HOUR
METER SWITCH
PULLDOWN
3 WAY
PILOT
VALVE
C
P
A
NOTE:
PRESSURE
'B'TO'C'
23
REMOTE
RELIEF
VALVE
24
BACKUP ALARM
PRESSURE SWITCH
MAST
2
*1
LR
JACK
2
*1
25
FT
JACK
2
*1
26
RR
2
JACK *1
T
P
27
28
30
29
35 34 33
32 31 30 29 28 27 26 25 24 23 22 21
10
20
9
19
8
18
7
17
16 15 14 13 12 11
ROTARY TORQUE
OPTION
10
20
CAB WALL
WATER INJECTION
OPTION
CAB
MAST SIDE
LH AIR CLEANER
INDICATOR
HOLES SHOWN ARE REPRESENTED
BY HEX BALLOONS ON SCHEMATIC
Hydraulic Systems
RH AIR CLEANER
INDICATOR
Ref. 439600
7-95
Pressure and Return PlumbingSKS-W
Ref. 426667 rev. A (1 of 2)

(split coolers)
7-96
Hydraulic Systems
Pressure and Return PlumbingSKS-W
Ref. 426667 rev. A (2 of 2)

(split coolers)
Hydraulic Systems
7-97
Suction and Return PlumbingSKS-W

RETURN
POWER BEYOND
MAST VALVE
GAUGE
VALVE BANK
"P"
B2
A2
PRESSURE
A2
B2
A2
B2
RETURN
A2
B2
A1
B1
POWER BEYOND
PRESSURE
"P"
VALVE BANK
RETURN MANIFOLD
A1
A2
A3
A4
B1
B2
B3
B4
HYD.
TANK
PRESSURE
"IN"
CASE DRAIN
RETURN
MS
MS
MAIN RETURN
L.H. PUMP
R.H. PUMP
PUMP DRIVE
GEARBOX
PUMP DRIVE
GEARBOX
PRESSURE
P PORT
SUCTION
S PORT
SUCTION
S PORT
Ref. 439495
with Linde Pumps
7-98
Hydraulic Systems
Suction and Return PlumbingSKS-W

RETURN
POWER BEYOND
MAST VALVE
GAUGE
VALVE BANK
"P"
B2
A2
PRESSURE
A2
B2
A2
B2
RETURN
A2
B2
A1
B1
POWER BEYOND
PRESSURE
"P"
17
VALVE BANK
RETURN MANIFOLD
A1
A2
A3
A4
B1
B2
B3
B4
HYD.
TANK
PRESSURE
"IN"
CASE DRAIN
RETURN
MAIN RETURN
L.H. PUMP
R.H. PUMP
TI PORT
TI PORT
S PORT
S PORT
PUMP DRIVE
GEARBOX
SUCTION
S PORT
PRESSURE
P PORT
SUCTION
S PORT
Ref. 425716 rev. C

Hydraulic Systems
7-99
Charge and Pilot PlumbingSKS-W
LH PUMP
GAUGE
"C" PORT
PILOT
OPERATED
VALVE
TO "P" ON
PULLDOWN
REMOTE
RELIEF
CAB
1
2
RH PUMP
RETURN MANIFOLD
HYDRAULIC
TANK
OUT
LOOP FILTERS
IN
IN
OUT
RELIEF VALVE
GCH
Ref. 439501 rev. B

with Linde Pumps
7-100
Hydraulic Systems
Charge and Pilot PlumbingSKS-W
LEFT PUMP
RIGHT PUMP
LEFT PUMP
Y2
RIGHT PUMP
Y2
Y1
Y1
MB
X3
FA
X3
FA
MB
FE
FE
MH
MH
10
HYDRAULIC
TANK
P. O. R. RELIEF
PRESET TO 450 psi
RETURN MANIFOLD
14 4 13 17 18
CAB
IN
OUT
IN
OUT
Ref. 408565 rev. D

Hydraulic Systems
7-101
Fan PlumbingSKS-W
Ref. 420107 rev. E
7-102
Hydraulic Systems
B2
B2
B2
MAST LOCK
WATER INJ.-DUST COLLECTOR
DUST CURTAIN
C2
A2
MAIN AIR
B2
V2
MAST ELEVATE
B1
A2
A2
A2
Mast Lock PlumbingSKS-W
A1
C1
V1
Ref. 423160 rev. A
Hydraulic Systems
7-103
Mast Elevating PlumbingSKS-W
RET.
29
B2
B2
B2
B2
B1
A1
A2
A2
A2
A2
EXT.
MAST ELEVATE
24
MAIN AIR
MAST LOCK
DUST CURTAIN
24
23
LOCATED ON HYDRAULIC TANK
35 34 33
32 31 30 29 28 27 26 25 24 23 22 21
10
20
RET.
EXT.
EXT.
9
19
8
18
7
17
16 15 14 13 12 11
RET.
ROTARY TORQUE
OPTION
WATER INJECTION
OPTION
CAB
MAST SIDE

Ref. 431602
7-104
Hydraulic Systems
B2
MAST ELEVATE
B2
MAIN AIR
B2
MAST LOCK
B2
B1
A1
A2
A2
A2
A2
Dust Curtain PlumbingSKS-W
DUST CURTAIN
V2
C2
C1
V1
Ref. 423895 rev. A
Hydraulic Systems
7-105
Jack PlumbingSKS-W
R.H. REAR
L.H. REAR
RETRACT
EXTEND
EXTEND
RETRACT
29
1
3
1
3
28
26
FRONT
LEFT REAR
A1
RIGHT REAR
A2
A3
25
27
A4
30
R.H. FRONT
EXTEND
RETRACT
1
3
B2
B3
B4
RIGHT REAR
LEFT REAR
FRONT
MAST ELEVATE
B1
L.H. FRONT
EXTEND
RETRACT
1
3
29
30
28
27
26
25
LOCATED ON HYDRAULIC TANK

2
35 34 33
ROTARY TORQUE
OPTION
32 31 30 29 28 27 26 25 24 23 22 21
10
20
9
19
8
18
7
17
WATER INJECTION
OPTION
16 15 14 13 12 11
CAB
MAST SIDE

Ref. 427968
7-106
Hydraulic Systems
Hydraulic System Test PlumbingSKS-W
R.H. LOOP
FAN
PUMP
R.H. CHARGE
4
5
1
UPPER
BANK
L.H.
LOOP
LOWER
BANK
1
L.H.
CONTROL
L.H.
CHARGE
R.H.
CONTROL
X2
FRONT VIEW OF TEST PANEL
Y2
Y1
X1
A1
A2
A3
A4
B1
B2
B3
B4
UPPER BANK
X2
Y2
B2
B1
A2
A1
B2
A2
B2
A2
B2
A2
Y1
X1
LOWER BANK
RETURN MANIFOLD
Ref. 426487 rev. A
NOTE: RETURN MANIFOLD
LOCATED IN MAST PIVOT
Hydraulic Systems
7-107
Notes
7-108
Hydraulic Systems
Hydraulic SchematicSKS
DUST COLLECTOR MOTOR

HOBO
CLAMP
PIPE POSITIONER
3
SWING
3
2
VIEWING HATCH
WATER PUMP MOTOR

(2250 PSI)
MAST ELEVATE
V1
C1
MAST LOCK
HOBO
3
2
ROTATE
MAIN AIR
V1
C1
PIPE RACK SWING
EF
CLAMP
(2250 PSI)
C2
C2
CF
V2
R.H. FRONT
L.H. REAR
MAST LOCK
V2
V1
C1
PIPE RACK SWING
V1
C1
C1
1
C2
HOBO SWING
L.H. FRONT
V2
V2
V1
C1
C2
V1
C1
3
C2
3
1
PIPE POSITIONER
PIPE RACK LOCK

1
DUST CURTAIN
V2
V1
C1
V1
C2
C2
V2
V2
PIPE RACK LOCK
PIPE RACK ROTATE
DUST CURTAIN
AUTO TOOL
R.H. REAR
C2
V2
A
L
L
25 bar
|A 1
X
A
25 bar
362 psi
8 bar
T
25 bar
362 psi
P
P
175 bar
2800 psi
DUST CURTAIN
WATER INJECTION
MAST LOCK
MAIN AIR
VIEWING HATCH
MAST ELEVATE
175 bar
2800psi
WINCH
L.H. REAR JACK
FRONT JACKS
R.H. REAR JACK
155 bar
2250 PSI
AUTO TOOL
HIGH SPEED
RELIEF
HOBO CLAMP
HOBO SWING
PIPE POSITIONER
SPARE
PIPE RACK ROTATE
3
STANDARD
SETTING
700 PSI
2
1900 PSI
HIGH SPEED
RELIEF
STANDARD
SETTING
700 PSI
2
1900 PSI
MAST ELEVATE
L.H. REAR JACK
FRONT JACKS
R.H. REAR JACK
ROTATION MOTORS
B
45 PSI
DRAIN
1700
MANIFOLD
RPM
OIL
COOLER
B
A
DRAIN
1700
MANIFOLD
THERMO VALVE
RPM
CHARGE
450 PSI
RETURN
MANIFOLD
BACK-UP ALARM
PRESSURE SWITCH
B2
A2
50 PSI
T1
PS Fa
Fe
Fa1
MB
B1
L.H. TRAM
A1
52
GPM
52
GPM
2100 RPM
PST
RH
MAIN RETURN FILTER
DR
DRILL/PROPEL VALVE
1.6mm
(.063")
A
X4 X2
X1 X3
ROTATION AND L.H.
TRACK PUMP
CROSS PORT RELIEFS
SET AT 5500 PSI
Fs
MH
MA
PUMP COMPENSATOR
SET AT 5000 PSI
B2
A2
50 PSI
T1
PS
Fa
Fa1
Fe
MB
B
B1
R.H. TRAM
A1
2100 RPM
17
GPM
30
GPM
PST
RH
DR
600 PSI
B
T
PULLDOWN VALVE
A
C
DRAIN
MANIFOLD
1.6mm
(.063")
A
X1
FEED AND R.H.
TRACK PUMP
X3
X4 X2
MH
CROSS PORT RELIEFS
PUMP COMPENSATOR
SET AT 5500 PSI
SET AT 5000 PSI
Fs
MA
CASE DRAIN FILTER
SKS DUAL PUMP SEPARATE COOLERS
Hydraulic Systems
7-109
Hydraulic SchematicSKS
DUST COLLECTOR MOTOR

HOBO
CLAMP
PIPE POSITIONER
3
SWING
3
2
VIEWING HATCH
WATER PUMP MOTOR

(2250 PSI)
MAST ELEVATE
V1
C1
MAST LOCK
HOBO
3
2
ROTATE
MAIN AIR
V1
C1
PIPE RACK SWING
EF
CLAMP
(2250 PSI)
C2
C2
CF
V2
R.H. FRONT
L.H. REAR
MAST LOCK
V2
V1
C1
PIPE RACK SWING
V1
C1
C1
1
C2
HOBO SWING
L.H. FRONT
V2
V2
V1
C1
C2
V1
C1
3
C2
3
1
PIPE POSITIONER
PIPE RACK LOCK
3
1
DUST CURTAIN
V2
V1
C1
V1
C2
C2
V2
V2
PIPE RACK LOCK
PIPE RACK ROTATE
DUST CURTAIN
AUTO TOOL
R.H. REAR
C2
V2
A
L
L
25 bar
|A 1
X
B
25 bar
362 psi
8 bar
T
25 bar
362 psi
P
P
175 bar
2800 psi
DUST CURTAIN
WATER INJECTION
MAST LOCK
MAIN AIR
VIEWING HATCH
MAST ELEVATE
175 bar
2800psi
WINCH
L.H. REAR JACK
FRONT JACKS
R.H. REAR JACK
155 bar
2250 PSI
AUTO TOOL
HOBO CLAMP
HOBO SWING
PIPE POSITIONER
SPARE
PIPE RACK ROTATE
HIGH SPEED
RELIEF
STANDARD
SETTING
700 PSI
2
1900 PSI
MAST ELEVATE
L.H. REAR JACK
FRONT JACKS
R.H. REAR JACK
ROTATION MOTORS
B
45 PSI
DRAIN
1700
MANIFOLD
RPM
OIL
COOLER
B
A
DRAIN
1700
MANIFOLD
THERMO VALVE
RPM
CHARGE
450 PSI
RETURN
MANIFOLD
BACK-UP ALARM
PRESSURE SWITCH
B2
A2
50 PSI
T1
PS Fa
Fe
Fa1
MB
B1
L.H. TRAM
A1
60 GPM
2100 RPM
PST
RH
MAIN RETURN FILTER
DR
DRILL/PROPEL VALVE
1.6mm
(.063")
A
X4 X2
X1 X3
ROTATION AND L.H.
TRACK PUMP
CROSS PORT RELIEFS
SET AT 5500 PSI
Fs
MH
MA
PUMP COMPENSATOR
SET AT 5000 PSI
B2
A2
50 PSI
T1
PS
Fa
Fa1
Fe
MB
B
B1
R.H. TRAM
A1
2100 RPM
17
GPM
30
GPM
PST
RH
600 PSI
B
T
A
C
DRAIN
MANIFOLD
PULLDOWN VALVE
DR
1.6mm
(.063")
A
X1
FEED AND R.H.
TRACK PUMP
X3
X4 X2
MH
CROSS PORT RELIEFS
PUMP COMPENSATOR
SET AT 5500 PSI
SET AT 5000 PSI
Fs
MA
CASE DRAIN FILTER
SKS SINGLE PUMP DUAL COOLERS
7-110
Hydraulic Systems
Hydraulic SchematicOpen Loop SKS (Rexroth Pumps)

EF
CF
WATER
PUMP
P
DUST
COLL.
81239
2250
PSI
WP
410089
DC
DUST COLLECTOR & WATER PUMP

T
421240
3
2
1
V1
C2
V2
C1
SWING
A6
PIPE
POSITIONER
(2250 PSI)
B
B6
CLAMP
3
1
84885
A3
(2250 PSI)
SPARE
B
B3
WINCH
BRAKE
A
B
T
P
B
P
CAROUSEL
LOCK
A8
B
B8
V2
C2
V1
C2B
AUTO
TOOL WRENCH
A5
T
A
B
02
84885
V2
HOBO
SWING
A2
C2
V1
C1
B
PULLDOWN GAGE
GC2
B5
HBP
B1
(2250 PSI)
B2
B2
HDR2
.016
C1
V2B
B7
LS
CAROUSEL
ROTATE
A7
G1
V1B
17.26
2
15.90 IN
C2A
A
B
0084242
0413307
84885
CLAMP
A2
A1
HOBO CLAMP
ROTATE
A4
B
B4
(2250 PSI)
-20
-24
ROTATE
P1
RETURN MANIFOLD
BLANK PLATE
A6
-24
84885
SPARE
B
MA
V2
C2
V1
P
C1
T1
RIGHT TRACK
180cc (10.98 CIR) @ 2100 R.P.M.
X2
X4
B5
X3
A5
X1
T2
424015
R
0408549
P2
T2
3100 kPa
(450 psi)
CHARGE
B6
0407730
0402263
0413307
CAROUSEL
SWING
B1
LEFT HAND
DIVERTER VALVE
V2
A1
C2
PRESSURE
SWITCH
REGERATION
SWITCH
P1
V1
-20 (TYP)
T1
LS
CB1
3
2
A
B
T
33.16 IN2
NC
NO
ON
ELECTRICAL
+
C1
V2A
P2
V1A
17.26
2
15.90 IN
33.16 IN2
CA1
T2
84885
BRAKE
VALVE
PULLDOWN
B9
BR
6.5 BORE x 4 1/2

ROD
BORE AREA 1 CYL = 33.16 IN
ROD AREA 1 CYL = 15.90 IN
CAIA-LHN
LIFTING
WINCH
DR
GC1
0410665
WINCH ASSEMBLY
W/BRAKE VALVE
& STATIC BRAKE
0410666
GR
A9
GV1
HDR1
MP22
FEED VALVE
VIEWING
HATCH
A4
V2
C1
V1
C2
V2
DUST
CURTAIN
B3
B
P
A
B
B2
P1
T1
A1
MAST LOCK
B
B1
0402263
84885
0411027
DR4
DR8
DR1
DR6
DR7
DR2
P7
DR3
1930 kPa
280 psi
424015
X
R
T2
X1
X3
X4
X2
416962
G
MA
TP2
V03
CC
20900kPa
11.59
CIR
0410663
M1
7.2
CIR
25.5cc/REV
419938
MH
FA
PULLDOWN
PC1
P4
TP13
V05
V06
V08
JACK MAST
RAISE
18960 kPa
(2750 psi)
V09 a
0.8
(mm)
P3
V22
V21
V15
34474 kPa
(5000 psi)
MAX PULLDOWN
18624 kPa
(2700 psi)
4
3
V16
TP10
TP1
JACK RH REAR
L.H. REAR
0095135
2
1
P6
3
1
JACK
L.H.
REAR
P5
TR
P9
TP8
MAST
ELEVATE
DR5
0436573
LS
MAST ELEVATE
EXTEND
.094
TE
TR
RETRACT
0056385
LS
RETRACT
V18
2
DRAIN
-16
-06
-16
BACK-UP ALARM
0436573
SUCTION MANIFOLD
0410672
NO
419935
419935
A 3.65 B
B 3.65 A
CIR
CIR
424706
419943
0088595
0088595
0088595
HYDRAULIC TANK
Hydraulic Systems
V17
TP12
LS
JACKS - FRONT
2
3
JACK
R.H.
REAR
LS4
LS
V12
1
3103 kPa
(450 psi)
V10
V14
PC2
3
1
TP5
3447 kPa
(500 psi)
P11
0095135
R.H. REAR
V13
TP4
JACK LH REAR
JACK
FRONT
0410091
2
TP6
2
P8
ROTARY - PSI
(IN CAB)
L.H. FRONT
P13
V11
P2
1
2
SET-UP
LOCK
a
LS3
0058495
0411027
TP9
0070049 x 4.
2
TRAM/DRILL SEL
ON = DRILL
OFF = TRAM
a
AUTO-PULL DOWN
V02
57319
MB B
Fe
TP11
PSI ADJUSTMENT
(IN CAB)
1
R.H. FRONT
V07
V20
LS2
T1
Ps
V19
LS5
TP3
1.56
CIR
DRILL/TRAM
INTERLOCK
a
V04
LS1
V01
57319
1.6mm
(.063")
ROTARY TORQUE
PSI ADJUSTMENT
(IN CAB)
(3000psi)
MAX
AUX PRESS
AUX PUMP RV
17500 kPa
(2500 psi)
P1
PILOT
CONTROL
BLOCK
T1
190cc/REV
FAN = 5.10, DC = 2.94
0408549
0402263
LSC
LEFT TRACK & ROTATION

180cc (10.98 CIR) @ 2100 R.P.M.
AUX PUMP (psi)

GUAGE (IN CAB)
AUX PUMP
OFF - LS
ON - HI a
TP7
421241
.032" ORF
CASE
DRAIN MANIFOLD
0401065
DRAIN MANIFOLD
0000000
FROM RECIEVER
MAIN
AIR
A2
0058495
MB
C2
A3
V1
FA Fe
C1
MH
Ps
84885
0402263
0402263
3.19
CIR
AUXILIARY PUMP
PRESSURE MANIFOLD
1412986
414277
3.2
CIR
1.6mm
(.063")
B4
AUX & FEED

190cc (11.59 CIR) @ 2100 R.P.M.
COOLER
0061684
45 PSI
(315 KPA)
60C
(140F)
CLOSE
150 PSI
424706
EXTEND
.094
TE
PRESSURE
SWITCH
Ref. 426498 rev. 02
7-111
Cab to Valve Stand PlumbingSKS
#23 AT CAB (MAST ELEV.)
#25 AT CAB (LEFT REAR JACK)
#27 AT CAB (FRONT JACK)
CAP-BLANK
#29 AT CAB (RIGHT REAR JACK)
EB
RRJA
#28 AT CAB (FRONT JACK)
#26 AT CAB (LEFT REAR JACK)
#24 AT CAB (MAST ELEV.)
29
23
FJA
LRJB
28
25
LRJA
FJB
26
27
EA
RRJB
24
CAP-BLANK
(P9)
P9
(PC1)
P3
(LS4)
CAP
(LS3)
#18 AT CAB ALSO TEE DIVERTER VALVE PILOT PRESSURE
LS4
LS3
(P8)
CAP-BLANK
SV
P2
#34 AT CAB ROTARY TORQUE (CAP IF NO ROTARY TORQUE)
PC1
30
SV
#14 AT CAB
CAP
P8
#30 AT CAB (RIGHT REAR JACK)
(P3)
#9 AT CAB
(P2)
CAP
REF.-VALVE STAND
7-112
Ref. 425185 rev. A

Hydraulic Systems
Rotary Torque ControlSKS

VALVE STAND ASSY
P7
TP2
DR4
DR8
DR1
DR6
DR7
DR2
HYDRAULIC MANIFOLD
DR3
AUX PUMP
OFF - LS
ON - HI a
V03
AUX PRESS
AUX PUMP RV
17500 kPa
(2500 psi)
P9
V19
PP
4 BS
1/
P5 P6
DR8
V04
LS5
TP3
V06
V20
2
LS2
V05
LS1
TP1
DR3
TP9
TRAM/DRILL SEL
ON = DRILL
OFF = TRAM
a
V22
PC1
P1
DR1
V18
DRILL/TRAM
INTERLOCK
a
V07
3
SIZE C10
-8
-
TP7
PILOT
CONTROL
BLOCK
V08
JACK MAST
RAISE
18960 kPa
(2750 psi)
P2
P13
P3
3
TP6
2
2
1
PC1
P4
V11
0.8
(mm)
SET-UP
LOCK
a
V09 a
2
TP11
TP5
V10
V12
AUTO-PULL DOWN
TP13
V13
LS3
P8
FOR BULKHEAD PORT

LOCATIONS - SEE CAB
V14
TP4
34
P11
PC2
V22
1
3103 kPa
(450 psi)
1
LS4
3447 kPa
(500 psi)
35
V21
V15
34474 kPa
(5000 psi)
MAX PULLDOWN
18624 kPa
(2700 psi)
4
3
V16
V17
1
2
3
2
2
a
TP12
TP10
P5
P6
TP1
V18
2
P9
TP8
DR5
SCHEMATIC
T
RELIEF VALVE
Hydraulic Systems
Ref. 428412 rev. A
7-113
FILTER 8
TOP PORT "1'

SIDE PORT "2"
FILTER 7
FILTER 6
Pressure and Return PlumbingSKS
SEE DETAIL D
FILTER 5
FILTER 4
FILTER 3
FILTER 2
FILTER 1
"X3" TO VALVE STAND

PORT "P11"
TO VALVE STAND
PORT "P1"
TO FILTER 6
AT HYDRAULIC TANK
TO LH FILTER
ON GEARBOX
"X" TO VALVE
STAND PORT "LS1"
TO RH FILTER
ON GEARBOX
"M" TO VAVE
STAND PORT "P7"
TO MANIFOLD ON
HYDRAULIC TANK
"G" TO CAB
PORT "33"
TO DRAIN MANIFOLD
ON VALVE STAND
TO LH FILTER
ON GEARBOX
VIEW A
TO SUCTION MANIFILD
AT HYDRAULIC TANK
TO FILTER 8
IN HYDRALUIC TANK
TO MANIFOLD ON
HYDRAULIC TANK
TO FILTER 1
PORT "2"
TO RH PUMP
PORT "F"
TO DRAIN MANIFOLD
AT VALVE STAND
C
TO FILTER 5
PORT "2"
TO RH FILTER
ON GEARBOX
TO DRAIN MANIFOLD
ON VALVE STAND
"MB" TO VALVE STAND

PORT "P4"
TO FILTER 4
PORT "2"
VIEW C
TO LH PUMP
PORT "F"
TO FILTER 3
PORT "2"
TO FILTER 2
PORT "2"
VIEW B
B
7-114
Ref. 434610 rev. A (1 of 2)
Hydraulic Systems
Pressure and Return PlumbingSKS
LS3 TO
SELECTOR VALVE
DR7
LS3
LS4
DR6
P11
V14
T-2
TA
10
1A
P11
P9
SIZE C10
-8
-
C-
PP
4 BS
1/
SIZE C10
-8
4
A
10
SIZE 10
V03
V08
P1
C8-
A
10
P2
PP
4 BS
1/
SIZE 10
3
T-
V06
V2A
C8-
TP3
4 BS
1/
PP
T-
SIZE 10
3
V05
C2B
C1A
V07
V15
C8-
V1B
P4
P4
V10
T-2
TP1
DR3
C2A
GR
T-
1A
DR8
V12
V09
P5 P6
DR3
10
1A
DR1
DR8
SIZE C10
-8
-
V21
11
T-2
V18
PC1
P8
DR7
LS3
V22
DR1
P2
P8
DR6
P9
PC1
LS4
V20
V11
TP6
GV1
V1A
P1
LS2
DR2
P3
P3
DR4
LS1 P7
LS5
LS5
DR4
LS2
DR2
P6
P5
91-A20-222-003
V2B
LS2
P7
LS1
CASE RETURN
C1B
V2A
CASE RETURN
X
M
MB
X3
FA
FA
MB
X3
CASE RETURN
CASE RETURN
LH REAR JACK
FRONT JACK
RH REAR JACK
MAST ELEVATE
TO FILTER 3
PORT 1
TO LH PUMP
PULLDOWN EXT.
PULLDOWN EXT.
PULLDOWN RET.
SEE DETAIL E
PULLDOWN RET.
TO CAB
DETAIL {E} SCALE: {4}X
TO LH FRONT PUMP
TO RH PUMP
TOOLBOX
TO FILTER 7
AT HYD. TANK
TO FILTER 6 IN
HYDRAULIC TANK
DDIM VARS
TO FILTER 5
PORT "1"
PTDIM VARS
HOLE CHART
RCCHART
VERTEX VARS
SECTION
SCREW DISPLAY
HOLE DISPLAY
BOMVAR
Hydraulic Systems
TO FILTER 4
PORT "1"
DETAIL D
TO "LS3" BULKHEAD
PLATE AT VALVE STAND
Ref. 434610 rev. A (2 of 2)
HOLEDIM
7-115
Jack PlumbingSKS
SEE
DETAIL "A"
EXTEND PORT
LS3
LS4
V14
T-2
A
10
SIZE C10
-8
-
RH
EXTEND PORT
C-
PP
FRONT
T-
V09
P4
1A
V07
C8-
TP3
SIZE C10
-8
-
PP
A
10
4 BS
1/
SIZE 10
3
T-
V12
V10
V05
SIZE 10
V08
C8-
A
10
P1
P2
PP
4 BS
1/
SIZE 10
3
T-
V06
1A
10
V15
C8-
P11
SIZE C10
-8
-
V21
T-2
TP1
V03
11
T-2
V18
4 BS
1/
DR8
DR3
T-
P9
PC1
P5 P6
P8
DR6
V22
DR1
1A
V20
TP6
V11
B
B
LH
P3
LS2
DR2
DR4
LS1 P7
91-A20-222-003
LS5
DR7
RETRACT PORT
RETRACT PORT
DETAIL A
TO FRONT JACKS
RETRACT PORT
TO FRONT JACKS
EXTEND PORT
ROUTE HOSES FOR FRONT JACKS
THRU CLAMPS ON CAB SIDE OF ENGINE SKID
EXT. RET.
TO LH REAR JACK
R.H. FRONT
EXTEND
RETRACT
1
3
EXTEND
FROM VALVE
BANK PORT "A"
RETRACT
FROM VALVE
BANK PORT "B"
CAB SIDE
FROM VALVE
BANK PORT "B"
TO FRONT JACKS
VIEW A
CLAMPS ON ENGINE SKID
VIEW B
TYP. AT ALL 4 JACKS
FROM VALVE
BANK PORT "A"
TO FRONT JACKS
Ref. 421450 rev. 06
7-116
Hydraulic Systems
Mast Lock PlumbingSKS
VALVE STAND
CONTROL VALVE
(422914) REF
PORT B
A
PORT A
COUNTER BALANCE VALVE

(#84885) REF
B
A
V2
C2
C1
V1
9P
1CP
6P
5P
8P
2P
4SL
3SL
LS3
LS4
DR7
DR6
V14
T-2
T-
10
A
1A
P11
P9
-8
SIZE C10
-8
SIZE C10
T-2
1A
V12
T-
V21
4
C-
10
-
PC1
P4
V09
1/
4 BS
PP
V10
T-2
1A
DR8
V07
V15
8C-
V05
T-
10
A
8C-
TP3
1/
4 BS
-8
SIZE C10
DR3
PP
3
SIZE 10
TP1
A1C
A2V
V18
11
4P
RG
B1V
V22
11P
A2C
B2C
DR1
P8
P5 P6
SIZE 10
V03
V08
T-
10
A
8C-
P1
P2
PP
1/
4 BS
3
SIZE 10
V20
V11
P3
LS2
TP6
DR2
LS1 P7
LS5 DR4
V06
5SL
2SL
91-A20-222-003
3P
1P
1VG
A1V
R
B2V
7P
1SL
A2V
B1C
Ref. 421474 rev. B
Hydraulic Systems
7-117
Fan Circuit PlumbingSKS
DR7
P9
TA
10
1A
SIZE C10
-8
-
P11
C-
1A
10
V12
V09
PP
C1A
1A
TP1
V07
V05
V2A
C8-
TP3
SIZE C10
-8
4
A
10
4 BS
1/
PP
T-
SIZE 10
V08
P1
C8-
A
10
P2
PP
4 BS
1/
SIZE 10
3
T-
V06
SIZE 10
3
C8-
V03
C2B
P4
V10
V15
DR3
V1B
P4
T-2
C2A
GR
TA
DR3
SIZE C10
-8
-
V21
11
T-2
V18
4 BS
1/
P2
P8
DR6
LS3
LS4
DR7
DR6
P11
V14
T-2
P9
PC1
P5 P6
DR8
P8
PC1
LS4
LS3
V22
DR1
DR1
DR8
V20
V11
TP6
V1A
GV1
P1
P3
LS2
DR2
LS1 P7
LS5 DR4
P6
P3
LS5
DR4
LS2
DR2
P5
91-A20-222-003
V2B
LS2
C1B
FRONT JACK
LH REAR JACK
RH REAR JACK
MAST ELEVATE
PULLDOWN EXT.
1 1/4"
FLOW
PULLDOWN EXT.
PULLDOWN RET.
PULLDOWN RET.
X
M
MB
X3
FA
V2A
P7
LS1
TO TEE FOR
FAN DRAINS
TO BULKHEAD PLATE
FOR COMPRESSOR FAN.
Ref. 429977 rev. A
7-118
Hydraulic Systems
Hydraulic Charge PlumbingSKS

DRAIN MANIFOLD
IN
OUT
OUT
IN
MAST SUPPORT
(DUST COLLECTOR SIDE)
X3
X2
T1
G
X3
X1
T1
MH
G
Fa
Fe
Fa1
Fe
Fs
Fa
Fe
Fa1
Fe
FH
Fs
13
NOTE:
Hydraulic Systems
HEX BALLOONS INDICATE BULKHEAD

LOCATION ON CAB WALL
Ref. 427523 rev. A
7-119
R.H. MOTOR
3/4 HOSE
1/4 HOSE
BRAKE
PRESSURE
7-120
1 1/4" HOSE
1 1/4" HOSE
RETURN
MANIFOLD
CASE
RETURN
ON MOTOR
1/4 HOSE
CAB
TO PORT A (TOP PORT)
1 1/4" HOSE
F
I
L
T
E
R
1/4 HOSE
TO PORT B
ON MOTOR
TO PORT A
ON MOTOR
1 1/4" HOSE
F
I
L
T
E
R
3/4 HOSE
3/4 HOSE
ON MOTOR
TO PORT B (TOP PORT)
Propel PlumbingSKS
DIVERTER
9
P
T
A1
B1
L.H. MOTOR
Ref. 421818 rev. 04
Hydraulic Systems
Valve Stand AssemblySKS

FEED CONTROL
VALVE
HYDRAULIC
MANIFOLD
JACK/MAST
VALVE
PILOT CONTROL
MANIFOLD
10
11
12
DR4
13
DR2
LS3
DR7
P8
A
10
1A
C-
11
PP
1A
SIZE C10
-8
-
P1
A
10
SIZE 10
V03
V08
C8-
A
10
T-
CONTROL
VALVE
C2B
V2A
P1
C8-
TP3
4 BS
1/
PP
T-
V05
C8-
V1B
C1A
V07
V15
TP1
C2A
GR
P4
P4
V10
DR3
DR3
P11
T-
T-2
P5 P6
DR8
10
V12
SIZE C10
-8
-
V21
V09
4 BS
1/
P8
T-
T-2
PC1
DR8
P11
V14
T-2
SIZE C10
-8
-
V18
P9
DR7
LS4
V22
DR1
P5/P6
LS3
LS4
DR6
DR1
P9
PC1
1A
14
DR6
PP
4 BS
1/
P2
V11
TP6
P2
P3
P3
LS2
DR2
DR2
DR4
LS2
LS1 P7
LS5
LS1
P7
LS5
DR4
91-A20-222-003
V1A
V20
GV1
V06
LS2
T
LS5
P7
RETURN
MANIFOLD
P5
LS5
LS1
B
A
PULLDOWN EXT.
PULLDOWN EXT.
PULLDOWN RET.
PULLDOWN RET.
X
M
MB
X3
FA
PULLDOWN
VALVE
HYDRAULIC
MANIFOLD
VALVE STAND
ASSEMBLY
SELECTOR
VALVE
ITEM 2 ALTERNATE POSITION
WHEN USING 600 GAL. TANK
REF. - MAST PIVOT
DRAIN
MANIFOLD
Ref. 428443 rev. B
Hydraulic Systems
7-121
Notes
7-122
Hydraulic Systems
Service Supplement for SKF and SKS

Rotary Drills with Linde Hydraulic Pumps
Contents
General .......................................................................................................................... S-3

SKS Pump Arrangement .............................................................................................. S-4
SKS Hydraulic Hose Plumbing.................................................................................... S-5
SKF Pump Arrangement .............................................................................................. S-6
SKF Hydraulic Hose Plumbing .................................................................................... S-7
HPV Pump Installation and Start-Up Instructions ..................................................... S-9
HPV Pump Repair Manual.......................................................................................... S-17
HPR Pump Installation and Start-Up Instructions ................................................... S-77
HPR Pump Repair Manual ......................................................................................... S-83
SKS Hydraulic Schematic with Linde Pumps ........................................................ S-129
SKF Hydraulic Schematic with Linde Pumps ........................................................ S-130
September 10, 2008
S-2
General
Some late model SKF and SKF rotary drills are supplied with hydraulic pumps manufactured by Linde. Others use hydraulic pumps manufactured by Rexroth. This supplement addresses the start-up and service of Linde pumps. Refer to the parts manual for your specific machine to
determine the correct pump.
A listing of Linde pumps used is shown below. Pump arrangement and functions are
shown on the following pages.
P/N
Linde Model No.
Used On *
Seal Kit P/N
435433
HPV210
SKS
V014525
435434
HPV135
SKF
V014639
435435
HPV135
SKF
V014639
435436
HPR135
SKF
V014559
435452
HPR210
SKS
V014344
* Includes all variations of the SKF and SKS series of machines (i.e., SKF-12, SKSS-16).
S-3
SKS Pump Arrangement
Linde Pumps Mounted in an SKSS-16
S-4
SKS Hydraulic Hose Plumbing
S-5
SKF Pump Arrangement
Linde Pumps Mounted in an SKF
S-6
SKF Hydraulic Hose Plumbing
S-7
Notes
S-8
HPV Pump Installation and Start-Up
Service Bulletin
HPV-02 Installation and Start-Up

Instructions
HPV-startup.doc
HPV-02, Section B
Rev. 2, 3-30-00
Page 1 of 7
Note: The oil level in the reservoir should always be at least 8 inches (~200mm) above the
highest point of the pump as illustrated below:
Installation:
Always cover or cap all HPV-02 case drain, control, and high pressure hydraulic lines
during the installation of a new or replacement HPV-02 pump.
Always ensure all connections to the HPV-02 replacement pump are capped or covered
during initial installation.
Connect and tighten each hydraulic line one at a time removing caps or covers just
before each connection is made.
Installation must be carried out in accordance with the circuit or piping diagram.
It is recommended that the HPV-02 pumps be mounted with the pump control facing
upward (as illustrated above).
S-9
Service Bulletin

Instructions
HPV-startup.doc
HPV-02, Section B
Rev. 2, 3-30-00
Page 2 of 7
The pump can optionally be mounted with the pump control facing to either side. During
start-up, additonal care must be taken to vent entrapped air from the pump control via
the highest flow stop adjustment (see the sketch above).
Avoid mounting the pump with the pump control facing down. Entrapped air is difficult to
remove and any contaminants in the hydraulic oil will eventually settle into the control.
Venting:
Positive venting is vital for the proper operation of the hydraulic system.
The highest case drain port on the pump housing must be connected to the reservoir. If
the pump control is mounted on top (as illustrated above), then the vent port in the pump
control should be connected to the reservoir as well.
All vent lines must be mounted continuously rising toward the reservoir. This allows any
entrapped air to escape freely from the pump case.
Piping:
Pipe work should be seamless drawn precision steel tube or hoses of suitable pressure
rating.
During installation, attention should be paid to cleanliness. The pipes must be deburred,
washed and blown through.
Scaled or rusted pipes must be scoured and then neutralized - Hoses must be brushed
and flushed through when contaminated.
IMPORTANT: The cleanliness of the circuit before commissioning has a crucial
influence on the operation and life expectancy of the hydraulic components.
Filling the Hydrostatic Transmission:
S-10
The initial filling of the system must be carried out in such a way that all of the air can
escape from the high pressure circuit and from the pump/motor cases before the
hydraulic units are operated.
Service Bulletin

Instructions
HPV-startup.doc
HPV-02, Section B
Rev. 2, 3-30-00
Page 3 of 7
The integral purge valve, which may be fitted as an option on the Linde hydraulic motors,
assists in the venting of air from the high pressure circuit. This optional purge valve is
illustrated in the schematic below.
- With a pressure differential of about 350 psi (25 bar) across the hydraulic motor, the
purge valve discharges a controlled amount of oil flow out of the high pressure circuit
into the motor case. Therefore, any entrained air may escape freely to the reservoir.
Again, refer to the schematic below.
The hydraulic motor(s) must be free to rotate under no load. For example, when a
vehicle is chocked up with the wheels/tracks clear of the ground and free to rotate.
If already fitted, loosen the vent plugs on the cooler.
Manually fill the HPV-02 pump case at the most accessible case drain port with filtered
oil. Manually fill the high-pressure (closed loop) lines with filterd oil if the lines are
extremely long. Fill the oil reservoir to the maxmium level with filtered oil, and fill the
motor case(s) to the maximum level via the most accessible case drain port with filtered
oil.
Connect bleed lines or hoses to high pressure gauge ports "Mp" and "Ms". Connect a
1000 psi (70 bar) pressure gauge or transducer to gauge port "X".
S-11
Service Bulletin

Instructions
HPV-startup.doc
HPV-02, Section B
Rev. 2, 3-30-00
Page 4 of 7
Disconnect the prime mover's starting mechanism to insure that the prime mover will
NOT start.
"Crank" the prime mover for at least ten seconds and stop while simultaneously
monitoring the charge pressure at port "X". Continue this procedure at least 5 times or
until the charge pressure at port "X" increases to the integrated boost relief valve setting
in the pump (Consult Linde if unsure what boost relief valve setting is in the pump - The
pump serial number is mandatory for this request). During this step, air in the closed
loop should be discharged from the bleed lines. All air must be removed from the closed
loop lines.
Check the hydraulic oil level in the reservoir and HPV-02 case. Add filtered oil to each
as required.
Reconnect the prime mover's starting mechanism.
Start the prime mover and leave at low idle. Operate the prime mover at low idle for
about 10 minutes while monitoring the charge pressure at port "X". The charge pressure
at port "X" should remain at the boost relief valve setting.
Turn the prime mover OFF. Disconnect the bleed lines from gauge ports "Mp" and "Ms"
and securely recap the ports.
WARNING: The wheels/tracks will turn during this next step.
S-12
Start the prime mover and set it at low idle, slowly stroke the pump 3 times to maximum
displacement in both directions for about 30 seconds each time.
Warm the hydraulic oil by steadily increasing the prime mover speed and by increasing
the load to the hydraulic motor(s). This will allow any air in the fluid to be released more
easily.
Check the HPV-02 hydraulic neutral setting, regulation begin setting, and the maximum
flow setting when the hydraulic oil reaches its normal operating temperature.
Check the oil level in the reservoir and fill with filtered oil if necessary before delivery of
the machine.
Service Bulletin

Instructions
HPV-startup.doc
HPV-02, Section B
Rev. 2, 3-30-00
Page 5 of 7
Routine Maintenance:
Maintenance of the hydraulic system is limited to changing the filter element of the HPV02 pump and changing the hydraulic fluid.
In order to gaurantee proper functions and efficiency of the hydraulic pumps, the purity
of the hydraulic oil over the entire operating period must comply to at least class 18/13
according to ISO 4406.
With modern filtration technology, however, much better values can be achieved which
contributes significantly to extending the life and durability of the hydraulic pumps and
complete system.
Changing the Filter:
The filter cartiridge fitted to the HPV-02 pump must be replaced for the first time after the
initial start-up, but at least after 100 hours of operation.
Further filter changes should be made after every 500 hours of operation. If possible,
these changes should be arranged to coincide with other routine maintenance work on
the equipment, e.g., those on the prime mover.
S-13
Service Bulletin

Instructions
HPV-startup.doc
HPV-02, Section B
Rev. 2, 3-30-00
Page 6 of 7
Note:
These recommendations are provided for guidance to insure long service life and proper
operation of the HPV-02 pump. However, depending on the operating conditions of the
HPV-02, it may not be necessary to adhere to these recommendations as long as the oil
cleanliness level and oil vicosity specifications are strictly adhered to.
Changing the Hydraulic Fluid:
Oil changes are carried out by first draining the tank, cooler, pump, and motor housings.
The high-pressure fluid must be changed after 1000-2000 hours of operation, according
to the application.
High working temperatures and frequent cooling-down phases with low temperatures
condense water and will shorten the life of the hydraulic fluid.
The oil remaining in the high-pressure circuit itself need not be changed. Do not open
up the high pressure lines if possible. The instructions regarding initial filling must
also be adhered to when changing the hydraulic fluid. In some applications, a complete
oil change may not be necessary. The oil lost during each filter change must be
replaced by fresh filtered oil.
Cleaning:
Cleaning of the hydraulic system when chaning oil is normally not necessary. If the
system becomes contaminated due to unusual circumstances (defect, etc.), then it must
be thoroughly cleaned before recommissioning. Housings and pipelines must be
flushed. If necessary, the pipelines and hydraulic units must be disassembled.
Service:
S-14
Maintenance and repairs should be undertaken only by skilled personnel who are
familiar and trained with the equipment. Linde offers an excellent after-sales service
capable of carrying out the work of repair and overhaul if required.
Only spare parts specified in the Linde spare parts catalogs should be used. The serial
number stamped on the unit name tag is relevant to the configuration of the unit.
Therefore, the serial number should be quoted when ordering spare parts.
Service Bulletin

Instructions
HPV-startup.doc
HPV-02, Section B
Rev. 2, 3-30-00
Page 7 of 7
Oil Selection and Viscosity Recommendations:

Suitable hydraulic oils are:
Mineral oil HLP to DIN 51524
Biodegradeable fluids upon request
Other pressure fluids upon request
Linde recommends only using hydraulic oils which are confirmed by the producer as
suitable for use in high pressure hydraulic installations. For the correct choice of suitable
hydraulic oils, it is necessary to know the working temperature in the hydraulic circuit
(closed loop). The hydraulic oil chosen must allow the working viscosity to be within the
optimum viscosity range (as shown below).
Attention: Due to pressure and speed influences, the temperature of the leakage fluid is
always higher than the circuit temperature. The temperature must not exceed 194F (90C)
in any part of the system. Under special circumstances, if the stated conditions cannot be
observed then please consult Linde.
Recommended viscosity range for optimum performance: 15 cSt to 30 cSt

Maximum allowable working viscosity range: 10 cSt to 80 cSt
Viscosity limitations: 6 cSt minimum viscosity
1000 cSt maximum viscosity (Intermittent for cold starts)
Oil temperature limitations: (-68)F to 194F
(-20) C to 90C
S-15
Notes
S-16
HPV Pump Repair Manual
Repair Manual
Repair Manual for HPV-02

Variable Displacement Pumps
HPV-02
Rev. 2, 11-21-02
Page 1 of 31
This Repair Manual is valid for all HPV-02 (55/75/105/135) pumps

Tools/Equipment Required:
metric wrenches and Allen wrenches
vertical press
oven or hot plate (minimum temperature of 350F required)
Green Loctite No. 648 (domestically available or Linde Part Number 7379200106)
Blue Loctite No. 243 (domestically available or Linde Part Number 7379200104)
M8 socket head cap screws (qty 2, Linde Part Number 9048348183)
rubber mallet or soft metal rod
snap ring wrench (to squeeze/compress the snap ring)
snap ring wrench (to expand the snap ring)
torque wrench capable of setting between 25 N-m (18 ft-lb) and 180 N-m (133 ft-lb)
rear bearing shims (refer to Linde Spare Parts Catalog for required part numbers)
cylinder barrel shims (refer to Linde Spare Parts Catalog for required part numbers)
mechanical neutral shims (refer to Linde Spare Parts Catalog for required part numbers)
finger shims (refer to Linde Spare Parts Catalog for required part numbers)
commercially available bearing race remover
sanding stone and solvent
petroleum jelly
butane torch
Loctite 515, Gasket Eliminator (domestically available)
Locquic Primer "T" (domestically available)
Linde Conversion Bulletin "VARIABLE-PLATE"
bearing puller body:
- (HPV55)
P/N (to be specified)
- (HPV75)
P/N 0009419133
- (HPV105 and 135)
P/N 0009419138
bearing collet:
- (HPV55)
- (HPV75)
P/N 0009419110
- (HPV105)
P/N 0009419146
- (HPV135)
P/N 0009419144
shaft seal assembly sleeve:
- (HPV55)
- (HPV75)
P/N 0009419746
- (HPV105)
P/N 0009419747
- (HPV135)
P/N 0009419733
rear bearing race driver:
- (HPV55)
- (HPV75)
P/N 0009419743
- (HPV105)
P/N 0009419741
- (HPV135)
P/N 0009419742
rear bearing driver:
- (HPV55)
P/N 8883036430
- (HPV75)
P/N 8883036400
- (HPV105)
P/N 8883036410
- (HPV135)
P/N 8883036420
S-17
Repair Manual

cylinder barrel compression plate kit:

- (HPV55)
- (HPV75)
- (HPV105)
- (HPV135)
shaft seal driver:
- (HPV55)
- (HPV75)
- (HPV105)
- (HPV135)
driver for front bearing race:
- (HPV55)
- (HPV75)
- (HPV105)
- (HPV135)
universal assembly fixture:
- (HPV55)
- (HPV75)
- (HPV105)
- (HPV135)
HPV-02
Rev. 2, 11-21-02
Page 2 of 31
P/N 8883035391
P/N 8883034481
P/N 8883034441
P/N 8883034491
P/N 0009419748
P/N 0009419750
P/N 0009419751
P/N 0009419753
P/N 0009419050
P/N 0009419051
P/N 0009419052
P/N 0009419053
The following sketches illustrate key items which will be referenced throughout this Repair Manual:
S-18
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 3 of 31
S-19
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 4 of 31
Disassembly Procedure:
1. Remove the Filter and Filter Flange from the

Rear Head.
S-20
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 5 of 31
2. Remove the Charge Pump.
3. Remove the O-Ring from the Charge Pump and

the O-Ring from the Rear Head.
4. Remove the Charge Pump Coupling.
5. Remove the pump control and all of the control

o-rings.
6. Use the following steps to remove the Finger:

a. With the butane torch, slowly heat the two
mounting bolts. You only need to heat them
enough to break the Blue Loctite No. 243
loose.
b. Remove the two mounting bolts and discard
them.
c. Pull the Finger from the pump.
S-21
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 6 of 31
7. Remove the Snap Ring from the Finger.
8. Remove all of the shims from the Finger.
9. Remove the seven mounting bolts from the Rear

Head.
10. Remove the Rear Head from the pump.
11. Remove the Port Plate.
12. Remove the two Mechanical Neutral Shims.
13. Remove the three o-rings from the sealing area

of the pump housing (for pump controls without
the integrated POR feature). For pump controls
with the integrated POR feature, there will be five
o-rings.
S-22
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 7 of 31
14. Use a sharp edge tool, sanding stone, and

solvent to remove any remaining sealant from
the sealing area of the pump housing.
15. Follow all steps in Linde Conversion Bulletin

VARIABLE-PLATE to remove the Rear Bearing
from the Drive Shaft.
16. Set the Rear Bearing aside.
17. Remove the Bearing Support Ring from the Drive

Shaft.
18. Remove the two metal split pins from the swash
plate.
S-23
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 8 of 31
19. Pull the Cylinder Barrel out of the pump housing.
20. Pull the remaining rotating group out of the pump

housing.
21. Pull the Drive Shaft out of the rotating group.
22. Remove the two Actuator Pistons from the HoldDown Clamp.
23. Disassemble the Swash Plate/Piston assembly

as illustrated. Please note that the four mounting
bolts that fasten the two Hold-Down Clamps to
the Swash Plate have Green Loctite No. 648 on
their threads. You must use heat to break the
Loctite loose before the bolts can be removed.
S-24
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 9 of 31
24. Remove the Snap Ring from the pump housing.
25. Press the Shaft Seal out of the pump housing.
26. Remove the Front Bearing Race from the pump

housing.
27. Remove the two brass Bearing Strips from the

pump housing.
28. There will be two brass pins (used to hold the

Bearing Strips in place) remaining in the pump
housing. If undamaged, leave them in the pump
housing.
S-25
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 10 of 31
29. Remove all plugs from the pump case drain

ports.
30. Remove the two Lube Tubes and all Lube Tube
Shims and Washers from the Rear Head.
31. Remove the Charge Relief Valve.
32. Remove the Main Relief Valve.
33. Remove the o-ring from the Rear Head in the

Main Relief Valve cavity.
34. Remove the o-ring plug from the high pressure

gauge port in the Rear Head.
S-26
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 11 of 31
35. Remove the Main Relief Valve from the other

side of the Rear Head.
36. Remove the o-ring from the Rear Head in the

Main Relief Valve cavity.
37. Remove the o-ring plug from the high pressure

38. Remove the Rear Bearing Race and all of the

Rear Bearing Shims from the Rear Head.
39. The Cylinder Barrel can be disassembled by

compressing the Cylinder Barrel Spring, and then
by removing the Snap Ring. Upon disassembly,
there should be the Snap ring, Cylinder Barrel
Shims, Washer, Cylinder Barrel Spring, and
Bottom Washer.
S-27
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 12 of 31
40. Position the drive shaft on a vertical press as

illustrated to the left. Press the Front bearing and
Shaft Seal Race off of the Drive Shaft.
41. The HPV-02 pump controls are non-serviceable items, hence no instructions will be provided for
disassembly of the pump controls.
42. The HPV-02 charge pumps are serviceable, but the disassembly and assembly instructions are not
provided in the main body of this Repair Manual. For instructions on how to disassemble and
assemble the HPV-02 charge pumps, please refer to Appendix G located at the end of this Repair
Manual.
This concludes the disassembly portion of this manual. At this point, all components of the
HPV-02 pump should have been completely disassembled. Careful inspection of all parts is
absolutely critical. Any parts showing signs of wear or damage should be discarded and
replaced with genuine Linde parts. It is also strongly recommended that all sealant-type parts
(o-rings, seal nuts, and shaft seal) be discarded and replaced with new genuine Linde parts.
All parts that are going to be reused must be thoroughly cleaned and flushed free of all
contaminants. Any remaining sealant material on the rear head and pump housing must be
scraped clean. The mounting surfaces of the pump housing and rear head should be cleaned
and deburred with a sanding stone and solvent.
S-28
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 13 of 31
Assembly Procedure:
1. If reusing the Shaft Seal Race, the inside
diametric surface must be scraped clean
to remove all leftover Loctite material.
Likewise, any remaining sealant material
on the inside diametric surface of the
Front Bearing and/or the bearing area of
the Drive Shaft should be removed.
2. If using an oven, warm it to 350F (If

using a hot plate, adjust it to 350F).
Heat both the Front Bearing and Shaft
Seal Race to 350F. Install the Front
Bearing onto the drive shaft.
3. Apply a narrow bead of Green Loctite No.

648 around the mounting surface of the
new drive shaft. Then with a small brush
or your finger, spread the Loctite into a
thin, uniform layer around the mounting
surface of the drive shaft.
4. Install the Shaft Seal Race onto the drive

shaft. Make sure to properly orient the
Shaft Seal Race with the tapered end
positioned towards the drive shaft splines.
Then wipe clean all excess Loctite.
S-29
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 14 of 31
5. Install the o-ring plug into the high pressure

gauge port in the Rear Head. Torque the plug to
47 N-m (35 ft-lb).
6. Repeat Step #5 for the other high pressure

7. Apply some petroleum jelly to the o-ring, then

insert it into the o-ring groove in the Rear Head.
8. Repeat Step #7 for the other Main Relief Valve

cavity in the Rear Head.
9. Verify that the o-ring on the Main Relief Valve is

in good condition, then install it into the Rear
Head. Torque the Main Relief Valve to 60 N-m
(44 ft-lb) for HPV55, 75, and 105. For HPV135,
torque to 170 N-m (125 ft-lb).
10. Repeat Step #9 for the other Main Relief Valve.
S-30
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 15 of 31
11. Verify that the o-ring on the Charge Relief Valve

is in good condition, then install it into the Rear
Head. Torque the Charge Relief Valve to
30 N-m (22 ft-lb) for HPV55, 75, and 105. For
HPV135, torque to 40 N-m (30 ft-lb).
12. Install the two brass Bearing Strips into the pump
housing. Prior to installation, apply a thin layer of
petroleum jelly to the bottom side of the Bearing
Strips to help secure them. If reusing the original
pins, press the Bearing Strips onto them. If new
pins are needed, first install the Bearing Strips.
Then install the new pins using a hammer and
punch.
IMPORTANT:
The top surface of the pins must be lower than
the top surface of the Bearing Strips
13. Place the Front Bearing Race into the cavity in

the pump housing.
S-31
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 16 of 31
14. Drive the Front Bearing Race into the pump

housing using the proper race driver tool.
15. As illustrated, place the Drive Shaft into the

pump housing.
16. Follow all steps outlined in Appendix C (located

at the end of this repair manual) to measure for
bearing end-play shimming.
17. Based on the measurement taken in Step #16,

install the proper amount of Rear Bearing Shims
into the Rear Head.
S-32
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 17 of 31
18. Using the proper race driver tool, drive the Rear
Bearing Race into the Rear Head.
19. Install the Snap Ring and Washer into the Cylinder Barrel. Do NOT install the Bottom Washer,
Cylinder Barrel Spring, or Cylinder Barrel Shims at this time. When installing the Snap Ring, make
sure to orient it so that the white mark is facing towards the bronze surface of the Cylinder Barrel. If
using a new Snap Ring without a white mark, apply a white mark with paint on the snap ring and
make sure to orient the Snap Ring as just described.
20. Follow all steps outlined in Appendix A (located at the end of this repair manual) to measure the
Cylinder Barrel lift-off and for proper shim selection.
21. Assemble the Cylinder Barrel as illustrated below. Make sure that the tapered edge of the Bottom
Washer is facing away from the Cylinder Barrel Spring. Addtionally, make sure the the Snap Ring is
positioned with the white mark as illustrated.
S-33
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 18 of 31
22. Follow all steps outlined in Appendix B (located at the end of this repair manual) to measure the
Piston Slipper Lift-Off and for proper shim selection.
23. Install the proper shim combination onto the

appropriate side of the Swash Plate.
24. Install the proper Hold-Down Clamp onto the

Swash Plate. Apply Green Loctite No. 648 to the
threads of the two new mounting bolts. Torque
each mounting bolt to:
[HPV55/75]
[HPV105/135]
32 N-m (24 ft-lb)

64 N-m (47 ft-lb)
25. Install the nine Pistons into the Hold-Down Plate.

As illustrated, make sure that the taper on the
Hold-Down Plate is positioned correctly. Then
set the entire assembly onto the Swash Plate.
S-34
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 19 of 31

other side of the Swash Plate.

[HPV55/75]
[HPV105/135]
32 N-m (24 ft-lb)

64 N-m (47 ft-lb)
28. Place the Cylinder Barrel on a non-abrasive

surface as illustrated. Then insert the nine
Pistons and the Swash Plate assembly into the
Cylinder Barrel.
S-35
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 20 of 31
29. Remove the Drive Shaft from the pump housing,

then insert it into the Cylinder Barrel as
illustrated.
30. Position the Drive Shaft onto a firm surface as

illustrated. Place the Bearing Support Ring onto
the Drive Shaft making sure to orient it correctly.
31. If using an oven, warm it to 350F (If using a hot

plate, adjust it to 350F). Heat the Rear Bearing
to 350F. Install the Rear Bearing onto the drive
shaft. Allow the Rear Bearing to cool for a
moment. Then use the rear bearing driver tool to
drive the Rear Bearing completely onto the Drive
Shaft.
S-36
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 21 of 31
32. Install the two Actuator Pistons into the HoldDown Clamp.
33. Slide the rotating group into the pump housing.
34. Follow all steps outlined in Appendix E to measure for and select the proper Lube Tube Shims.
35. Follow all steps outlined in Appendix F to measure for and select the proper Mechanical Neutral
Shims.
36. Remove the rotating group from the pump housing and set it aside.
S-37
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 22 of 31
37. With a brush, apply Locquic Primer T to the

sealing area of the Rear Head.
38. Insert the two Lube Tubes and Shims into the
Rear Head. Make sure that they are inserted
into the correct cavities in the Rear Head. When
inserting the Lube Tube Shims, make sure that
the tapered edge faces away from the Lube Tube
as illustrated below.
39. Pre-lubricate the running surface of the Port

Plate (the surface with the dampening slots) with
some mineral based oil or lubricant.
40. Install the Port Plate onto the Rear Head making
sure to orient it with the dampening slots facing
away from the Rear Head.
S-38
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 23 of 31
41. Place the rotating group onto the Port Plate. You
have to lift the Port Plate a little (as shown) to
permit the two Actuator Pistons to fit into the
cavities. Make sure that the two Lube Tubes are
properly positioned into the spherical cavities in
the two brass Hold-Down Clamps.
42. Apply Loctite 515 Gasket Eliminator to the

sealing surface of the pump housing. Spread the
sealant with your finger or with a clean brush
over the entire sealing surface of the pump
housing. The result should be a thin, uniform
coat of sealant.
43. Install the o-rings into the sealing area of the

pump housing.
44. Install the Mechanical Neutral Shims in the

proper positions. Make sure that they are
oriented properly with the rounded edge facing
towards the pump housing (away from the Rear
Head).
S-39
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 24 of 31
45. Slowly lower the pump housing onto the Rear

Head.
46. Torque each mounting bolt as follows:
HPV55
HPV75
HPV105
HPV135
(M10 bolt) 64 N-m (47 ft-lb)

(M8 bolt) 32 N-m (24 ft-lb)
(M12 bolt) 110 N-m (81 ft-lb)
(M12 bolt) 110 N-m (81 ft-lb)
(M14 bolt) 180 N-m (133 ft-lb)
47. To help verify that the two Lube Tubes and the
Swash Plate are properly positioned, use the
photo to identify the two passages in which to
supply air pressure (shop air through a nozzle
will work). Supply air into the two passages and
make sure that the Swash Plate moves and
holds pressure by staying stroked. (Hint: As the
Swash Plate moves, you can look through the
open control cavity and the case drain port in the
pump housing to visually verify that the Lube
Tubes are in position)
S-40
Repair Manual

Clean This
Surface
HPV-02
Rev. 2, 11-21-02
Page 25 of 31
48. Use cleaning solvent and a lintfree rag to thoroughly clean the
surface indicated in the sketch.
The old Shaft Seal had Loctite on
its outside diametric surface and
remnants of the Loctite may still
be on the indicated surface of the
housing.
Assembly
Sleeve
49. Place the Assembly Sleeve Tool
over the drive shaft as
illustrated. Apply petroleum jelly
to the outside surface of the
Assembly Sleeve Tool.
Shaft Seal
Green Loctite
No. 270 On
This Surface
Petroleum Jelly
On This Surface
50. As illustrated, apply petroleum

jelly to the inside diametric
surface of the new Shaft Seal.
Then apply Green Loctite No.
270 to the outside diametric
surface of the Shaft Seal, and
spread it to a uniform thickness
with your finger.
S-41
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 26 of 31
51. Lightly press the Shaft Seal

onto the Assembly Sleeve
Tool as illustrated.
Shaft Seal
52. Using the proper shaft seal driver tool, drive the
Shaft Seal into the pump housing.
Snap Ring
53. Reinstall the Snap Ring making sure
that it is fully engaged into the snap
ring groove.
S-42
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 27 of 31
54. Install the Charge Pump Coupling onto the Drive

Shaft.
55. Apply some petroleum jelly to the o-ring and

place it in the o-ring groove in the Rear Head.
56. Apply some petroleum jelly to the o-ring and

place it in the o-ring groove in the Charge Pump.
S-43
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 28 of 31
57. Install the Charge Pump onto the pump.
58. Install the two Mounting Bolts and torque each

one to 85 N-m (63 ft-lb).
59. Install the two metal split pins into the swash
plate. Take care during the installation to avoid
dropping the split pins into the pump housing.
S-44
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 29 of 31
60. Insert the Finger onto the two metal spilt pins in
the Swash Plate. Make sure to orient the Finger
as illustrated.
61. Following the manufacturer's recommendations,

apply Blue Loctite No. 243 to the threads of the
two new Finger Mounting Bolts.
62. Install the two new mounting bolts into the pump
and torque each one to 34 N-m (25 ft-lb).
63. Follow all steps outlined in Appendix D (located

at the end of this Repair Manual) to properly
measure and select shims for the Finger.
64. Based on the measurements from Step #63,

install the Finger Shims.
S-45
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 30 of 31
65. Install the Finger Snap Ring.
66. Apply petroleum jelly to each o-ring for the pump

control and place all o-rings in the appropriate
o-ring groove.
67. Install the control onto the pump making sure

that:
a. The Finger is properly positioned into the
female linkage inside the control.
b. The metal split pins in the pump control
are aligned with the corresponding
passage in the pump housing.
S-46
Repair Manual

HPV-02
Rev. 2, 11-21-02
Page 31 of 31
68. Fasten the control with four Control Mounting

Bolts. Torque each mounting bolt to:
25 N-m (18 ft-lb) For HPV-02 Controls

Without the integrated
POR feature
34 N-m (25 ft-lb) For HPV-02 Controls With

the integrated POR
feature
69. Install the Filter and Filter Flange onto the Rear
Head. Torque each mounting bolt to 25 N-m (18
ft-lb).
70. Make sure to install plugs in all open ports and

cover the two pump workports.
S-47
Repair Manual
Appendix A: Procedure to Shim

the Cylinder Barrel
Appendix A
Rev. 1, 7-22-02
Page 1 of 3
Note:
Refer to the Linde Spare Parts Catalog for the shim part numbers available for the
pump size you are working on
The parts and dimension shown in the following illustration will be used for this procedure:
1. Install the Bearing and Shaft Seal Race on the drive shaft.
2. Make sure to install the Bearing Race as illustrated above.
3. Use the proper race driver tool to ensure that the Bearing Race is installed completely
into the housing.
S-48
Repair Manual

the Cylinder Barrel
Appendix A
Rev. 1, 7-22-02
Page 2 of 3
4. As demonstrated during the training, remove the cylinder barrel spring and bottom
washer from the cylinder barrel. Then reinstall the Washer and Snap Ring back into the
cylinder barrel. Do NOT reinstall the cylinder barrel shims.
IMPORTANT:
Make sure to reinstall the Snap Ring in the proper orientation as emphasized
during the training.
5. Install the cylinder barrel onto the drive shaft as illustrated above.
6. Measure and record dimension X to the nearest 0.01mm.
Dimension X =
mm
7. As illustrated below, measure and record dimension Y to the nearest 0.01mm.

Dimension Y =
mm
8. Calculate Dimension Z and record the value below to the nearest 0.01mm:
Dimension Z = (Dimension X) (Dimension Y)
Dimension Z =
mm
S-49
Repair Manual

the Cylinder Barrel
Appendix A
Rev. 1, 7-22-02
Page 3 of 3
9. Based on the value for Dimension Z, select the quantity of cylinder barrel shims to
acquire a clearance of 0.10mm to 0.30mm. Refer to the example below.
Example: HPV105-02 Pump

Dimension X = 4.75mm
Dimension Y = 3.00mm
Dimension Z = (4.75mm) (3.00mm) = 1.75mm
You must calculate a range for the cylinder barrel shims:

(maximum clearance) = (1.75mm) (0.30mm) = 1.45mm
(minimum clearance) = (1.75mm) (0.10mm) = 1.65mm
You must select a shim (or combination of shims) that is between 1.45mm and 1.65mm
S-50
Repair Manual
Appendix B: Procedure to Shim

For Piston Slipper Lift-Off
Appendix B
Rev. 1, 8-13-02
Page 1 of 3
pump size you are working on.
The parts and dimensions shown in the following illustration will be used for this procedure:
IMPORTANT:
Pump pistons must be replaced as a complete set. If one or more pistons are
damaged, then discard all of them and replace them with a new set of pistons.
1. As illustrated on the following page, measure and record the following parts individually
to the nearest 0.01mm:
Hold-Down Clamp
Hold-Down Plate
Piston Slipper [select any piston]
(Dimension Q)
(Dimension R)
(Dimension S)
Dimension Q =
mm
Dimension R =
mm
Dimension S =
mm
S-51
Repair Manual

Appendix B
Rev. 1, 8-13-02
Page 2 of 3
2. Do the following calculation and record the value below to the nearest 0.01mm:
Dimension Y = (Dimension R) + (Dimension S)
Dimension Y =
mm
Dimension Z = (Dimension Y) (Dimension Q)
Dimension Z =
mm
4. Based on the value for Dimension Z, select the proper Shims to acquire a clearance of
0.01mm to 0.03mm. Refer to the example below.
5. Repeat steps #1 through #4 for the Hold-Down Clamp on the other side of the pump.
IMPORTANT:
There are two Hold-Down Clamps on each pump. The two Hold-Down Clamps are
different from each other. Likewise, the Shims beneath them are different from each
other. It is critical that each Hold-Down Clamp be measured and shimmed
accordingly.
S-52
Repair Manual

Appendix B
Rev. 1, 8-13-02
Page 3 of 3

Part #1: (For the first Hold-Down Clamp)
Dimension Q = 10.39mm
Dimension R = 5.50mm
Dimension S = 5.99mm
Dimension Y = (5.50mm) + (5.99mm) = 11.49mm
You must calculate a range for the Shims:

(maximum clearance) = (1.10mm) + (0.03mm) = 1.13mm
(minimum clearance) = (1.10mm) + (0.01mm) = 1.11mm
Select a Shim (or combination of Shims) that is between 1.11mm and 1.13mm for the first
Hold-Down Clamp. To compensate for measuring errors, it is recommended that you select
a shim between the two extreme values 1.12mm.
Part #2: (For the second Hold-Down Clamp)
Dimension R = 5.50mm (same value as in Part #1)
Dimension S = 5.99mm (same value as in Part #1)

Select a Shim (or combination of Shims) that is between 1.09mm and 1.10mm for the
second Hold-Down Clamp. To compensate for measuring errors, it is recommended that
you select a shim between the two extreme values 1.09mm.
S-53
Repair Manual
Appendix C: Procedure to Shim

for Bearing End-Play
Appendix C
Rev. 0
Page 1 of 3
The parts and dimension shown in the following illustration will be used in this procedure:
into the housing.
4. Measure and record Dimension A as illustrated above to the nearest 0.01mm
Dimension A =
S-54
mm
Repair Manual

Appendix C
Rev. 0
Page 2 of 3
5. As illustrated below, measure and record Dimension B and Dimension C to the

nearest 0.01mm. Measure each component individually.
Dimension B =
mm
Dimension C =
mm
6. As illustrated below, measure and record Dimension D to the nearest 0.01mm. Make
sure to remove ALL existing shims before taking the measurement for Dimension D.
Dimension D =
mm
S-55
Repair Manual

Appendix C
Rev. 0
Page 3 of 3
7. Calculate and record Dimension X to the nearest 0.01mm:

Dimension X = (Dimension A) + (Dimension D)
Dimension X =
mm
8. Calculate and record Dimension Y to the nearest 0.01mm:

Dimension Y = (Dimension B) + (Dimension C)
Dimension Y =
mm
9. Calculate and record Dimension Z to the nearest 0.01mm:

Dimension Z =
mm
10. Based on the value for Dimension Z, select the quantity of shims to get between an
interference of 0.02mm and a clearance of 0.07mm. Refer to the example below.

Dimension A = 8.70mm
Dimension B = 3.50mm
Dimension C = 22.23mm
Dimension D = 19.70mm
Dimension X = (8.70mm ) + (19.70mm) = 28.40mm
You must calculate a range for the shims:

You must select a shim (or combination of shims) that is between 2.60mm and 2.69mm.
S-56
Repair Manual
Appendix D: Procedure to
Shim Control Finger
Appendix D
Rev. 0
Page 1 of 2
Procedure A: For HPV-02 Cam Control

1. The new Finger for the Cam Control must be installed:
a. As illustrated below, install the Finger into the pump by pressing it onto the two metal
split pins. Refer to the illustration to insure the Finger is oriented correctly.
b. Following the manufactorer's recommendations, apply Blue Loctite No. 243 to the
threads of the two new M8 S.H.C.S.
c. Install the two new M8 S.H.C.S. into the pump and torque each one to 34 N-m
(25 ft-lb).
S-57
Repair Manual
Appendix D: Procedure to
Shim Control Finger
Appendix D
Rev. 0
Page 2 of 2
2. Using the digital depth calipers, measure from the designated edge of the Finger to the
pump housing.
3. Select enough Shims so that the measurement adds up to 19.4mm (+0.1/-0.0mm)
including the Snap Ring as illustrated above.
Procedure B: For All Other HPV-02 Controls

1. Repeat Step #1 from Procedure A.
2. As illustrated below, use digital depth calipers to measure from the designated edge of
the Finger to the pump housing.
3. Select enough Shims so that the measurement adds up to 25.4mm (+0.1/-0.0mm)
including the Snap Ring as illustrated below.
S-58
Repair Manual
Appendix E: Procedure to Shim

Lube Tubes
Appendix E
Rev. 0
Page 1 of 5
Linde Universal Tool

- For HPV55-02 pumps
Part Number 0009419050
lube tube washers (as required)
lube tube shims (refer to the appropriate Linde spare parts catalog for part numbers)
digital depth calipers (capable of measuring to the nearest 0.01mm)
sharp edge tool (to remove sealant from pump housing)
sanding stone
solvent
The illustration below can be used to identify some key parts of the Linde universal tool that
will be referenced throughout this Appendix.
S-59
Repair Manual

Lube Tubes
Appendix E
Rev. 0
Page 2 of 5

2. Remove and discard all of the o-rings on the sealing area of the pump housing.
3. Use the sharp edge tool to remove all sealant on the sealing area of the pump housing
and the Rear Head.
4. Use the sanding stone and solvent to clean and debur the sealing area of the pump
housing and the Rear Head.
5. As illustrated below, install the Linde universal tool onto the pump. Use the three
fasteners to attach the Linde universal tool to the pump housing.
S-60
Repair Manual

Lube Tubes
Appendix E
Rev. 0
Page 3 of 5
6. Insert the two Lube Tubes into the Lube Tube Adjustments, as illustrated above, and
make sure that both Lube Tubes are properly positioned into the Hold-Down Cavity.
7. With your fingers, lightly tighten both Lube Tube Adjustments.
8. As illustrated below, measure Dimensions A and B with digital depth calipers and
record the measurements to the nearest 0.01mm.
Dimension A =
mm
Dimension B =
mm
(Note: Dimension A is for the Lube Tube between the two Actuator Pistons)
9. As illustrated on the following page, measure Dimensions C and D on the Rear Head
with digital depth calipers and record the measurements to the nearest 0.01mm.
(Note: Dimension C is for the Lube Tube between the two Actuator Pistons)
S-61
Repair Manual

Lube Tubes
Dimension C =
mm
Dimension D =
mm
Appendix E
Rev. 0
Page 4 of 5
10. Do the following calculations and record the results to the nearest 0.01mm:
Dimension E = (Dimension C) (Dimension A) + (25.00)
Dimension E =
mm
Dimension F = (Dimension D) (Dimension B) + (25.00)

Dimension F =
mm
(Note: Dimension E is for the Lube Tube between the two Actuator Pistons)
Note:
Dimensions E and F are the clearances between the end of the Lube Tubes and the
cavities in the Rear Head. These clearances must be filled with Lube Tube Shims (and
Washers as required) to provide a final clearance of 0.01mm to 0.15mm. Please refer to the
illustration and the example on the following page.
S-62
Repair Manual

Lube Tubes
Appendix E
Rev. 0
Page 5 of 5

Dimension E = (11.51mm) (34.88mm) + (25.00mm) = 1.63mm
Dimension F = (11.53mm) (34.93mm) + (25.00mm) = 1.60mm
You must calculate a shim range for each Lube Tube:

-
For the Lube Tube between the two Actuator Pistons: (reference Dimension E)
Select a Lube Tube Shim between 1.48mm and 1.62mm thick
For the other Lube Tube: (reference Dimension F)

Select a Lube Tube Shim between 1.45mm and 1.59mm thick
S-63
Repair Manual
Appendix F: Procedure to Shim

Mechanical Neutral
Appendix F
Rev. 0
Page 1 of 5
Linde Universal Tool

mechanical neutral shims (refer to the appropriate Linde spare parts catalog for the part
numbers)
digital calipers (capable of measuring to the nearest 0.01mm)
digital depth calipers (capable of measuring to the nearest 0.01mm)
sharp edge tool (to remove sealant from pump housing)
sanding stone
solvent
The illustration below can be used to identify some key parts of the universal tool that will be
referenced throughout this Appendix.
S-64
Repair Manual

Mechanical Neutral
Appendix F
Rev. 0
Page 2 of 5
Note:
If you do NOT have the proper Lube Tube Shims, perform all steps in Appendix E before
continuing with Appendix F.
1. If you are proceeding from Appendix E, then skip steps #2 through #7.
3. Remove and discard all of the o-rings on the sealing area of the pump housing.
4. Use the sharp edge tool to remove all sealant on the sealing area of the pump housing
and the Rear Head.
5. Use the sanding stone and solvent to clean and debur the sealing area of the pump
housing and the Rear Head.
S-65
Repair Manual

Mechanical Neutral
Appendix F
Rev. 0
Page 3 of 5
6. As illustrated on the previous page, install the universal tool onto the pump. Use the
three fasteners to attach the universal tool to the pump housing.
Insert the two Lube Tubes into the Lube Tube Adjustments and make sure that both
Lube Tubes are properly positioned into the Hold-Down Cavity.
7. With your fingers, lightly tighten both Lube Tube Adjustments.
8. As illustrated below, use the Neutral Adjustments on the universal tool to make sure that
Dimensions G and H are NOT different by more than 0.06mm (use the digital depth
calipers to measure this mechanically places the pump in neutral).
S-66
Repair Manual

Mechanical Neutral
Appendix F
Rev. 0
Page 4 of 5
9. Measure and record Dimension G and H to the nearest 0.01mm:

Dimension G =
mm
Dimension H =
mm
10. Remove the universal tool from the pump.
11. As illustrated below, measure and record Dimensions I, J, K, and L to the nearest
0.01mm:
Dimension I =
Dimension K =
mm
mm
Dimension J =
mm
Dimension L =
mm
S-67
Repair Manual

Mechanical Neutral
Appendix F
Rev. 0
Page 5 of 5
12. Do the following calculations and record the results to the nearest 0.01mm:
Dimension M = (Dimension I) + (Dimension J) - (Dimension G) + 0.05
Dimension M =
mm
Dimension N = (Dimension K) + (Dimension L) - (Dimension H) + 0.05

Dimension N =
mm
13. Select mechanical neutral shims that have the same thickness as Dimension M and
N. The allowable tolerance for the mechanical neutral shims is (+0.10mm)/(-0.00mm).

Dimension G = 34.12mm
Dimension I = 28.74mm
Dimension J = 9.87mm
Dimension H = 34.14mm
Dimension K = 28.73mm
Dimension L = 10.03mm
Dimension M = (28.74mm) + (9.87mm) (34.12mm) + (0.05mm) = 4.54mm
Select a mechanical neutral shim 4.54mm to 4.64mm thick
Dimension N = (28.73mm) + (10.03mm) (34.14mm) + (0.05mm) = 4.67mm
Select a mechanical neutral shim 4.67mm to 4.77mm thick
S-68
Repair Manual
Appendix G: Procedure to Repair

Charge Pump
Appendix G
Rev. 0
Page 1 of 8
Note:
The Charge Pump illustrated in this Appendix is an external feed charge pump. If you are working
on an internal feed charge pump, contact the Linde Service Department if you have any specific
questions about the repair instructions.
Disassembly Instructions:
1. Remove the Charge Pump from the HPV-02

pump.
2. Remove the Cold-Start Relief Valve.
3. Remove the tapered thread Plug (illustrated to

the left) from the Charge Pump and discard it.
On occasion, there may be a plug with an o-ring
on it (not illustrated). If the charge pump you are
working on has this type of plug, then you can
reuse it.
4. Remove the Rear Cover Plate and O-Ring from

the Charge Pump.
S-69
Repair Manual

Charge Pump
Appendix G
Rev. 0
Page 2 of 8
5. Remove the seven Fastening Bolts and

Washers.
6. Flip the Charge Pump over, then remove the Port

Plate.
7. Remove the O-Ring that rests beneath the Port

Plate.
8. Pull the Shaft/Inner Gear Assembly out of the

Charge Pump.
9. Pull the Outer Gear from the Charge Pump.
S-70
Repair Manual

Charge Pump
Appendix G
Rev. 0
Page 3 of 8
10. To disassemble the Shaft/Inner Gear Assembly:

a. Remove one of the flat Snap Rings from
the Shaft.
b. Slide the Inner Gear off of the Shaft.
c. Pull the Shear Key from the Shaft.
d. Remove the other flat Snap Ring.
Assembly Instructions:
1. Install one flat Snap Ring onto the Shaft.
2. Apply some petroleum jelly onto the Shear Key.

Then insert the Shear Key into the slot in the
Shaft.
S-71
Repair Manual

Charge Pump
Appendix G
Rev. 0
Page 4 of 8
3. Align the notch on the Inner Gear with the Shear

Key, then slide the Inner Gear up to the flat Snap
Ring on the Shaft.
IMPORTANT:
The Inner Gear has a sharp, flat edge on one
side and a small taper on the other side. The
edge with the small taper must be facing away
from the external splines of the Shaft when
installed. Failure to install the Inner Gear as
described will lead to improper operation of the
Charge Pump and/or permanent damage to the
Charge Pump.
4. Install the other flat Snap Ring onto the Shaft.

5. (If reusing the original Needle Bearing in the
Charge Pump housing, then skip this step) Apply
a thin, uniform layer of Green Loctite No. 270 to
the outer race of the new Needle Bearing. The
orientation of the Needle Bearing is important.
On one face of the Needle Bearing, there will be
some stamping (bearing manufacturer's name,
etc.) and the other side will be blank. The side of
the Needle Bearing with the stamping must be
facing away from the Charge Pump housing
when installed. Install the new Needle Bearing
into the Charge Pump housing and wipe away
any excess Loctite.
6. Install the Shaft/Inner Gear Assembly into the

Charge Pump housing as illustrated making sure
to orient the assembly correctly.
HINT:
The small tapered edge on the Inner Gear should
be facing downward.
S-72
Repair Manual

Charge Pump
Appendix G
Rev. 0
Page 5 of 8
7. Install the Outer Gear into the Charge Pump

Housing.
IMPORTANT:
The Outer Gear has a sharp, flat edge on one
side and a small taper on the other side. The
edge with the small taper must be facing
downward (as illustrated to the left) when
installed. Failure to install the Outer Gear as
described will lead to improper operation of the
Charge Pump and/or permanent damage to the
Charge Pump.
8. Apply some petroleum jelly to the O-Ring, then

install the O-Ring into the Charge Pump housing.
9. (If reusing the original Needle Bearing in the Port Plate, then skip this step) Apply a thin, uniform
layer of Green Loctite No. 270 to the outer race of the new Needle Bearing.
The orientation of the Needle Bearing is important. On one face of the Needle Bearing, there will be
some stamping (bearing manufacturer's name, etc.) and the other side will be blank. The side of the
Needle Bearing with the stamping must be facing away from the Port Plate when installed. Install
the new Needle Bearing into the Port Plate and wipe away any excess Loctite.
S-73
Repair Manual

Charge Pump
Appendix G
Rev. 0
Page 6 of 8
10. Install the Port Plate onto the Charge Pump.

HINT:
The seven holes on the Port Plate are NOT
evenly spaced, hence the Port Plate can only be
install in one position where all seven holes are
aligned.
11. Install the seven Fastening Bolts and Washers to

fasten the Port Plate to the Charge Pump.
Torque each Fastening Bolt to 13 N-m (10 ft-lb).
12. Apply some petroleum jelly to the O-Ring, then

install the O-Ring into the Charge Pump housing.
S-74
Repair Manual

Charge Pump
Appendix G
Rev. 0
Page 7 of 8
13. Install the Cover Plate and fasten it to the Charge

Pump with the two Hex Head Bolts. Torque each
Hex Head Bolt to 46 N-m (34 ft-lb).
Note:
For Steps #14 and #15, it is important to know the rotation for the pump. The positions for the Plug and
Cold-Start Relief Valve are dependent on the pump rotation as illustrated below.
S-75
Repair Manual

Charge Pump
Appendix G
Rev. 0
Page 8 of 8
14. Apply Blue Loctite No. 243 to the threads of a

new Plug. Install the Plug into the Charge Pump.
Torque the Plug to 60 N-m (44 ft-lb). For those
special plugs with the o-ring, you do NOT need
to apply Loctite.
15. Install the Cold-Start Relief Valve into the Charge

Pump. Torque the Cold-Start Relief Valve to 30
N-m (22 ft-lb).
16. Install plastic shipping plugs into the two Charge

Pump workports.
S-76
HPR Pump Installation and Start-Up
S-77
S-78
S-79
S-80
S-81
Notes
S-82
HPR Pump Repair Manual
Repair Manual
Repair Manual for HPR-02

HPR-02
Rev. 1, 8-7-02
Page 1 of 28
This Repair Manual is valid for all single HPR-02 (55/75/105/135) pumps; For the HPR105-02
double pump, refer to Linde repair manual HPR-D-02.
metric wrenches and Allen wrenches
vertical press
oven or hot plate (minimum temperature of 350F required)
rubber mallet or soft metal rod
snap ring wrench (to squeeze/compress the snap ring)
torque wrench capable of setting between 2.7 N-m (2.0 ft-lb) and 180 N-m (133 ft-lb)
rear bearing shims (refer to Linde Spare Parts Catalog for required part numbers)
cylinder barrel shims (refer to Linde Spare Parts Catalog for required part numbers)
commercially available bearing race remover
steel sleeve or bushing (to press rear bearing onto drive shaft - no part number)
steel impact block (no part number)
sanding stone and solvent
petroleum jelly
Loctite 515, Gasket Eliminator (domestically available)
Locquic Primer "T" (domestically available)
bearing puller body:
- (HPR55)
- (HPR75)
P/N 0009419133
- (HPR105 and 135)
P/N 0009419138
bearing collet:
- (HPR55)
- (HPR75)
P/N 0009419110
- (HPR105)
P/N 0009419146
- (HPR135)
P/N 0009419144
shaft seal assembly sleeve:
- (HPR55)
- (HPR75)
P/N 0009419745
- (HPR105)
- (HPR135)
rear bearing race driver:
- (HPR55)
- (HPR75)
P/N 0009419743
- (HPR105)
P/N 0009419741
- (HPR135)
P/N 0009419742
cylinder barrel compression plate kit:
- (HPR55)
P/N 8883035391
- (HPR75)
P/N 8883034481
- (HPR105)
P/N 8883034441
- (HPR135)
P/N 8883034491
S-83
Repair Manual

shaft seal driver:

- (HPR55)
- (HPR75)
- (HPR105)
- (HPR135)
driver for front bearing race:
- (HPR55)
- (HPR75)
- (HPR105)
- (HPR135)
Linde Conversion Bulletin "VARIABLE-PLATE"
HPR-02
Rev. 1, 8-7-02
Page 2 of 28

P/N 0009419748
P/N 0009419749
P/N 0009419750
P/N 0009419751
The following sketches illustrate an HPR-02 single pump and some key items which will be
referenced throughout this Repair Manual:
S-84
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 3 of 28
S-85
Repair Manual
S-86

HPR-02
Rev. 1, 8-7-02
Page 4 of 28
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 5 of 28
Disassembly Procedure:
1. Remove the two hex head bolts from the PTO
Cover plate.
2. Remove the PTO Cover plate and PTO O-Ring

from the back of the pump.
3. Remove the nine Mounting Bolts from the Rear

Head.
5. Remove the Port Plate from the pump.
6. Use a sharp edge tool, sanding stone, and

solvent to remove any remaining sealant from
the pump housing sealing area.
7. Follow all steps in Linde Conversion Bulletin

VARIABLE-PLATE to remove the Rear Bearing
from the Drive Shaft.
S-87
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 6 of 28
8. Set the Rear Bearing aside.
9. Remove the Bearing Support Ring from the Drive

Shaft.
10. Remove the entire rotating group from the pump

housing.
11. Set the rotating group onto a soft, non-abrasive

surface as illustrated.
S-88
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 7 of 28
12. Pull the Drive Shaft straight up and out of the

rotating group.
13. Pull the Swash Plate/Piston/Actuator assembly

out of the Cylinder Barrel.
14. Disassemble the Swash Plate/Piston/Actuator

assembly as illustrated. Please note that the four
bolts that fasten the two Hold-Down Clamps to
the Swash Plate have Green Loctite No. 648 on
their threads. You must use heat to break the
Loctite loose before the bolts can be removed.
S-89
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 8 of 28
15. Remove the two brass Bearing Strips from the

pump housing.
16. There will be two brass pins (used to hold the

Bearing Strips in place) remaining in the pump
housing. If undamaged, leave them in the pump
housing.
17. Remove the Front Bearing Race from the pump

housing.
18. Remove the Snap Ring.
19. Press the Shaft Seal out of the pump housing.
S-90
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 9 of 28
20. If the pump has a side inspection cover on the

housing, as illustrated, then remove it. If not,
then disregard this step.
21. Remove all plugs from the pump case drain

ports.
22. Remove the two Lube Tubes and all Lube Tube
Shims from the Rear Head.
S-91
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 10 of 28
23. Remove the Pump Control from the Rear Head

by removing the three mounting bolts.
24. Remove the Displacement Adjustment Studs and

Seal Nuts from the Rear Head.
25. Remove the Rear Bearing Race and all of the

Rear Bearing Shims.
26. All other reusable metal and plastic plugs should

be removed from the Rear Head.
S-92
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 11 of 28
27. There are two types of Pump Controls for the

HPR-02 pumps The Load Sense/Pressure
Compensator Control (illustrated to the left) and
the Load Sense/Power Mode Control (illustrated
below). Disassemble the Load Sense/Pressure
Compensator control by removing the four
mounting bolts from the side cover.
28. Finish disassembling the Load Sense/Pressure

Compensator Control by removing the metal
plugs and remaining spools.
29. Disassemble the Load Sense/Power Mode

Control (illustrated to the left) by removing the
four mounting bolts from the side cover. Remove
the solenoid from the control by removing the
four mounting bolts.
S-93
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 12 of 28
30. Prior to disassembling the Cylinder Barrel,

please note that there is a white mark on the
Snap Ring. The white mark identifies the top
surface of the Snap Ring. This will become
important during the Assembly portion of this
manual.
31. (For the HPR55-02 and HPR75-02 only) The

Cylinder Barrel can be disassembled by
by removing the Snap Ring. Upon disassembly,
there should be the Snap ring, Cylinder Barrel
Shims, Washer, Cylinder Barrel Spring, and
Bottom Washer.
32. (For the HPR105-02 and HPR135-02 only) The

Cylinder Barrel can be disassembled by
by removing the Snap Ring. Then the remaining
parts within the Cylinder Barrel can be removed
They are the Snap Ring, Outer Bushing, Inner
Bushing (with two Piston Rings), Washer,
Cylinder Barrel Spring, and Bottom Washer.
S-94
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 13 of 28
33. Position the drive shaft on a vertical press as

illustrated to the left. Press the Front bearing and
Shaft Seal Race off of the Drive Shaft.
34. As illustrated, remove the Piston Rings from the

two Actuator Pistons.
This concludes the disassembly portion of this manual. At this point, all components of the
HPR-02 pump should have been completely disassembled. Careful inspection of all parts is
absolutely critical. Any parts showing signs of wear or damage should be discarded and
replaced with genuine Linde parts. It is also strongly recommended that all sealant-type parts
(o-rings, seal nuts, and shaft seal) be discarded and replaced with new genuine Linde parts.
All parts that are going to be reused must be thoroughly cleaned and flushed free of all
contaminants. Any remaining sealant material on the rear head and pump housing must be
scraped clean. The mounting surfaces of the pump housing and rear head should be cleaned
and deburred with a sanding stone and solvent.
S-95
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 14 of 28
Assembly Procedure:
1. If using the Load

Sense/Pressure
Compensator Pump
Control (illustrated to
the left), then
reassemble it as
shown.
2. Torque each of the

mounting bolts on the
side cover to 14 N-m
(10 ft-lb).
3. If using the Load

Sense/Power mode
Pump Control
(illustrated to the
left), then
reassemble it as
shown.

mounting bolts on
the side cover to 14
N-m (10 ft-lb)

solenoid mounting
bolts to 2.7 N-m
(2.0 ft-lb).
S-96
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 15 of 28
6. Install the Displacement Adjustment Studs and

new Seal Nuts into the Rear Head. There is no
need to torque the Seal Nuts at this time since
both maximum and minimum displacements will
have to be adjusted during testing of the pump.
Note:
As illustrated on page 2, the longer
Displacement Adjustment Stud should be
installed in the larger Cavity of the Rear Head
7. If reusing the Shaft Seal Race, the inside

diametric surface must be scraped clean
to remove all leftover Loctite material.
Likewise, any remaining sealant material
on the inside diametric surface of the
Front Bearing and/or the bearing area of
the Drive Shaft should be removed.
8. If using an oven, warm it to 350F (If

using a hot plate, adjust it to 350F).
Heat both the Front Bearing and Shaft
Seal Race to 350F. Install the Front
Bearing onto the drive shaft.
9. Apply a narrow bead of Green Loctite No.

648 around the mounting surface of the
new drive shaft. Then with a small brush
or your finger, spread the Loctite into a
thin, uniform layer around the mounting
surface of the drive shaft.
10. Install the Shaft Seal Race onto the drive

shaft. Make sure to properly orient the
Shaft Seal Race with the tapered end
positioned towards the drive shaft splines.
Then wipe clean all excess Loctite.
S-97
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 16 of 28
11. If applicable, install the side inspection cover

onto the pump housing. Make sure that the oring is in place prior to installing the cover.
Torque each bolt to 23 N-m (17 ft-lb).
12. Install the two brass Bearing Strips into the pump
housing. Prior to installation, apply a thin layer of
petroleum jelly to the bottom side of the Bearing
Strips to help secure them. If reusing the original
pins, press the Bearing Strips onto them. If new
pins are needed, first install the Bearing Strips.
Then install the new pins using a hammer and
punch.
IMPORTANT:
The top surface of the pins must be lower than
the top surface of the Bearing Strips.
13. Place the Front Bearing Race into the cavity in

the pump housing.
S-98
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 17 of 28
14. Drive the Front Bearing Race into the pump

housing using the proper race driver tool.
15. As illustrated, place the Drive Shaft into the

pump housing.
16. Follow all steps outlined in Appendix C (located

at the end of this repair manual) to measure for
bearing end-play shimming for HPR55-02 and
HPR75-02 pumps. For HPR105-02 and
HPR135-02 pumps, follow all steps outlined in
Appendix D.
17. Based on the measurement taken in Step #16,

install the proper amount of Rear Bearing Shims
into the Rear Head.
S-99
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 18 of 28
18. Using the proper race driver tool, drive the Rear
Bearing Race into the Rear Head.
19. Install the Piston Rings on the two Actuator

Pistons. Be sure to orient the taper on each
Piston Ring as illustrated below.
Steps #20, #21, and #22 are ONLY valid for the HPR55-02 and HPR75-02 pumps If working on
an HPR105-02 or HPR135-02 pump, then disregard these steps.
20. Install the Snap Ring and Washer into the Cylinder Barrel. Do NOT install the Bottom Washer,
Cylinder Barrel Spring, or Cylinder Barrel Shims at this time. When installing the Snap Ring, make
sure to orient it so that the white mark is facing towards the bronze surface of the Cylinder Barrel. If
using a new Snap Ring without a white mark, apply a white mark with paint on the snap ring and
make sure to orient the Snap Ring as just described.
21. Follow all steps outlined in Appendix A (located at the end of this repair manual) to measure the
Cylinder Barrel lift-off and for proper shim selection.
22. Assemble the Cylinder Barrel as illustrated below. Make sure that the tapered edge of the Bottom
Washer is facing away from the Cylinder Barrel Spring. Addtionally, make sure the the Snap Ring is
positioned with the white mark as illustrated.
S-100
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 19 of 28
23. (This step is ONLY valid for HPR105-02 and HPR135-02 pumps) Assemble the Cylinder Barrel as
illustrated below. Make sure that the tapered edge of the Bottom Washer is facing away from the
Cylinder Barrel Spring (Note: There is no shimming required for this Cylinder Barrel).
S-101
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 20 of 28
24. Follow all steps outlined in Appendix B (located at the end of this repair manual) to measure the
Piston Slipper Lift-Off and for proper shim selection.

appropriate side of the Swash Plate.

[HPR55/75]
[HPR105/135]
32 N-m (24 ft-lb)

64 N-m (47 ft-lb)
27. Install the nine Pistons into the Hold-Down Plate.

As illustrated below, make sure that the taper on
the Hold-Down Plate is positioned correctly.
Then set the entire assembly onto the Swash
Plate.
S-102
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 21 of 28

other side of the Swash Plate.
29. Position the two Actuator Pistons into the Swash

Plate. Note that one piston is larger than the
other. Position the Actuator Pistons such that
when installed into the Rear Head, they fit into
the appropriate cavity.
[HPR55/75]
[HPR105/135]
32 N-m (24 ft-lb)

64 N-m (47 ft-lb)
31. Place the Cylinder Barrel on a non-abrasive

surface as illustrated. Then insert the nine
Pistons and the Swash Plate assembly into the
Cylinder Barrel.
S-103
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 22 of 28
32. Remove the Drive Shaft from the pump housing,

then insert it into the Cylinder Barrel as
illustrated.
33. Position the Drive Shaft onto a firm surface as

illustrated. Place the Bearing Support Ring onto
the Drive Shaft making sure to orient it correctly.
34. If using an oven, warm it to 350F (If using a hot

plate, adjust it to 350F). Heat the Rear Bearing
to 350F. Install the Rear Bearing onto the drive
shaft. Allow the Rear Bearing to cool for a
moment. Then use the steel sleeve and
impact block tools to drive the Rear Bearing
completely onto the Drive Shaft.
S-104
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 23 of 28
35. Insert the rotating group from Step #33 into the pump housing. Follow all steps outlined in Appendix
E (located at the end of this repair manual) to measure for and select the proper Lube Tube Shims.
It is absolutely critical that this measurement be done correctly. After the measurements have been
done and the proper shims are selected, make sure that the Lube Tubes and Shims are properly
labeled as to ensure that they are installed into the proper cavity in the Rear Head.
36. Insert the two Lube Tube and Shims into the
Rear Head. Make sure that they are inserted
into the correct cavities in the Rear Head. When
inserting the Lube Tube Shims, make sure that
the tapered edge faces away from the Lube Tube
as illustrated below.
S-105
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 24 of 28
37. Install the Port Plate onto the Rear Head making
sure to orient it with the dampening slots facing
away from the Rear Head. Additionally, the Port
Plate must be positioned properly. The suction
side of the Port Plate (the side with the long slot)
must be oriented towards the suction port in the
Rear Head.
38. Pre-lubricate the running surface of the Port
Plate with some mineral based oil or lubricant.
39. Place the rotating group on the Rear Head as

illustrated. Make sure that the two Lube Tubes
are securely positioned in the Hold-Down
Clamps.
40. With a brush, apply Locquic Primer T to the

sealing area of the Rear Head.
41. Place the Drive Shaft Assembly Sleeve tool onto

the splines of the drive shaft, then apply a layer
of petroleum jelly on the tool.
S-106
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 25 of 28
42. Apply Loctite 515 Gasket Eliminator to the

sealing surface of the pump housing. Spread the
sealant with your finger or with a clean brush
over the entire sealing surface of the pump
housing. The result should be a thin, uniform
coat of sealant.
43. As illustrated, install the pump housing onto the

Rear Head.
44. Carefully position the pump as illustrated to the

left. Then turn in each Mounting Bolt with a hand
tool until snug.
45. Torque each mounting bolt as follows:
HPR55/75 (M8 bolt) 32 N-m (24 ft-lb)

(M12 bolt) 110 N-m (81 ft-lb)
HPR105
(M12 bolt) 110 N-m (81 ft-lb)
HPR135
(M14 bolt) 180 N-m (133 ft-lb)
46. Install a new PTO O-Ring into the PTO cavity of

the Rear Head. Use some petroleum jelly to help
hold the o-ring in position.
S-107
Repair Manual

HPR-02
Rev. 1, 8-7-02
Page 26 of 28
47. Install the PTO Cover onto the Rear Head.

Torque each hex head bolt to 80 N-m (59 ft-lb).
48. Install the pump control onto the Rear Head

making sure to replace all of the control o-rings
with new o-rings. Torque each mounting bolt to
23 N-m (17 ft-lb).
49. Make sure to install plugs in all open ports and

cover the two pump workports.
S-108
Repair Manual

Clean This
Surface
HPR-02
Rev. 1, 8-7-02
Page 27 of 28
50. Use cleaning solvent and a lintfree rag to thoroughly clean the
surface indicated in the sketch.
The old Shaft Seal had Loctite on
its outside diametric surface and
remnants of the Loctite may still
be on the indicated surface of the
housing.
Assembly
Sleeve
51. Place the Assembly Sleeve Tool
over the drive shaft as
illustrated. Apply petroleum jelly
to the outside surface of the
Assembly Sleeve Tool.
Shaft Seal
Green Loctite
No. 270 On
This Surface
Petroleum Jelly
On This Surface
52. As illustrated, apply petroleum

jelly to the inside diametric
surface of the new Shaft Seal.
Then apply Green Loctite No.
270 to the outside diametric
surface of the Shaft Seal, and
spread it to a uniform
thickness with your finger.
S-109
Repair Manual

Shaft Seal
HPR-02
Rev. 1, 8-7-02
Page 28 of 28
53. Lightly press the Shaft Seal

onto the Assembly Sleeve
Tool as illustrated.
54. Using the proper shaft seal driver tool, drive the
Shaft Seal into the motor housing.
Snap Ring
55. Reinstall the Snap Ring making sure
that it is fully engaged into the snap
ring groove.
S-110
Repair Manual

the Cylinder Barrel
Appendix A
Rev. 0
Page 1 of 3
Note:
IMPORTANT:
This Conversion Bulletin is ONLY valid for HPR55-02 and HPR75-02 pumps. HPR10502, HPR135-02, and HPR105D-02 pumps have cylinder barrels that DO NOT need to
be shimmed.
The parts and dimension shown in the following illustration will be used for this procedure:
into the housing.
S-111
Repair Manual

the Cylinder Barrel
Appendix A
Rev. 0
Page 2 of 3
4. As demonstrated during the training, remove the spring and spring support ring from the
cylinder barrel. Then reinstall the Washer and Snap Ring back into the cylinder barrel.
Do NOT reinstall the cylinder barrel shims.
IMPORTANT:
Make sure to reinstall the Snap Ring in the proper orientation as emphasized
during the training.
5. Install the cylinder barrel onto the drive shaft as illustrated above.
6. Measure and record dimension X to the nearest 0.01mm.

Dimension X =
mm
7. As illustrated below, measure and record dimension Y to the nearest 0.01mm.

Dimension Y =
mm
8. Calculate Dimension Z and record the value below to the nearest 0.01mm:
Dimension Z =
S-112
mm
Repair Manual

the Cylinder Barrel
Appendix A
Rev. 0
Page 3 of 3
9. Based on the value for Dimension Z, select the quantity of cylinder barrel shims to
acquire a clearance of 0.05mm to 0.12mm. Refer to the example below.
Example: HPR75-02 Pump

Dimension X = 4.80mm
Dimension Y = 3.00mm
You must calculate a range for the cylinder barrel shims:

You must select a shim (or combination of shims) that is between 1.68mm and 1.75mm
S-113
Repair Manual

Appendix B
Rev. 1, 8-13-02
Page 1 of 3
pump size you are working on.
The parts and dimensions shown in the following illustration will be used for this procedure:
IMPORTANT:
Pump pistons must be replaced as a complete set. If one or more pistons are
damaged, then discard all of them and replace them with a new set of pistons.
1. As illustrated on the following page, measure and record the following parts individually
to the nearest 0.01mm:
S-114
Hold-Down Clamp
Hold-Down Plate
Piston Slipper [select any piston]
(Dimension Q)
(Dimension R)
(Dimension S)
Dimension Q =
mm
Dimension R =
mm
Dimension S =
mm
Repair Manual

Appendix B
Rev. 1, 8-13-02
Page 2 of 3
Dimension Y = (Dimension R) + (Dimension S)
Dimension Y =
mm
Dimension Z = (Dimension Y) (Dimension Q)
Dimension Z =
mm
4. Based on the value for Dimension Z, select the proper Shims to acquire a clearance of
0.01mm to 0.03mm. Refer to the example below.
5. Repeat steps #1 through #4 for the Hold-Down Clamp on the other side of the pump.
IMPORTANT:
There are two Hold-Down Clamps on each pump. The two Hold-Down Clamps are
different from each other. Likewise, the Shims beneath them are different from each
other. It is critical that each Hold-Down Clamp be measured and shimmed separately.
S-115
Repair Manual

Appendix B
Rev. 1, 8-13-02
Page 3 of 3
Example: HPR75-02
Part #1: (For the first Hold-Down Clamp)
Dimension R = 5.50mm
Dimension S = 5.99mm

Select a Shim (or combination of Shims) that is between 1.11mm and 1.13mm for the first
Hold-Down Clamp. To compensate for measuring errors, it is recommended that you select
a shim between the two extreme values 1.12mm.
Part #2: (For the second Hold-Down Clamp)
Dimension R = 5.50mm (same value as in Part #1)
Dimension S = 5.99mm (same value as in Part #1)

Select a Shim (or combination of Shims) that is between 1.08mm and 1.10mm for the
second Hold-Down Clamp. To compensate for measuring errors, it is recommended that
you select a shim between the two extreme values 1.09mm.
S-116
Repair Manual

Appendix C
Rev. 0
Page 1 of 3
IMPORTANT:
Appendix C is ONLY valid for HPR55-02 and HPR75-02 pumps. For HPR105-02,
HPR135-02 and HPR105D-02 pumps, refer to Appendix D for instructions to shim
for bearing end-play.
into the housing.
Dimension A =
mm
S-117
Repair Manual

Appendix C
Rev. 0
Page 2 of 3
5. As illustrated below, measure and record Dimension B and Dimension C to the

nearest 0.01mm. Measure each component individually.
Dimension B =
mm
Dimension C =
mm
6. As illustrated below, measure and record Dimension D to the nearest 0.01mm. Make
sure to remove ALL existing shims before taking the measurement for Dimension D.
Dimension D =
S-118
mm
Repair Manual

Appendix C
Rev. 0
Page 3 of 3

Dimension X = (Dimension A) + (Dimension D)
Dimension X =
mm

Dimension Y = (Dimension B) + (Dimension C)
Dimension Y =
mm

Dimension Z =
mm


S-119
Repair Manual
Appendix D: Procedure to Shim

Appendix D
Rev. 0
Page 1 of 4
IMPORTANT:
Appendix D is ONLY valid for HPR105-02, HPR135-02, and HPR105D-02 pumps. For
HPR55-02 and HPR75-02 pumps, refer to Appendix C for instructions to shim for
bearing end-play.
into the housing.
Dimension A =
S-120
mm
Repair Manual

Appendix D
Rev. 0
Page 2 of 4
5. The following sketch illustrates some key items which will be measured in the following
steps:
6. As illustrated on the following page, measure and record Dimension B, Dimension C,

and Dimension D to the nearest 0.01mm. Measure each component individually.
Dimension B =
mm
Dimension C =
mm
Dimension D =
mm
S-121
Repair Manual

Appendix D
Rev. 0
Page 3 of 4
7. As illustrated below, measure and record Dimension E to the nearest 0.01mm. Make
sure to remove ALL existing shims before taking the measurement for Dimension E.
Dimension E =
S-122
mm
Repair Manual

Appendix D
Rev. 0
Page 4 of 4

Dimension X = (Dimension A) + (Dimension E)
Dimension X =
mm

Dimension Y = (Dimension B) + (Dimension C) + (Dimension D)
Dimension Y =
mm

Dimension Z =
mm
Dimension E = 19.50mm
Dimension Y = (19.20mm) + (5.03mm) + (17.01mm) = 41.24mm

S-123
Repair Manual

Lube Tubes
Appendix E
Rev. 0
Page 1 of 5
Note:
This procedure can be performed with or without the Rear Bearing on the drive shaft. The
following illustrates how to measure the Lube Tube shimming without the Rear Bearing on
the drive shaft.
1. As illustrated below, install the two Lube Tubes into the unit. Make sure that the two
Lube Tubes are properly positioned into the Hold Down Clamp Cavity as shown.
2. Thoroughly clean all surfaces of the Cylinder Barrel Compression Plate. Then use a
sanding stone and solvent to thoroughly clean the top mounting surface of the unit
housing to ensure all sealant material is removed.
S-124
Repair Manual

Lube Tubes
Appendix E
Rev. 0
Page 2 of 5
3. Orient the Cylinder Barrel Compression Plate with the male pilot facing away from the
cylinder barrel. Set the Cylinder Barrel Compression Plate on top of the unit housing.
Match up the threaded holes in the unit housing with the four S.H.C.S. on the plate for
alignment purposes.
IMPORTANT:
Make sure to use the four Washers with the S.H.C.S. to avoid bottoming the S.H.C.S. in
the threaded holes in the unit housing.
4. Fasten the Cylinder Barrel Compression Plate to the unit housing by tightening the four
S.H.C.S. with a hand tool.
5. Center the swash plate (to the position of zero displacement) by moving the two actuator
pistons. For best results, the swash plate should be at its zero displacement position.
As illustrated below, use depth micrometers to measure dimensions "A" and "B".
Measure dimensions "A" and "B" to the nearest 0.01mm and record the values below:
Dimension "A" =
mm
Dimension "B" =
mm
Please note that there are two Lube Tubes designated Lube Tube "A" and Lube Tube
"B". Make sure to keep each Lube Tube properly labeled to avoid mixing them up. Also
make sure that dimension "A" corresponds with Lube Tube "A" (and the same for
dimension "B" and Lube Tube "B")
S-125
Repair Manual

Lube Tubes
Appendix E
Rev. 0
Page 3 of 5
6. As illustrated above, measure dimension "C" to the nearest 0.01mm and record the
value below:
Dimension "C" =
mm
7. Do the following calculation and record the value to the nearest 0.01mm:
Dimension "D" = (Dimension "C") - (Dimension "A") =
mm
Dimension "E" = (Dimension "C") - (Dimension "B") =
mm
8. Use a sanding stone and solvent to thoroughly clean the mounting surface of the Rear
Head to ensure all sealant material is removed.
9. As illustrated below, use depth micrometers to measure dimensions "F" and "G".
Measure dimensions "F" and "G" to the nearest 0.01mm and record the values below:
Dimension "F" =
mm
Dimension "G" =
mm
Please note that there are two Lube Tube Cavities designated Cavity for Lube Tube "A"
and Cavity for Lube Tube "B". These two cavities must correspond to the two Lube
Tubes from step #5. Also make sure that dimension "F" corresponds with Lube Tube "A"
(and the same for dimension "G" and Lube Tube "B")
S-126
Repair Manual

Lube Tubes
Appendix E
Rev. 0
Page 4 of 5
10. Do the following calculations and record the value to the nearest 0.01mm:
Dimension "H" = (Dimension "F") - (Dimension "D") =
Dimension "I" = (Dimension "G") - (Dimension "E") =
mm
mm
11. Refer to the illustration below for the following explanation:

Dimension "H" is the clearance between the end of Lube Tube "A" and the Cavity for
Lube Tube "A" in the Rear Head. This clearance must be filled with a Lube Tube Shim
and/or Washer. The thickness of the Lube Tube Shim must be selected such that a
clearance of 0.01mm to 0.15mm remains once the Washer and Lube Tube Shim is
installed. Refer to the example.
Dimension "I" is the clearance between the end of Lube Tube "B" and the Cavity for
Lube Tube "B" in the Rear Head. This clearance must be filled with a Lube Tube Shim
and/or Washer. The thickness of the Lube Tube Shim must be selected such that a
clearance of 0.01mm to 0.15mm remains once the Washer and Lube Tube Shim is
installed. Refer to the example.
Use the Linde Spare Parts Catalog to select the correct Lube Tube Shims
IMPORTANT:
When installing the Lube Tube Shim, be sure to orient it with the Tapered Edge facing
towards the bottom of the cavity or downward as illustrated above.
S-127
Repair Manual

Lube Tubes
Appendix E
Rev. 0
Page 5 of 5
Example: HPR105-02
Dimension D = (18.03mm) (8.15mm) = 9.88mm
Dimension E = (18.03mm) (8.10mm) = 9.93mm
Dimension F = 11.51mm
Dimension G = 11.53mm
Dimension H = (11.51mm) (9.88mm) = 1.63mm
Dimension I = (11.53mm) (9.93mm) = 1.60mm
You must calculate a shim range for each Lube Tube individually:
Lube Tube A:
You must select a shim between 1.48mm and 1.62mm thick for Lube Tube A.
Lube Tube B:
You must select a shim between 1.45mm and 1.59mm thick for Lube Tube B.
S-128
Section 8
Fig. 8-0 Electronic Control Module - Cummins QST30

Electronic Engine - Left Side
1. Electronic Control Module (ECM)
2. Plug-Ins (shown disconnected)
Disconnect from ECM BEFORE welding.
Fig. 8-0a Electronic Control Module - Cummins

QST30
Electronic Engine - Right Side
Electrical Components
CAUTION:
DO NOT weld on any part of the machine without first

disconnecting the negative battery cable or place the battery disconnect switch in the open position. On machines
equipped with electronic engine, disconnect the connections to the Electronic Control Module (ECM) on the engine
before welding.
Fig. 8-0b Cat C27 ECM
SKS Electrical Components
8-1
Jump Starting
Fig. 8-1 Connection of Battery Cables
Jump Starting
8-2
1.
DO NOT smoke or use open flame near batteries.
2.
DO NOT jump start if the battery fluid is frozen or slushy as the battery may explode. The battery
should be warmed to at least 40oF (4.4oC) before attempting a jump start.
3.
Jump start only with an external power source, having an electrical system of the same voltage,
ground polarity and equipped with battery or batteries of comparable size or larger.
4.
DO NOT jump start using motor generator sets, welders or other sources of DC power.
5.
DO NOT jump start 24V electrical systems with two 12V batteries connected in series. The current
drain will be too high on the 12V batteries possibly causing an explosion.
6.
DO NOT permit metal-to-metal contact between the machine and starting vehicle and do not allow
jumper cable terminal clips to contact either vehicle as arcing may result in fire or explosion.
7.
Use only jumper cables that are clean, in good condition, and are heavy enough to handle the starting current.
8.
DO NOT use battery terminal for jump starting. Arcing at battery could result in explosion. Connect
jumper cables as shown in Figure 8-1.
9.
Stand as far away as possible from batteries before actual starting.
Batteries and Circuit Breakers

Batteries
1.
Acid burn, fire and explosion hazards exist when working around drill and vehicle batteries. Sulfuric
acid in batteries will cause severe burns. Batteries emit hydrogen gas, which will burn or explode if
sparks or flame are present.
2.
Always add battery water before starting up, not after shutting down. Keep batteries filled and
charged. A discharged battery will freeze at much higher temperatures than a fully charged battery.
3.
Wear protective clothing, gloves, an acid-resistant apron and a face shield when servicing batteries.
4.
Always loosen vent caps from the weak batteries and cover with a cloth before charging.
5.
DO NOT short across battery terminals. The spark can ignite gases.
6.
Be sure battery fluid is at the proper level.
7.
When charging batteries, always disconnect battery charger from its power source or turn it off
before connecting or disconnecting charger leads to battery terminals.
8.
When removing a battery, disconnect ground (-) terminal FIRST.
9.
When installing a battery, connect ground (-) terminal LAST.
Circuit Breakers
Circuit breakers are located in the operator's cab on the side of the control console (fig. 8-2). They
are disabled by pulling out on the knob and reset by pushing in on the knob. Before working on an electrical
system, disable it at the circuit breaker or remove the positive battery terminal connector. Always place an
"Out of Service" tag on the ignition switch to alert someone that the machine is being worked on.
Fig. 8-2 Cab Instrument Panel

62. 15 AMPCab Lights
63. 15 AMPIgnition 24V
64. 10 AMPWipers
65. 50 AMPMain Power
66. 15 AMPControl Panel
67. 5 AMPHeater & Drill Lights
68. 15 AMPStarter
69. 5 AMP12 Volt Circuit
70. 50 AMPDrill Lights
71. 15 AMPAdditional Lights
72. 15 AMPECM
73. 10 AMPFront Lights
8-3
Welding Precautions

Electronic Engine - Left Side

Electronic Engine - Right Side
Fig. 8-5 Cat C27 ECM
8-4
Welding Precautions
CAUTION:
DO NOT weld on any part of the machine without first

disconnecting the negative battery cable or place the battery disconnect switch in the open position. On machines
equipped with electronic engine, disconnect the connections to the Electronic Control Module (ECM) on the engine
before welding.
Whenever possible, remove component to be welded from machine. If this is not possible or practical,
then follow the steps below to provide minimum risk of damage to electrical components.
1.
Stop engine. Turn the switched power to the OFF position.
2.
Disconnect negative battery cable from battery, or if equipped with a battery disconnect switch,
place switch in OPEN position.
3.
Disconnect the connectors from the ECM. Move the plug-ins so they can not accidently make contact with any of the ECM pins again.
4.
Connect welder ground clamp directly to part being welded. If this is not done, any electronic components or bearings between the ground and the weld could be severely damaged by the current
flow from the welder.
5.
Protect wiring harness and wire rope from weld spatter.
6.
Use standard welding practices to weld materials. All work is to be done by a certified welder.
8-5
Heater & A/C Unit
BLU 14
RED 14
192
M
197
PRESSURIZER
FAN MOTOR
194
159
10
RED 12
REF
OPTIONS
RELAY
RED 14
15
193
MED (RED)
HIGH (ORANGE)
RED 14
REF
CAB JUNCTION
BOX TERMINALS
OFF
LOW (YELLOW)
RESISTOR
RED 14
195
ROTARY
SWITCH
A/C
TOGGLE SHITCH
YLW 14
PWR TO AC CONDENSOR 192
YLW 14
GRN 14
PWR TO BINARY SW.
195
PWR TO AC CLUTCH 196
RED 14
YLW 14
GRN 14
196
THERMOSTAT
REF
ENGINE JUNCTION
BOX TERMINAL
GRN 14
AC CLUTCH 196
A/C HEATER UNIT
196
A/C COMPRESSOR
CLUTCH
GRN 14
196
RED 14
192
85 87
87a
85 87
87a
M
86
30
86
RELAY
30
RELAY
YEL 14
195
LOW
PRESS
HIGH
PRESS
BINARY SWITCH
A/C CONDENSER
LOW PRESSURE PROTECTION
HIGH PRESSURE PROTECTION
OPENS
30-15 PSIG
(FALLING PRESSURE)
270-330 PSIG
(RISING PRESSURE)
CLOSES
40 PSIG MAXIMUM
(RISING PRESSURE)
70-90 PSIG BELOW
(OPENING PRESSURE)
Fig. 8-6 Heater & A/C/Unit (ref. 425136 rev. F)
8-6
CONDENSER #942078
W/ #416970 SHOCK
MOUNT KIT
CONDENSATE
DRAIN HOSE
HEATER-A/C UNIT
A
IR
O
W
#8 90 OR STRAIGHT
FEMALE FITTING #405852
90 #405859 STRAIGHT
#6 90 OR STRAIGHT
FEMALE FITTING #405851
90 #405858 STRAIGHT
5/8" HEATER OUTLET
LOW PRESSURE SWITCH

#404279 ATTACH TO
FITTING #405924
13/32" I.D. DISCHARGE LINE
RECEIVER DRIER
#402720 USE W/
MOUNTING BRACKET
#510563
NOTE: DRYER FOUND INSIDE

CONDENSER BOX.
BACK VIEW
1/2" I.D. SUCTION LINE
CAB WALL
5/8" HEATER INLET
SIDE VIEW
Fig. 8-6a Heater & A/C Unit (ref. 425136 rev. F)
FLOW
5/16" I.D. LIQUID LINE
#6 90 FEMALE
FITTING #405851
5/16" I.D. LIQUID LINE
FL
FRONT VIEW
A/C COMPRESSOR
402828
#10 90 FITTING
WITH 134a ACCESS
PORT #405900
#8 90 FITTING
WITH 134a ACCESS
PORT & SWITCH
PORT #405903
HIGH PRESSURE
SWITCH #404274
ATTACH TO
FITTING #405903
3" FLEX HOSE FROM PRESSURIZER
Heater & A/C Unit
8-7
Filter Indicator Lights Wiring

LOOP
FILTER
#1
LOOP
FILTER
#2
LOOP
FILTER
#3
LOOP
FILTER
#4
LOOP
FILTER
#5
CHARGE
FILTER
#1
CHARGE
FILTER
#2
MAIN
FILTER
#1
MAIN
FILTER
#2
CASE
FILTER
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
2
3
4
5
6
7
8
9
10
11
LOOP #1
LOOP#2
LOOP#3
LOOP#4
LOOP#5
10
CASE
11
COMP
WHITE
BLACK
RED
WHITE-16 GA
GREEN-16 GA
RED
GREEN-16 GA
BLACK-16 GA
WHITE
BLACK
GREEN-16 GA
WHITE-16 GA
RED
WHITE-16 GA
BLACK-16 GA
WHITE
BLACK
BLACK-16 GA
RED
GREEN-16 GA
LOOP#1
LOOP#2
LOOP#3
LOOP#4
LOOP#5
CHARGE#1
CHARGE#2
MAIN #1
MAIN #2
CASE
COMP
MAIN #2
NO
C
CASE
COMP
MAIN #1
NC
LOOP#1
CHARGE#2
NO
C
LOOP#2
LOOP#3
LOOP#4
LOOP#5
CHARGE#1
CHARGE#2
MAIN #1
MAIN #2
CHARGE#1
BLACK
WHITE
2
NO
C
WHITE-16 GA
RED
GREEN-16 GA
BLACK-16 GA
WHITE
BLACK
WHITE-16 GA
RED
GREEN-16 GA
1
1
NO
C
BLACK-16 GA
WHITE
BLACK
WHITE-16 GA
RED
GREEN-16 GA
NO
C
BLACK-16 GA
WHITE
WHITE-16 GA
BLACK
WHITE
BLACK
BLACK-16 GA
NO
C
WHITE-16 GA
RED
GREEN-16 GA
NO
C
BLACK-16 GA
WHITE
BLACK
WHITE-16 GA
RED
GREEN-16 GA
NO
C
BLACK-16 GA
WHITE
BLACK
GREEN-16 GA
WHITE-16 GA
RED
WHITE-16 GA
BLACK-16 GA
WHITE
BLACK
BLACK-16 GA
NO
C
RED
NO
C
GREEN-16 GA
NO
C
COMPRESSOR
FILTER
12
GRY/BLK-16 GA
GRY/GR-16 GA
WHITE-16 GA
WHITE-16 GA
WHITE-16 GA
WHITE-16 GA
WHITE-16 GA
WHITE-16 GA
WHITE-16 GA
WHITE-16 GA
WHITE-16 GA
WHITE-16 GA
WHITE-16 GA
TERMINAL BOX
KEY
LOOP
FILTER
#1
LOOP
FILTER
#2
LOOP
FILTER
#3
LOOP
FILTER
#4
LOOP
FILTER
#5
CHARGE
FILTER
#1
CHARGE
FILTER
#2
MAIN
FILTER
#1
MAIN
FILTER
#2
CASE
FILTER
COMPRESSOR
FILTER
CAB CONSOLE
Fig. 8-7 Filter Indicator Lights Wiring (ref. 400346 rev. G)

8-8
Engine Stop Wiring (optional)
Fig. 8-8 Emergency Kill Switch Wiring - Ground Level (ref. 409395)
8-9
Jack Interlock Option
Fig. 8-9 Jack Interlock Option (ref. 426662)
8-10
Drill Pipe in Hole Interlock Option
Fig. 8-10 Drill Pipe in Hole Interlock Option (ref. 426662)
8-11
Tram Interlock Option
Fig. 8-11 Pipe in Hole & Jack Interlock Combination (ref. 426662)
8-12
Joystick Adjustments (electric)
Fig. 8-12 Electric Joysticks

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

4. Right Track Control (426108)
Fig. 8-13 Right Hand Cab Section Cutaway

Items located under operator control panel, mounted to left cab wall.
8-13

GENERAL DESCRIPTION, ADJUSTMENT PROCEDURES & TROUBLESHOOTING
Printed Circuit Board (P.C. Board) Terminal Board Connections (All terminals may not be present on your P.C. Board)
(+)
Positive voltage 12VDC or 24VDC depending on the controller ordered.
(-)
Negative side of the supply voltage.
(X)
Auxiliary output: Supply voltage is present whenever the controller is turned on. Output
current
should not exceed 3 amps.
(A)
Output terminal to proportional coil when the control handle is moved in the "A" direction.
(B)
Output terminal to proportional coil when the controller handle is moved in the "B" direction.
(C)
Common return when high current P.C. Boards are used. The coil's ground or (-) connection
must be return to the P.C. Board "C" terminal, not to ground.
(R)
Range terminal: See Dual Range Option.
Most P.C. Boards have LEDs (Light Emitting Diodes) which can be used for troubleshooting, or simply as an indication of output at a specific terminal. LEDs are located near the (A) and (B) terminals.
Standard Coil Connections:
Dual Coil: Two coils or solenoids, with each coil having at least 2 connections. One is connected
to the P.C. Board (A) terminal, the other is connected to the negative (-) side of the supply voltage.
The other coil is connected to the (B) terminal and the negative (-) side of the supply voltage. Two or
more P.C. Boards can be paralleled to operate the same coil.
Fig. 8-14 Adjustment Detail and Dual Coil Connections
Adjustment Procedures:
Adjustments are made by turning a trimpot adjustment screw. It may be necessary to turn the adjustment screw several turns (5 or more) to observe a change in output.
Clockwise (CW) adjustment of the trimpot increases the output.
Counterclockwise (CCW) adjustment of the trimpot decreases the output.
Adjustment affects output current and voltage to the coil. The minimum and maximum output current is preset at the factory. However, for optimum performance, they must be adjusted while the
equipment is operating.
8-14

Although the following adjustments affect the current/voltage or percentage of duty cycle, the best
way to adjust the function is to observe the response or speed of the function. The following adjustments affect function response, or speed. There may be some interaction between adjustments. It
may be necessary to repeat the adjustment in order to achieve the desired response.
Threshold Adjustment: Adjusts the initial current flow, function response, or speed when the handle is
first moved from the off position. Deflect the handle slowly to the position where the controller first
turns on. Adjust the threshold trimpot screw for start-up or creep speed. If the speed is too fast,
turn the trimpot screw CCW; if the speed is too slow, turn the trimpot screw CW. This adjustment
should be done first.
Maxout Adjustment: Adjusts the full stroke current, maximum function response, or speed when the
handle is deflected to its full travel. Fully deflect the handle, and adjust the maxout trimpot for maximum desired function response or speed. To obtain proportional resolution, it is important that the
function starts to slow down as soon as the handle is moved back from the fully deflected position.
The ideal adjustment occurs when the function just begins to move when the handle is deflected,
and the output increases until it reaches its maximum desired response or speed at the end of
handle travel.
Integrated Ramp System (IRS): Allows the input signal to come on and go off in a controlled manner. CW rotation of the trimpot increases ramp time and slows the response time. CCW rotation
decreases ramp time and increases the response time. To increase ramp time, turn the adjusting
screw CW a few turns, then move the controller handle abruptly. Continue to adjust until a smooth
response is observed. Most controllers have on/off contacts which remove power from the PC
board when the handle is returned to the "off" position. When the handle is abruptly returned to
neutral, the output will not ramp down, and the function will stop.
Ramp Thru Off: The P.C. board should be adjusted as outlined in the IRS adjustment procedure. If the
handle is abruptly returned to neutral (OFF), the output will ramp down to off.
Dual Range: When supply voltage is applied to the (R) terminal, the board is in "Hi Range". When voltage is not applied to the (R) terminal, the board is in "Lo Range".
Hi Range Adjustment: With supply voltage applied to the (R) terminal, fully deflect the handle. Adjust
the "Hi Range" trimpot for desired "Hi Range" response or speed. Refer to "Maxout" adjustment procedures. Whenever the dual range switch or contact is closed, the output should be
adjusted for the maximum function response or speed.
Lo Range Adjustment: With no voltage on the (R) terminal, fully deflect the handle. Adjust the "Lo
Range" trimpot for the desired "Lo Range" response or speed. Again refer to "Maxout" adjustment procedures. Whenever the dual range switch or contact is open, you are in "Lo Range".
8-15

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

A.
3.
The functions reaches maximum speed before the handle is fully deflected.
A.
4.
Perform "Threshold" adjustment procedures.

Perform "Maxout" adjustment procedures.
The function speed remains constant regardless of the degree of handle deflection.
A.
Perform "Maxout" adjustment procedures.
IRS Option:
1.
Function speed reacts too slowly or too quickly in relation to handle deflection.
A.
Check "IRS" (Ramp) trimpot adjustment. CW increases ramp time, CCW

decreases ramp time.
Dual Range Option:

1.
8-16
Controller will not switch between "HI" and "LO" range.

A.
Check to see that source voltage is present at the "R" terminal when in "HI" range,
and absent when in "LO" range.
B.
Check trimpot adjustments.
Electrical Schematic
109
NOTE: See Parts Manual to establish the

correct drawings for your machine.
YLW 16
TACH SIGNAL
53
B+
RED 4
ALT
BLU 16
TS1
OFF
207
STOP
DIA
A/C SYSTEM BUSS
GRN 16
ENG
PROTECTION
TAN/BRN 16
203
109
ORG/GRY 16
ISC ON/OFF
DIAGNOSTIC
13
ENG PROTECTION
14
DIAGNOSTIC
OFF/ON
15
60A
442042
60A
442042
TS
29
ISC 1 (1800 RPM)
23
ISC 2 (2100 RPM)
24
ECM HARNESS
50 PIN CONNECTOR
ENGINE RIGHT BANK
TAN/ORG 16
16
ISC 1(1800 RPM)
ISC 2(2100 RPM)

CUMMINS
21 PIN CONNECTOR
BLK 12
-V BATTERY
20A
ENGINE
ECM FUSE
102
ECM HARNESS
31 PIN CONNECTOR
20
CUMMINS
ENGINE CONTROL
MODULE CONNECTIONS
ENGINE
ECM FUSE
102
12
ISC ON/OFF
ORG/BLU 16
OPTIONAL
REMOTE
START
CIRCUIT
BREAKER
BRN/RED 16
21
TS
(LOCATED IN ENGINE
SKID JUNCTION BOX)
STOP
GRY/ORG 16
ON
SEE SHEET 6
RED 6
MAIN BUSS
CIRCUIT BREAKER
ALTERNATOR
CUMMINS
31 PIN CONNECTOR
BRN/YLW 16
(LOCATED IN ENGINE
SKID JUNCTION BOX)
60A
442042
104
BLK 4
421321
DIAGNOSTIC
OPTIONAL SIGMA
A/C SYSTEM BUSS
CIRCUIT BREAKER
B-
CUMMINS ALTERNATOR
TACHOMETER SIGNAL (SEE SHEET 3)
RED 12
-V BATTERY
+V BATTERY
+V BATTERY
KEY SWITCH
ECM HARNESS
21 PIN CONNECTOR
20A
INTERSTAGE TEMP
HIGH PRESSURE
COMPRESSOR ONLY
7
REMOTE START
KEY SWITCH
OFF
REMOTE
STOP PB
ON
BLU 16
265 F
NC
NC
65237 240 F
LOW PRESSURE
NC COMP
83327
NC 7
PB
NC
N0
PB
NC
BLU 16
402278
16864
HIGH PRESSURE COMP

V000898
250 F
N0
207
OPTIONAL
REMOTE ENGINE
STOP SWITHCES
N0
402278
402278
BLU 16
COMPRESSOR OVER
TEMPERATURE SWITCH
BLK 16
1156000
VOLTMETER
L
1155171
7 RED/BLU 16
REMOTE
START
REMOTE START SOLENOID

CIRCUIT BREAKER
PB
15A
57913
42259
OPTIONAL CUMMINS QST30 ENGINE ARRANGEMENT

52
9
100 GRY 16
DUST COLLECTOR TIMER
OPTIONAL ADDITIONAL BATTERIES

143
BATTERY
DISCONNECT
SWITCH
12 VDC
50A
ON
KS1
RED 10
16
191
BLK 16
IGNITION CONTACTOR
CIRCUIT BREAKER
GRY/PNK 16
57
15A
IGNITION SOLENOID
CONTACTOR
S3
57 GRY/PNK 16
105
RED 000
START
S3
ENGINE OIL PRESSURE
OPTIONAL
SIGMA A/C SOLENOID
CONTACTOR
S4
TAN/WHT 16
425881
41758
PB1
NO
PRELUB
PUMP
17
OPTIONAL
DUST COLLECTOR
TIMER
47840
16864
RED 10
BLK 000
107
MAIN POWER
CIRCUIT BREAKER
16
58
12 VDC
RED 000
OFF
WHT/GRN 16
57912
STANDARD-2) 8D 12V BATTERIES
108
KEY SWITCH
142
RED 000
ENGINE HOUR
METER (CONSOLE)
HRM
96198
168437
12 VDC
141
WHT/GRN 16
N0

12 VDC
ENGINE HOUR
METER (ENGINE)
HRM
PS1
GRN/BLK 16
15A
57913
WHT/BLU 16
LOCATED AT ENGINE
96198

CIRCUIT BREAKER
OPTIONAL
BATTERY JUMP START
190
OPTIONAL
REMOTE ENGINE
START SWITHCES
47840
STARTER SOLENOID
CIRCUIT BREAKER
200
42259
BLK
PS
15A
PRELUB
PRELUB
PRESSURE SWITCH
NC
A447 PNK
4 PSI
PRELUBE FUSE
(LOCATED IN PRELUB HARNESS)
101
PRE
NO
RED 6
RED 000
301
PUR 6
S2T
NO
105
BLK 000
S1T
NO
110
BLK 000
TOP STARTER
SOLENOID
CUMMINS
BLU 16
WHT
S2T
TOP STARTER
MOTOR WITH PRELUBE PUMP
337
50A
108
1
2
109
108
S2B
NO
RED 000
105
BLK 000
RED 6
NO
S2B
P/N : XXX
135A
413223
S6
110
BLK 000
AC/DC INVERTER
PURE SIN WAVE
110VAC
WHT 14
BOTTOM STARTER
SOLENOID
307
426393
LOCATED WITH INVERTER
430956
GRN 16
WHT 16
BLK 16
WHT/BLK 16 3 SEC
TIME DELAY
GRN 16
PRE
OPTIONAL
PRELUB
SOLENOID, 3 SEC TIME DELAY
AFTER PRESSURIZING ENGINE OIL
SYSTEM TO START
ORG
17
BLU 12
S1T
PRELUB
STARTER SOLENOID
S1B
BOTTOM
STARTER SOLENOID
PRELUBE HARNESS CONNECTOR
MICROWAVE OVEN
600W
YEL 16
PRELUB TIMER
SWITCH/SOLENOID
RED 14
NO
ORG
(DUAL STARTERS STANDARD WITH CUMMINS QST30)
S1B
INVERTER CIRCUIT
BREAKER
LOCATED IN INVERTER BOX
307
BOTTOM STARTER
MOTOR
1
2
OPTIONAL MICROWAVE OVEN
426453
15
INDICATES WIRE COLOR WITH (NUMBER) - PNK (#2) 18
58
79
NOTE: DO NOT USE P/N'S TO ORDER REPLACEMENT PARTS
Ref. 437150 rev. A (1 of 6)
109
8-17
OPTIONAL
BATTERY JUMP START
STANDARD CATERPILLAR ENGINE ARRANGEMENT
15
58
79
12 GRN/BLK 16
12 VDC
426393
142
RED 000
141
108
186
BATTERY
DISCONNECT
SWITCH
12 VDC
RED 000
PB2
186
143
STANDARD-2) 8D 12V BATTERIES

12 VDC
105
12 GRN/BLK 16
10
GRN/WHT 16
425881
96192
168437
PS3
S2T
RED 000
DRILL HOUR
METTER
HRM
N0
41758
OPTIONAL
ATTENTION HORN
HRN
96908
PS2
BLK 000
107
RED 16
42259
RED 000
108
MICROWAVE SOLENOID
CONTACTOR
S6
12 VDC
105
BLK 000
12 GRN/BLK 16
TOP STARTER
MOTOR
13
GRN/RED 16
FRONT
TRAM ALARM
N0
32817
69499
S1T
110
S2T
BLK 000
TOP STARTER
SOLENOID
TS1
109
RED 000
108
105
BLK 000
DRILL
74
WHT/BLK
16 (SXL)
GRY 16
72
S2B
10
RED 6
110
S2B
BLK 000
BOTTOM STARTER
MOTOR
ROTATION
JOYSTICK RELAY
37
WHT/BLK
16 (SXL)
DCV
BOTTOM STARTER
SOLENOID
DRILL/PROPELL
DIVERTER VALVE
ENGERGIZE TO DRILL
DE-ENERGIZED TO PROPEL
PARKING BRAKE
RELEASE VALVE
ENGERGIZE TO RELEASE BRAKE

DE-ENERGIZED TO DRILL
410280
WHT/BLK 16
DCV
RED 14
S6
AC/DC INVERTER
PURE SIN WAVE
135A
413223
PROPEL
340997
224
INVERTER CIRCUIT
BREAKER
LOCATED IN INVERTER BOX
R2
340440
OPTIONAL DUAL STARTERS

S1B
REAR
TRAM ALARM
32817
MICROWAVE OVEN
110VAC
75
430956
53
OPTIONAL MICROWAVE OVEN
600W
WHT 14
426393
LOCATED WITH INVERTER
433410
WHT (#0) 18
10
426453
B+
RED 4
R3
ROTATION/CAB SIDE PROPEL

JOYSTICK RELAY
340440
B-
ALT
104
BLK 4
75
ALTERNATOR
ORG/GRN 16
10
R5
FEED/DUST COLLECTOR SIDE PROPEL

JOYSTICK RELAY
340440
CATERPILLAR
WIRING HARNESS
RED 14
55
+BAT (UNSWITCHED)
RED 14
+BAT (UNSWITCHED)
207
REMOTE SHUTDOWN SW
7
RED 6
203
GRN 16
71
+BAT (SWITCHED)
DIAGNOSTIC LAMP
THROTTLE POSITION SENSOR

RED 14
+BAT (UNSWITCHED)
54
31
31
27
27
26
26
24
24
10
10
BLK 16
J2/P2
R1
32
CATERPILLAR
ECM
204
16
RED 10
PRP 16
100
THROTTLE POSITION
SENSOR
BLK 16
250 F
BLU 16
265 F
OFF
NC
PB
PB
NC
BLU 16
N0
REMOTE START
KEY SWITCH
NC
65237 240 F
LOW PRESSURE
COMP
83327
NC
N0
402278
207
ON
52
15A
BLK 16
9 WHT/GRN 16
96192
206
GRN 12
BLU 16
KEY SWITCH
OFF
RED 10
ON
8 WHT/GRN 16
57
GRY/PNK 16
58
RED 10
START
PB1
BRN
NO
BLK
42259
CS NDE JACK UP
PROX SWITCH
BLU
7
6
WHT (#7) 18
418673
136
PPL/YLW 16
+
BRN
BLK
CS DE JACK UP
PROX SWITCH
BLU
136
15
58
79
73
59
S3
191
BLK 16
OPTIONAL
DUST COLLECTOR
TIMER
IGNITION SOLENOID
CONTACTOR
INDICATES WIRE COLOR WITH (NUMBER) WIRE GAGE - PNK (#2) 18
RED 16
S4
SIGMA A/C SOLENOID

CONTACTOR
NOTE: DO NOT USE P/N'S TO ORDER REPLACEMENT PARTS

ORDER REPLACEMENT PARTS FROM MACHINE PARTS BOOK
47840
ABREVIATION DEFINITIONS: DCS - DUST COLLECTOR SIDE

CS - CAB SIDE
DE - DRILLING END
NDE - NON-DRILLING END
STARTER SOLENOID
CIRCUIT BREAKER
15A
GRN/BLK 16
8-18
R1
NC
8 77
TAN/YLW 16
47840
16864
S3
IGNITION CONTACTOR
CIRCUIT BREAKER
15A
DCS NDE JACK UP

PROX SWITCH
136
17
BLU 12
S1T
TOP OR SINGLE
STARTER SOLENOID
47840
S1B
47840
58
11
ENGINE HOUR
METER (CONSOLE)
HRM
N0
58
R2
73
OPTIONAL
REMOTE ENGINE
START SWITHCES
(LOCATED AT ENGINE
JUNCTION BOX)
PS1
GRN/BLK 16
16
BLK
TAN/GRN 16
96192
57
15
BRN
BLU
418673
100
50A
57912
PROPEL INTERLOCKS
+
ENGINE HOUR
METER (ENGINE)
HRM
42259
KS1
OPTIONAL
VOLTMETER
EITHER INJECTION
SOLENOID VALVE
(MAY ALSO BE
LOCATED IN CAB)
ETH
190 WHT/BLU 16
MAIN POWER
CIRCUIT BREAKER
DCS DE JACK UP
PROX SWITCH
136
PPL/WHT 16
PB
168437
136
PPL/GRN 16
PROPEL INTERLOCK
PIPE IN THE HOLE
LIGHT (LIGHT ON INDICATES
JACKS UP)
REMOTE
START
57913
16
COMPRESSOR OVER
TEMPERATURE SWITCH
319151
GRN/BRN 16
205 GRN 12
53
BLK
418673
PB

CIRCUIT BREAKER
BRN
42259
15A
GRN
416874
BLU
BLU 16
57913
GRY (#7) 18 134
418673
319240
REMOTE START SOLENOID

CIRCUIT BREAKER
PROPEL INTERLOCK
PIPE IN THE HOLE
PROXIMITY SWITCH
BLK 16
+
133
PROPEL INTERLOCK
RELAY
402278
EITHER
INJECTION
16864
BLK 16
OPTIONAL
REMOTE ENGINE
STOP SWITHCES
N0
402278
R1
340440
HIGH PRESSURE COMP

V000898
NC
REMOTE
STOP PB
10
RED/GRN 16
135
TAN/RED 16
INTERSTAGE TEMP
HIGH PRESSURE COMPRESSOR ONLY
139
NO 4
410482
SIGNAL
DIAGNOSTIC LAMP
7
GRY (#0) 18
60A
60A
CAT SUPPLIED TERMINATION RESISTOR
LOAD
NC 2
-3
71
RED
1 +
CATERPILLAR ENGINE
ENGINE CONTROL MODULE
ELECTRONICS GROUND STUD
BLU 16
PROPEL INTERLOCK
PIPE IN THE HOLE
LIGHT (LIGHT ON INDICATES
PIPE PRESENT)
416873
CAT SUPPLIED ENGINE SERVICE TOOL CONNNECTION
14
GRY (#9) 18
NC
J1/P1
GRN/BLK 16
109
MAIN BUSS
CIRCUIT BREAKER
(LOCATED IN ENGINE
SKID JUNCTION BOX)
OPTIONAL
REMOTE
START
CIRCUIT
BREAKER
32
WHT (#6) 18
56
15A
73
102
P61/J61
140 RED/BLK 16
ENGINE ECM
CIRCUIT BREAKER
BOTTOM
STARTER SOLENOID
Ref. 437150 rev. A (2 of 6)
79
15
58
79
59
73
15
NC
NO
58
47
79
59
NO
NC
WHT 16
ENGINE COOLANT
TEMP SENDER
SPRING RETURN HANDLE

LOCKING CENTER POSITION
C
59
GRY 16
WHT (#6) 18
440314
R5
BLU (#8) 18
87
60
59
DCV
11
78
R5
DC SIDE MAIN PUMP
DCV
59
96193
GRY 16
V014499
59
60
GRY 16
60
GRY 16
FUEL TANK
LEVEL SENDER
BLK 16
84609
ON
98 PPL 16 (SXL) +
OFF
CARD
BLK
CONTROL
AUTO FEED
16
BLK/ORG 16
BLK 16
BLK 16
ENGINE OIL
PRESSURE SENDER
319152
59
L
319151
GRY 16
RED 16
YLW 16
VOLTMETER
MAG PICKUP
LOCATED IN FLYWHEEL HOUSING
I
60
426233
ENGINE OIL
PRESSURE GAUGE
AUTO FEED CONTROL
FUEL TANK
LEVEL GAUGE
319145
GRY 16
ENGINE COOLANT
TEMP GAUGE
GRY 16
DC SIDE MAIN PUMP
NC
65226
BRN 16
319240
TS
319240
NC
11
R5
95 PNK (#2) 18
R5
PNK (#6) 18
96
NO
319147
GRY 16
60
88 BLU (#4) 18
319153
GRY 16
A
NO
BLK 16
319240
DC SIDE PROPEL
JOYSTICK
GRY 16
TACHOMETER
STANDARD CATERPILLAR ENGINE
413271
L
96194
97 PPL 16 (SXL)
HOIST CONTROL VALVE
PNK (#5) 18
JOYSTICK
FEED-HOIST/PULLDOWN
15
DRILL LIGHT
MAIN POWER
CIRCUIT BREAKER
50A
57912
RED 16
TACHOMETER
OPTIONAL CUMMINS ENGINE
TACH SIGNAL FROM ALTERNATOR
YLW 16
(SEE SHT 1)
96194
CAB ROOF
LIGHT, RIGHT REAR
CAB ROOF LIGHT

CIRCUIT BREAKER
S5
GRN 10
64
GRY 16
TACH SIGNAL
PULLDOWN CONTROL VALVE
GRN 10
99 PNK (#0) 18
59
33
BLU/GRY 16
33
15A
57913
75321

NO
NC
NC
440314
153
75321
OPTIONAL PIPE RACK SWING

INTERLOCK OVERRIDE SWITCH
R4
6
OFF
75321
155 ORG (#7) 18
R4
89 GRY (#6) 18
TS
NO
ON
407791
PIPE RACK SWING

INTERLOCK RELAY
R4 LOCATED ON SHT 4
NC
154 ORG (#5) 18
NC
DRILL LIGHT
FRONT
69681
75321

C
CAB SIDE PROPEL

JOYSTICK
440314
R3
86 YLW (#3) 18
R3
73
GRY (#6) 18
CAB SIDE MAIN PUMP

75321
NO
NC
11
R3
85 GRN (#4) 18
DCV
82
NC
DCV
CAB SIDE MAIN PUMP
11
NO
76
BLU (#4) 18
GRN 10
15A
57913
V014499
161
GRY 14
75321
ROTATE
JOYSTICK
75321
FRICTION HOLD HANDLE

NO
NC
NC
79
75321
319240
GRN/YLW16
BLK 16
COMPRESSOR
TEMP SENDER
319153
L
319146
DRILL LIGHT
CIRCUIT BREAKER
80
15
58
79
47
59
GRN/GRY 16
69
5A

CS - CAB SIDE
DE - DRILLING END
DRILL LIGHT
REAR DECK
DRILL LIGHT
MAST
66
GRN/GRY 16
S6
LIGHT SOLENOID
CONTACTOR
47840
65226
OFF
ON
66
GRN/GRY 16
S5
47840
65226
OFF
ON
68
LIGHT SOLENOID
CONTACTOR
CAB DOME
LIGHT
GRN/GRY 16
67
88194
65226
58
DRILL LIGHT
REAR DECK
75321
ON
COMPRESSOR
TEMP GAUGE
GRN/GRY 16
GRN/GRY 16
15A
57913
GRN/GRY 16
GRY 16
CONTROL PANEL
CIRCUIT BREAKER
GRY 16
DRILL LIGHT
FRONT DECK
NO
440315
59
OPTIONAL
DRILL LIGHT
FRONT
DRILL LIGHT
FRONT DECK
DRILL LIGHT
CIRCUIT BREAKER
S6
75321
R2
DRILL LIGHT
FRONT
5 ADDITIONAL DRILL LIGHTS
R3
GRN (#8) 18
81 BRN (#8) 18
11
3
84
NO
81
GRY (#0) 18
75321
82 BRN (#4) 18
YLW (#9) 18
83
CAB ROOF
LIGHT, LEFT FRONT
GRN/GRY 16
18
10A
NO
NC
CAB ROOF
LIGHT, RIGHT FRONT
75321
DRILL LIGHT
CIRCUIT BREAKER
NO
CAB ROOF
LIGHT, LEFT REAR
NO
79
47
OFF
Ref. 437150 rev. A (3 of 6)

8-19
58
79
58
47
YEL/GRN 16
TS
47
ENGAGE
A
DCV
31
GRY 16
79
47
AUTO TOOL WRENCH

ENGAGE
TS
47
YEL/ORG 16
DISENGAGE
DCV
WHT/RED 16
35
WHT/YLW 16
AUTO TOOL WRENCH

DISENGAGE
DOWN
66425
BLU/WHT 16
TS
GRY 16
OUT
A
DCV
41
DUST CURTAIN
UP
DCV
DUST CURTAIN
DOWN
410088
410093
47
DCV
GRY 16
32
66425
36
UP
HOBO SWING
OUT
DUST COLLECTOR
TS
47
23
PNK/BRN 16
24
BRN/WHT 16
A
DCV
DUST COLLECTOR
DCV
WATER INJECTION
GRY 16
42
66425
BLU/PNK 16
IN
DCV
HOBO SWING
IN
WATER INJECTION
66424
410093
ORG/BLK 16
TS
47
RELEASE
39
410089
DCV
HOBO CLAMP
RELEASE
DCV
HOBO CLAMP
CLAMP
GRY 16
40
66425
WHT
ORG/WHT 16
CLAMP
RED
ON
47
150
+ OIL INJECTION
TIMER
WHT/BRN 16
GRY 16
410093
TS
47
UP
GRY 16
A
DCV
171
57641
WINCH
UP
BLK 16
66425
YEL/GRN 16
DOWN
DCV
BIT OIL INJECTION

PANEL LIGHT
WINCH
DOWN
151
PNK/BLU 16
410093
GRY/WHT 16
TS
LOCK
ON
TS
A
DCV
20
57797
MAST LOCK
LOCK
47
OFF
RED/WHT 16
UNLOCK
DCV
MAST LOCK
UNLOCK
YLW/BRN 16
TS
V004434
LOCK
A
DCV
29
TAN/WHT 16
STANDARD PIPE POSITIONER

PIPE POSITIONER
EXTEND (ENGAGES PIPE)
TS
47
GRY 16
AUTOMATIC PIPE POSITIONER CONTROL

WITH MANUAL OVERRIDE
AUTO
GRY 16
YLW/RED 16
UNLOCK
DCV
410093
BLK/YEL 16
TS
LOCK
GRY 16
A
DCV
43
66425
PIPE POSITIONER
RETRACT
GRY/RED 16
PNK/BLK 16
OUT
R6 AND R7 LOCATED IN
ELECTRICAL BOX MOUNTED
IN MAST
157
PIPE RACK LOCK

LOCK
GRN/BLK 16
DCV
A
DCV
25
BRN
157
PIPE RACK LOCK

UNLOCK
BLK
DCV
51
YLW/WHT 16
DCV
27
PIPE RACK SWING

IN
30
87a
30
R7
YLW/BLK 16
CCW
DCV
22
BLU/YEL 16
216
8-20
79
47
214 YLW/BRN 16
404002
BLU 16
215 YLW/RED 16
404002
DCV
21
DCV
PIPE POSITIONER
RETRACT
DCV
PIPE POSITIONER
ENGAGE PIPE
PIPE POSITIONER
ENGAGE INDICATOR LIGHT
RED
416873
PIPE RACK POSITION LIMIT SWITCH

SHOWN IN "PIPE RACK IN" POSITION
NC 2
1
GRN/BLK 16
MAIN AIR VALVE

OPEN
NO 3
156 ORG/GRN 16
10
R4
BLK 16
2
PIPE RACK SWING

INTERLOCK RELAY
SEE SHT 2 FOR R4 CONTACT SET
340440
CLOSE
87a
LIMIT SWITCH SENSES PIPE RACK POSITION AND

PREVENTS ROTARY HEAD FROM CONTACTING CAROUSEL
SHOULD CAROUSEL BE UNDER THE ROTARYHEAD,
UNLESS OVERRIDE SWITCH IS USED
157
OPEN
GRY/BLU 16
B
58
87
404002
NC
PIPE RACK SWING INTERLOCK SYSTEM
PIPE RACK INDEX

CCW
GRY 16
66425
PIPE POSITIONER OVERRIDE

RETRACT
PIPE RACK INDEX

CW
410093
47
BLK 16
OPTIONAL
TS
87
R6
NC
28
66425
403689
NO
30
NO
CW
BLK 16
R6
PIPE RACK SWING

OUT
30
51
418673
410093
TS
86
BLU
R7
BLK/PNK 16
IN
GRY 16
R6
85
26
66425
PIPE POSITIONER OVERRIDE

RETRACT TOGGLE SWITCH
(LOCATED ON OPERATOR CONSOLE)
403689
410093
TS
BLK 16
86
UNLOCK
GRY 16
51
R7
85
RETRACT
SEE OPTIONAL AUTOMATIC

PIPE POSITIONER BELOW
44
66425
TAN/PNK 16
30
30
66425
47
THREAD LUBE
407791
410093
47
SV
GRY 16
66425
47
TAN 16
152
GRY 16
19
47
OIL INJECTION PUMP
55672
170
47
OIL INJECTION TIMER
RED
65226 OFF
YEL/BLU 16
OIL INJECTION
TIMER ACTIVE LIGHT
BLK
DCV
410088
MAIN AIR VALLVE

CLOSE

CS - CAB SIDE
DE - DRILLING END
81187
58
79
157
Ref. 437150 rev. A (4 of 6)

58
79
58
157
172
173
WIPER
CIRCUIT BREAKER
116
10A
GRY 16
172
GRY 16
69681
HI
118
PPL/BLU 16
120
PPL/YLW 16
119
PPL/WHT 16
N0
178
416873
400017
CHARGE
FILTER #2
PS
P
L
H
DECK WIPER MOTOR
172
GRN/GRY 16
342364
WHT 16
NC
N0
179
416873
400017
127
YLW/BLK 16
W
328990
DECK WASHER PUMP
LOOP
FILTER #1
PS
172
330310
WHT 16
NC
GRN/GRY 16
N0
174
416873
400017
OFF LO
124
P
B
WHT 16
NC
GRN/GRY 16
OFF LO
HI
CHARGE
FILTER #1
PS
117
BLU/WHT 16
126
BLU/YLW 16
125
BLU/PNK 16
L
H
129
YLW/RED 16
172
FRONT WIPER MOTOR
WHT 16
NC
GRN/GRY 16
N0
175
342364
416873
400017
LOOP
FILTER #3
PS
FRONT WASHER PUMP

172
328990
LOOP
FILTER #2
PS
330310
WHT 16
NC
GRN/GRY 16
N0
176
416873
400017
HI
OFF LO
121
172
P
B
117
123
PNK/BLK 16
122
PNK/YLW 16
128
YLW/GRN 16
GRY 16
W
328990
LOOP
FILTER #4
PS
PNK/BLU 16
GRN/GRY 16
REAR WIPER MOTOR
WHT 16
NC
N0
416873
400017
342364
177
184
REAR WASHER PUMP
330310
183
OPTIONAL ROTARYHEAD
TACHOMETER
RED/GRY 16
185
GRY 16
OPTIONAL
TAN/BLU 16
417219
BLK 16
414898
LEVELING JACK UP
INDICATOR LIGHTS
+
165
BRN
GRN/BLK
16
BLK
BLK 16
81187
DCS NDE JACK UP

PROX SWITCH
BLU
4
418673
166
PPL/GRN 16
DCS NDE JACK UP

INDICATOR LIGHT
BLK
BLK 16
418673
RED 16
168
PPL/WHT 16
DCS DE JACK UP
INDICATOR LIGHT
GRN
418677
+
BRN
BLK
BLK 16
NOT PRESENT
WHEN PROPEL
INTERLOCK OPTION
IS SELECTED
187
GRN/BLK 16
DCS PINNED
CS NDE JACK UP
PROX SWITCH
BLU
418673
6
81187
167
PPL/YLW 16
81187
CS NDE JACK UP
INDICATOR LIGHT
BLK
BLK 16
BLU
418673
CS UNPINNED
5
CS DE JACK UP
PROX SWITCH
OPTIONAL
MAST UNLOCKED
INDICATOR LIGHT
GRN
418677
+
BRN
RED 16
2
189
DCS DE JACK UP
PROX SWITCH
BLU
189
GRN
418677
+
BRN
TAN/RED 16
DCS UNPINNED
GRN/BLU 16
189
RED
416873
169
TAN/YLW 16
CS DE JACK UP
INDICATOR LIGHT
OPTIONAL
MAST LOCKED
INDICATOR LIGHT
GRN
418677
188
GRN 16
ORG/YLW 16
188
5
TEST SWITCH
OPTIONAL
GRN/BLK 16
173
81187
FILTER
BYPASS INDICATOR LIGHTS
65226
GRY/BLK 16
GRN
416874
CS PINNED
172
211
RED 16
RED
ORG
COMPRESSOR
FILTER
PS
172
WHT 16
NC
GRN/GRY 16
N0
212
ORG 16
GRN/GRY 16
ENTERTAINMENT RADIO/CD
CASE
FILTER
WHT 16
N0
+
163
181
ORG 14
416873
MAIN
FILTER #1
PS
WHT 16
NC
GRN/GRY 16
N0
C
400015
58
172
173
198

CS - CAB SIDE
180
416873
162
+
2
58
OPTIONAL
ENTERTAINMENT
RADIO/CD PLAYER
418693
201
RED 18
5A
ORG 18
YLW
RED 16
1
ORG
MEMORY
MODULE
+24VDC SM2412-M
BLK
421289
162
DE - DRILLING END
5A
172
24/12VDC
CONVERTER
+12VDC
418334
400016
172
OPTIONAL
DEI POWER
CONDITIONER
416873
PS
NC
GRN
182
400017
172
BLK
DEI PWR COND
RED 16
CB
RADIO
BLK 16
OPTIONAL
CB
RADIO
401337
Ref. 437150 rev. A (5 of 6)

8-21
172
OPTIONAL
24V
2 3 4 5 6 7 8 9 10 11 12 13 14
N0
LUBE SYSTEM
CHARGED PRESSURE SWITCH
146 ORG 16
PS
145 ORG 16
MUST CUT
24 VDC
JUMPER
AUTOMATIC
LUBE SYSTEM
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
OPTIONAL
LINCOLN LUBRICATION
TIMER BOX
GRN/BLK 16
144
YLW 16
147
148
PNEUMATIC SOLENOID VALVE
SV
YLW 16
GRN/BLK 16
144
CAB HEATER RHEOSTAT

5A
164 RED/YLW 16
38595
45838
196
159 RED 12
10A
69681
192
OPTIONAL
CAB
HEATER FAN MOTOR
GRY/YLW 16
ORG 16
AIR CONDITIONING
COMPRESSOR CLUTCH
CC
RED 14
AIR CONDITIONING
CONDENSER UNIT
85 87
87a
85 87
87a
M
86
30
86
RELAY
RELAY
LOW
PRESS
RED 14
30
HIGH
PRESS
OPTIONAL
AIR PRO A/C
BINARY SWITCH
A/C CONDENSER UNIT

408321
195
193
BLK/WHT 16
197
BRN 14
PRESSURIZER
FAN MOTOR
M
PRESSURIZER
FAN MOTOR
HIGH (ORANGE)
LOW (YELLOW)
AIR CONDITIONING
HEATER UNIT
OFF
MED (RED)
RESISTOR
A/C
THERMOSTAT
TOGGLE SHITCH
ROTARY
SWITCH
15A
57913
194
A/C HEATER UNIT

425127
RED 14
OPTIONAL
SIGMA A/C
A/C SYSTEM BREAKER
CIRCUIT BREAKER
A/C SYSTEM BUSS
50A
S4
WHT 10
(LOCATED IN CAB)
NO
AIR CONDITIONER
CIRCUIT BREAKER
30A
(LOCATED IN SIGMA UNIT)
AIR CONDITIONER
AIR CONDITIONER
CLUTCH
CIRCUIT BREAKER
SIGMA
LP
14
N0
ORG 16
15A
REFERGERATOR
CIRCUIT BREAKER
15A
RED 12
REFRIGERATOR
24VDC
430986
8-22
CC
A/C COMPRESSOR CLUTCH
(LOCATED IN SIGMA UNIT)
OPTIONAL
REFRIGERATOR

CS - CAB SIDE
Ref. 437150 rev. A (6 of 6)
DE - DRILLING END
Wiring DiagramSKS
VIOLET 16
99
RED 14
319153
COMPRESSOR TEMP
FUEL
96193
OIL
31945
VOLT
319151
TACH
96194
33
52
45
31
91
46
33
52
45
COMP TEMP WATER TEMP

319146
319147
LIGHT
335245
TYP
6 PLACES
47
5
1
47
47
5
6
RUN
47
47
6
47
319240
4 PLACES
47
OIL PRESSURE
SIGNAL
+
-
GREEN/YELLOW 16
WHITE 16
BROWN 16
TACH
TACH
RUN KEY

47
DIAGNOSTIC LAMP
ENGINE HOUR
7
8
ENG
BOX
COMP
TEMP
CATERPILLAR
ENG
BOX
ENG
BOX
BLACK/ORANGE 16
3
4
ENG
BOX
BLUE 16
319152
OIL
PRESS
TACH
SENDER
ENG
BOX
RED 16
J2/P2
P3/J3
ENG
BOX
ENG
BOX
WHITE/GREEN 16
ENG
BOX
GREEN 16
32189
ENGINE
HOUR
VIOLET 16
99
319153
WATER
TEMP
FUEL
ENG
BOX
YELLOW 16
WIRING HARNESS
SEE DETAIL C -SHT 2

SEE DETAIL D -SHT 2
47
FUEL LEVEL
START
GRAY 16
WATER TEMP
CATERPILLAR
3412E ECM
10
10
24
24
26
26
27
27
J1/P1
COMP
TEMP
VIOLET/RED 16
N.O.
ECM DIAGNOSTIC LAMP
RED 10
START
47
GREEN/WHITE 16
KEY
9
ETHER
16
96192
ETHER
SOLENOID
DRILL HR
12
11
12
11
14
GREEN/BLACK 16
12
ORANGE 16
F
18
BACKUP ALARM
17
GRAY 16
A/C
47
GRAY 16
18
DRILL LIGHT POWER
TOP
LIGHTS
18
DRILL
LIGHT
MAIN
POWER
A GREEN/GRAY 16
18
LIGHT SWITCH
15
13
14
51
GREEN/BROWN 16
ENG
BOX
11
ENG
BOX
13
MAST OPTIONS
GREEN/RED 16
ORANGE 16
DRILL
LIGHT
18
47
ORANGE 16
14
MAIN POWER
CONTROL
PANNEL
15
ENG
BOX
MAIN
POWER
12
VOLT
START
16
RED 10
47
ENG
BOX
17
STARTER BUTTON
17
BLUE 12
ENG
BOX
RED 6
18
15
50
15
50
DOME
LIGHT
18
16
17
GRAY 16
47
88194
24V LIGHT
BULB
FRONT LIGHTS
THROTTLE POS
47
18
GREEN/GRAY 16
ENG
BOX
99
VIOLET 16
ENG
BOX
15
50
16
53
53
ALTERNATOR
RED 6
STARTER
+
-
18
GREEN/GRAY 16
18
GREEN 10
BLACK 16
15
VIOLET 16
RED 14
RED 14
99
RED 14
15
18
47
MAST LOCK
18
MAST UNLOCK
19
MAST LOCK
20
MAIN AIR
MAIN AIR CLOSE
47
21
MAIN AIR OPEN
22
DUST COLL
WATER INJ
DUST/WATER
PIPE RACK OUT
PIPE RACK
IN/OUT
HOBO CLAMP
24
PIPE RACK IN
CAROUSEL INDEX CW
25
35
CAROUSEL INDEX CCW
39
26
36
CAROUSEL
INDEX
DUST CURT
SEE SHT 2
PIPE POSITIONER IN
27
PIPE POSITIONER OUT
PIPE
POSITIONER
47
47
21
22
23
24
19
19
20
18
21
BLUE/YELLOW 16
21
22
PINK/BROWN 16
22
25
26
27
28
29
30
23
24
PINK/BLACK 16
25
BLACK/PINK 16
26
25
YELLOW/WHITE 16
27
26
YELLOW/BLACK 16
28
YELLOW/BROWN 16
29
47
AUTO TOOL IN
30
28
WINCH DOWN
34
WINCH UP
DUST CURTAIN DOWN
DUST CURTAIN UP
31
32
YELLOW/GREEN 16
51
PIPE
POSITIONER
51
AUTO
TOOL
51
WINCH
51
DUST
CURTAIN
33
51
HOBO
CLAMP
51
HOBO
SWING
OIL INJECTION
HOBO RELEASE
34
35
36
33
YELLOW/BLUE 16
34
WHITE/YELLOW 16
51
PIPE
RACK LOCK
33
35
WHITE/RED 16
34
DUST/
WATER
NOTES: SEE CAB & ENGINE SUBASSEMBLIES
FOR COMPONMENT PART NUMBERS.
SEE 405306 FOR GUAGE PANEL LAYOUT.
SEE 405413 FOR SWITCH PANEL LAYOUT.
51
BLACK 16
50
+
TIMER
D.C.
-
38
39
51
36
35
WHITE/BROWN 16
36
38
40
ORANGE/BLACK 16
51
39
ORANGE/WHITE 16
40
40
44
HOBO SWING OUT
HOBO SWING IN
47
PIPE RACK LOCK
PIPE RACK UNLOCK
45
WHITE
51
39
HOBO CLAMP
THREAD LUBE
51
51
32
YELLOW/GRAY 16
37
38
43
51
31
YELLOW/ORANGE 16
OIL INJECT
PIPE RACK LOCK
CAROUSEL
INDEX
52
51
51
31
AUTO TOOL OUT
32
33
51
WITH ENGINE
HOURMETER
18
51
27
YELLOW/RED 16
32
WINCH
47
PIPE
RACK
29
31
SEE SHT 2
51
51
51
18
MAIN
AIR
FRONT
LIGHTS
24
30
AUTO TOOL
51
51
23
BROWN/WHITE 16
DUST COLLECTOR
ENGINE O.P.
51
20
GRAY/BLUE 16
MAST
LOCK
51
28
30
42
20
RED/WHITE 16
GRAY/WHITE 16
29
HOBO SWING
41
19
23
47
SELECTOR
SWITCH
99
47
47
40
GREEN/GRAY 16
18
99
47
GRAY/YEL 16
52
BATTERIES
GRAY 16
REAR
13
AC
GREEN 10
16
17
FRONT
13
ENG
BOX
15
47
15
11
12
16
BLUE 12
LIGHT RELAY
47840
13
14
RED 10
47
47
GREEN/GRAY 16
ETHER
12
99
18
GRAY 16
13
96192
ENGINE HR
12
32189
DRILL
HOUR
BACK-UP
69499
12
IGNITION
SOLENOID
17
47
10
10
16
OIL INJECTION LIGHT
THREAD LUBE
41
42
43
44
45
46
BLUE/WHITE 16
41
BLACK/WHITE 16
42
BLACK/YELLOW 16
41
43
GRAY/RED 16
42
51
44
43
PINK/BLUE 16
TAN 16
51
45
44
LIGHT
38
45
51
51
49
OIL INJECTION LIGHT
51
46
THREAD
LUBE
SOLENOID
TIMER
PUMP
46
51
1410758
TIMER
BOX
Ref. 425138 rev. C (1 of 3)
OIL
INJECTION
8-23
Wiring DiagramSKS
L.H.
JOYSTICK
ROTATE
JOYSTICK
HOIST/PULLDOWN
JOYSTICK
AUTO
PRPL
PRPL
97
98
AUTO
CARD
BLK
PNK #0
PNK #5
PNK #6
99
IF PIPE RACK
SWING INTERLOCK
OPTION NOT USED,
CONNECT PWR
FROM ROTATE JOYSTICK
TO HOIST/PULLDOWN
JOYSITCK WITH WIRE #89
PNK #2
BLK
GRN #8
GRY #6
GRN #4
YLW #9
YEL #3
BLK
BLK
YEL #9
WHT #6
BLU #4
BLU #8
WHT #7
WHT #6
BLK
R.H.
JOYSTICK
REF CAB JUNCTION

BOX TERMINALS
96
78
95
96
95
89
84
6
7
DN.
PULLDOWN
CONTROL
VALVE
PULLDOWN
CONTROL
VALVE
OVERIDE
OFF
154
ORG #5
WHT #7
6
5
YEL #9
GRN #8
GRN #4
YEL #3
76
YEL #9
WHT #7
77
6
4
UP
85
ON
155
REF CAB JUNCTION

BOX TERMINALS
ORG #7
83
GRY #6
86
153
6
4
157
88
11
82
87
88
BLU #4
-2
87
BLU #8
RELAY #4
N.C.
+10
11
81
REF CAB JUNCTION

BOX TERMINALS
NC 2
-2
+10
1
11
ORG/GRN #16
156
156
157
3
NO
PIPE RACK SWING

LIMIT SWITCH
N.O.
IGNITION
82
BRN #4
POWER FROM
IGNITION RELAY
SEE SHT 1
81
BRN #8
75
73
POWER FROM
DRILL/PROPEL SW.
SEE SHT 1
POWER FROM
IGNITION RELAY
SEE SHT 1
PROPEL MODE
OPTIONAL PIPE RACK

SWING INTERLOCK
74
L.H. TRAM/ROTATE
PUMP
WHT 16
R.H. PUMP
8-24
GRN 16
BLK
11
+10
-2
RELAY #2
N.C.
GRN/BLK 16
SEE SHT 3 FOR

INTERLOCK OPTIONS
INVOLVING THIS RELAY
WHT/BRN 16
+10
-2
WHT/BRN 16
RELAY #3
N.C.
BLK
WHT 16
BLK
RELAY #1
N.C.
IGNITION
DRILL MODE
POWER FROM
DRILL/PROPEL SW.
SEE SHT 1
Ref. 425138 rev. C (2 of 3)
Wiring DiagramSKS
TAN/RED 16
REF L.H.
JOYSTICK
SHOWN ON SHT 2
PRPL/GRN 16
REF R.H.
JOYSTICK
SHOWN ON SHT 2
133
PRPL/GRN 16
133
BL
K
TAN/RED 16
132
TAN/RED
RIGHT
REAR
JACK
BRN
U
BL
(+)
PRPL/GRN 16
TAN/RED
133
137
-2
136
PRPL/GRN 16
136
133
133
TAN/RED
WHT 6
+10
REF CAB JUNCTION

BOX TERMINALS
130
136
136
11
POWER FROM
RELAY #2, TERMINAL #8
SEE SHT 2
REF RELAY #1, N.C.

SHOWN ON SHT 2
OPTIONAL
JACK INTERLOCK CIRCUIT
WHEN USED INDEPENDANTLY
BL
K
U
BL
BRN
BL
K
LEFT
REAR
JACK
134
BLK 16
K
BL
BRN
BL
U
RIGHT
FRONT
JACK
WHT 7
131
133
WHT 4
136
(-)
78
JACK INTERLOCK
JACKS UP =
GREEN LIGHT
135
LEFT
FRONT
JACK
136
REF L.H.
JOYSTICK
SHOWN ON SHT 2
136
133
REF R.H.
JOYSTICK
SHOWN ON SHT 2
JACK INTERLOCK
JACKS UP =
GREEN LIGHT
132
78
(-)
REF CAB JUNCTION

BOX TERMINALS
135
BLK 16
132
TAN/RED
16
130
LOAD
LOAD
BLK
REF CAB JUNCTION

BOX TERMINALS
PROPEL INTERLOCK
PIPE PRESENT =
RED LIGHT
+10
11
138
WHT
REF RELAY #1, N.C.

SHOWN ON SHT 2
139
PRPL/GRN 16
PROPEL INTERLOCK
PIPE PRESENT =
RED LIGHT
+10
1
11
138
WHT
REF RELAY #1, N.C.

SHOWN ON SHT 2
139
139
RED/GRN 16
3
-2
-2
4
LOAD
WHT 6
136
WHT 4
140
140
WHT 6
140
131
140
130
133
78
4
LOAD
WHT 4
131
BLK
WHT 7
BLK
BLK
WHT 6
PIPE PRESENT PROXIMITY SW.
(+)
134
REF R.H.
JOYSTICK
SHOWN ON SHT 2
REF CAB JUNCTION

BOX TERMINALS
136
REF L.H.
JOYSTICK
SHOWN ON SHT 2
RIGHT
REAR
JACK
BRN
U
BL
OPTIONAL
DRILL STEEL & JACK INTERLOCK
CIRCUITS WHEN USED SIMILTANEOUSLY
WHT 7
133
U
BL
BRN
BL
K
BL
U
BRN
K
BL
PRPL/GRN 16
BLK
136
PRPL/GRN 16
LEFT
REAR
JACK
136
136
WHT 6
PRPL/GRN 16
TAN/RED
TAN/RED 16
WHT 7
BRN
K
BL
RIGHT
FRONT
JACK
WHT 4
LEFT
FRONT
JACK
K
BL
BRN
BL
U
WHT 6
BL
U
TAN/RED 16
136
PRPL/GRN 16
133
POWER FROM
SEE SHT 2
POWER FROM
SEE SHT 2
139
RED/GRN 16
OPTIONAL
DRILL STEEL INTERLOCK CIRCUIT
Ref. 425138 rev. C (3 of 3)

8-25
Cab Wiring HarnessSKS

CAB WIRING
TOP OF CAB
8-26
ITEM
RDI P/N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
44089
44093
17816
17821
99329
17820
17819
17814
17817
88009
88010
88011
88012
88013
44090
17823
17824
35399
88015
99313
99353
99351
99333
99341
99362
99348
99330
88016
88017
88018
88019
88020
88021
88022
44092
88023
88024
88025
88026
17824
44090
88015
45259
45252
45257
78138
99320
99321
99331
99327
99328
99352
99339
99361
17818
44091
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------
COLOR
GAUGE
GRAY --------------------GREEN/YELLOW STRIPE -----WHITE -------------------BROWN -------------------BLACK/ORANGE ------------YELLOW ------------------RED ---------------------BLUE --------------------GREEN -------------------WHITE/GREEN ------------GREEN/WHITE ------------GREEN/BROWN ------------GREEN/BLACK ------------GREEN/RED --------------ORANGE ------------------GREEN -------------------RED ---------------------BLUE --------------------GREEN/GRAY -------------RED/WHITE ---------------GRAY/WHITE --------------GRAY/BLUE ---------------BLUE/YELLOW -------------PINK/BROWN --------------BROWN/WHITE -------------PINK/BLACK --------------BLACK/PINK --------------YELLOW/WHITE -----------YELLOW/BLACK -----------YELLOW/BROWN -----------YELLOW/RED -------------YELLOW/GREEN -----------YELLOW/ORANGE ----------YELLOW/GRAY ------------YELLOW/BLUE ------------WHITE/YELLOW -----------WHITE/RED --------------WHITE/BLACK ------------WHITE/BROWN ------------RED ---------------------ORANGE ------------------GREEN/GRAY
------------TERMINAL 3/16 STUD 16/14-TERMINAL 1/4 EYE 12/10 --TERMINAL 3/16 EYE 16/14 -TERMINAL 1/4 STUD 16/14 -ORANGE/BLACK ------------ORANGE/WHITE ------------BLUE/WHITE --------------BLACK/WHITE -------------BLACK/YELLOW ------------GRAY/RED ----------------PINK/BLUE ---------------TAN ---------------------BLACK -------------------VIOLET -------------------
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
10
10
12
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
10
16
16
----16
16
16
16
16
16
16
16
16
16
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------
DESCRIPTION
TERMINAL
POWER-TEMP,FUEL,OIL,VOLT --COMPRESSOR TEMP -----------WATER TEMP ----------------FUEL ----------------------OIL PRESSURE --------------TACH ----------------------TACH ----------------------RUN-KEY -------------------ECM DIAGNOSTIC LAMP -------ENGINE HOUR ---------------DRILL HOUR ----------------ETHER ---------------------KEY DRILL HOUR ------------BACK-UP ALARM POWER -------A/C COMPRESSOR ------------DRILL LIGHT POWER --------MAIN POWER ---------------STARTER BUTTON ------------FRONT LIGHTS --------------MAST UNLOCK ---------------MAST LOCK -----------------MAIN AIR CLOSE -----------MAIN AIR OPEN ------------DUST COLLECTOR ------------WATER INJECTION ----------PIPE RACK OUT -------------PIPE RACK IN --------------PIPE RACK INDEX CW --------PIPE RACK INDEX CCW -------PIPE POSITIONER IN --------PIPE POSITIONER OUT -------AUTO TOOL IN --------------AUTO TOOL OUT -------------WINCH DOWN ----------------WINCH UP -----------------DUST CURTAIN DOWN ---------DUST CURTIAN UP -----------DRILL/PROPELL -------------OIL INJECTION -------------POWER TO AC ---------------AC COMPRESSOR -------------TOP LIGHTS ------------------------------------------------ -------------------------- -------------------------- ---------------------HOBO RELEASE --------------HOBO CLAMP ----------------HOBO SWING OUT ------------HOBO SWING IN -------------PIPE RACK LOCK ------------PIPE RACK UNLOCK ----------OIL INJECTION LIGHT -------THREAD LUBE ---------------GROUND --------------------THROTTLE POSITION SENSOR ---
47
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
16
14
18
----39
40
41
42
43
44
45
46
51
99
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
COMP
QTY
QTY
EACH
6'-0" -----6'-0" -----12'-0" 6'-0"

36'-0" 6'-0"
12'-0" -----12'-0" -----18'-0" 6'-0"
12'-0" 6'-0"
6'-0"
6'-0"
12'-0" 6'-0"
6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----26'-0" ----------- 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----15'-0" -----15'-0" -----15'-0" -----65 EACH-----12 EACH-----110 EACH----3 EACH 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
Ref. 419305
Cab/Engine Skid WiringSKS

WIRING-CAB/ENGINE SKID
ITEM
RDI P/N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
44093
17816
17821
99329
17820
17819
17814
17817
88009
88011
88013
----17823
17824
35399
88015
44090
44091
----88058
88059
88060
88061
45258
45259
57860
57854
96331
96331
96332
17830
76582
30211
96333
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------
COLOR
GAUGE
GREEN/YELLOW STRIPE -----WHITE -------------------BROWN -------------------BLACK/ORANGE-------------YELLOW ------------------RED ---------------------BLUE --------------------GREEN -------------------WHITE/GREEN STRIPE ------GREEN/BROWN STRIPE ------GREEN/RED STRIPE ---------------------------------GREEN -------------------RED ---------------------BLUE --------------------GREEN/GRAY STRIPE -------ORANGE ------------------VIOLET -------------------------------------------VIOLET/YELLOW STRIPE ----VIOLET/GREEN STRIPE -----VIOLET/BLUE STRIPE ------VIOLET/WHITE STRIPE -----TERMINAL-3/16 STUD-10/12 TERMINAL-3/16 STUD-16/14 CONDUIT-1" --------------CONNECTOR-CONDUIT-1" ----GROUND CABLE ------------POSITIVE CABLE ----------BATTERY ENDS-POSITIVE ---EYELETS -----------------TERMINAL STRIP-----------HEATER HOSE -------------BATTERY ENDS-NEGATIVE ----
16
16
16
16
16
16
16
16
16
16
16
-10
10
12
16
16
16
-16
16
16
16
------------
-------------------------------------------------------------------------------------------------------
DESCRIPTION
TERMINAL
COMPRESSOR TEMP -----------WATER TEMP ----------------FUEL ----------------------OIL PRESSURE --------------TACH ----------------------TACH ----------------------RUN-KEY -------------------DIAGNOSTIC LAMP -----------ENGINE HOUR ---------------ETHER ---------------------BACK-UP ALARM ----------------------------------------LIGHT POWER ---------------KEY POWER -----------------STARTER BUTTON POWER ------LIGHT ---------------------A/C COMPRESSOR ------------THROTTLE POSITION ------------------------------------EXTRA ---------------------EXTRA ---------------------EXTRA ---------------------EXTRA -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1
2
3
4
5
6
7
8
9
11
13
-15
16
17
18
14
99
-----------------
QTY
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
24'-0"
24'-0"
24'-0"
24'-0"
24'-0"
24'-0"
24'-0"
24'-0"
24'-0"
24'-0"
24'-0"
-----24'-0"
24'-0"
24'-0"
24'-0"
24'-0"
24'-0"
-----24'-0"
24'-0"
24'-0"
24'-0"
8 EACH
26 EACH
22'-0"
2 EACH
12'-0"
--------------- ---------------- ---------------
12'-0"
2 EACH
2 EACH
1 EACH
12'-0"
2 EACH
35 --------- 344931 -- LOOM CRGTD SPLIT 1/2

36 --------- 344930 -- LOOM CRGTD SPLIT 3/8
---- -- ---- ---------------------------- --
-------- 12
EACH
---- -- ---- ---------------------------- --
-------- 12
EACH
37 --------- 344929 -- LOOM CRGTD SPLIT 1/4
---- -- ---- ---------------------------- --
-------- 12
EACH
Ref. 419306
8-27
Mast WiringSKS
WIRING-MAST (SEE SCHEMATIC 95934)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
88010
88012
99313
99353
99348
99330
88016
88017
88018
88019
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
COLOR
---------------------
GAUGE
GREEN/WHITE STRIPE ------GREEN/BLACK STRIPE ------RED/WHITE----------------GRAY/WHITE---------------PINK/BLACK---------------BLACK/PINK---------------YELLOW/WHITE ------------YELLOW/BLACK STRIPE -----YELLOW/BROWN STRIPE -----YELLOW/RED STRIPE --------
16
16
16
16
16
16
16
16
16
16
-------------------------------
DESCRIPTION
TERMINAL
DRILL HOUR METER ----------DRILL HOUR METER ----------MAST LOCK -----------------MAST LOCK -----------------PIPE RACK IN/OUT ----------PIPE RACK IN/OUT ----------PIPE RACK CAROUSEL --------PIPE RACK CAROUSEL --------PIPE POSITIONER -----------PIPE POSITIONER ------------
RED/WHITE
B
31
10
12
19
20
25
26
27
28
29
30
QTY
-----------------------------------------------------------------------
88020 --- YELLOW/GREEN STRIPE ------ 16 ---- AUTO TOOL ------------------ 31 - -------88021 --- YELLOW/ORANGE STRIPE ----- 16 ---- AUTO TOOL------------------- 32 - -------88022 --- YELLOW/GRAY STRIPE ------- 16 ---- BREAKOUT ------------------- 33 - -------44092 --- YELLOW/BLUE STRIPE ------- 16 ---- BREAKOUT ------------------- 34 - -------45265 --- CONNECTOR-FEMALE-16/14 --- -- ---- ---------------------------- -- - -------45259 --- TREMINAL-3/16 STUD-16/14 - -- ---- ---------------------------- -- - -------35659 --- CONDUIT-3/4" ------------- -- ---- ---------------------------- 35 - -------56780 --- CONNECTOR-STR-CONDUIT-3/4" -- ---- ---------------------------- 36 - -------350477--- CONNECTOR-CROUSE HIN ----- -- ---- ---------------------------- -- - -------122227--- UNION-PIPE-3/4" ---------- -- ---- ---------------------------- -- - -------JB7201123-P CLAMP-TUBING-1.25" ---------- -- ---- ---------------------------- --------39999 --- P CLAMP-1.06--------------- -- ---- ---------------------------- -- - -------99320 --- ORANGE/BLACK ------------- 16 ---- HOBO CLAMP------------------ -- - -------99321 --- ORANGE/WHITE-------------- 16 ---- HOBO CLAMP------------------ -- - -------99331 --- BLUE/WHITE --------------- 16 ---- HOBO SWING------------------ -- - -------99327 --- BLACK/WHITE -------------- 16 ---- HOBO SWING------------------ -- - -------99328 --- BLACK/YELLOW-------------- 16 ---- PIPE RACK LOCK-------------- -- - -------99352 --- GRAY/RED------------------ 16 ---- PIPE RACK LOCK-------------- -- - -------95124 --- -------------------------- -- ---- CONNECTOR-8 WAY-MALE-------- -- - -------95126 --- -------------------------- -- ---- CONNECTOR-FEMALE-8 WAY------ -- - -------95129 --- -------------------------- -- ---- CONNECTOR-2 WAY-MALE-------- -- - -------95125 --- -------------------------- -- ---- TERMINAL- MALE-------------- -- - -------95128 --- -------------------------- -- ---- CONNECTOR-2 WAY-FEMALE------ -- - -------95127 --- -------------------------- -- ---- TERMINAL-FEMALE------------- -- - --------
ORANGE/WHITE
BLACK/WHITE
YELLOW/GREEN
GRAY/RED
A B
RDI P/N
29
33
GRAY/WHITE
ITEM
YELLOW/WHITE
YELLOW/GRAY
BLUE/WHITE
PINK/BLACK
31
A
GREEN/BLACK
A B
BLACK/PINK
YELLOW/BROWN
BLACK/YELLOW
YELLOW/ORANGE
GRAY/WHITE
RED/WHITE
MAST HARNESS
26'-0"
26'-0"
26'-0"
26'-0"
12 EACH
28 EACH
18'-0"
2 EACH
1 EACH
1 EACH
1 EACH
5 EACH
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
2 EACH
2 EACH
2 EACH
20 EACH
2 EACH
20 EACH
YELLOW/WHITE
YELLOW/GRAY
BLUE/WHITE
PINK/BLACK
33
30
ORANGE/BLACK
YELLOW/BLACK
YELLOW/RED
YELLOW/BLUE
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
GREEN/WHITE
30
BLACK/PINK
YELLOW/BROWN
BLACK/YELLOW
YELLOW/ORANGE
ORANGE/WHITE
BLACK/WHITE
YELLOW/GREEN
GRAY/RED
29
ORANGE/BLACK
YELLOW/BLACK
YELLOW/RED
YELLOW/BLUE
A B
GREEN/BLACK
GREEN/WHITE
MAST VALVE
8-28
Ref. 96330 rev. A

Engine Skid/Engine/AC WiringSKS
WIRING-ENGINE SKID/ENGINE/AIR CONDITIONER

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
RDI P/N
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
COLOR
GAUGE
DESCRIPTION
TERMINAL
COMP
QTY
44093 --- GREEN/YELLOW ------------ 16 ---- COMPRESSOR TEMP ------------ 1 --------- 18'-0"
17816 --- WHITE -------------------- 16 ---- WATER TEMP ----------------- 2 --------- 18'-0"
17821 --- BROWN -------------------- 16 ---- FUEL ----------------------- 3 --------- 18'-0"
99329 --- BLACK/ORANGE ------------- 16 ---- OIL PRESSURE --------------- 4 --------- 18'-0"
17820 --- YELLOW ------------------- 16 ---- TACH ----------------------- 5 --------- 18'-0"
17819 --- RED ---------------------- 16 ---- TACH ----------------------- 6 --------- 18'-0"
17814 --- BLUE --------------------- 16 ---- RUN-KEY -------------------- 7 --------- 18'-0"
17817 --- GREEN -------------------- 16 ---- ECM DIAGNOSTIC LAMP -------- 8 --------- 18'-0"
88009 --- WHITE/GREEN ------------- 16 ---- ENGINE HOUR ---------------- 9 --------- 18'-0"
88011 --- GREEN/BROWN ------------- 16 ---- ETHER ---------------------- 11 --------- 18'-0"
88013 --- GREEN/RED --------------- 16 ---- BACK-UP ALARM POWER -------- 13 --------- 18'-0"
44090 --- ORANGE ------------------- 16 ---- A/C COMPRESSOR ------------- 14 --------- 18'-0"
17823 --- GREEN -------------------- 10 ---- DRILL LIGHT POWER --------- 15 --------- 2'-0"
17824 --- RED ---------------------- 10 ---- MAIN POWER ---------------- 16 --------- 2'-0"
35399 --- BLUE --------------------- 12 ---- STARTER BUTTON ------------- 17 --------- 12'-0"
88015 --- GREEN/GRAY -------------- 16 ---- FRONT LIGHTS --------------- 18 --------- 26'-0"
44089 --- GRAY --------------------- 16 ---- POWER/ENGINE HOUR --------- 47 --------- 12'-0"
99333 --- BLACK -------------------- 16 ---- GROUND -------------------- 51 --------- 6'-0"
99355 --- GRAY/YELLOW -------------- 16 ---- DUST COLLECTOR ------------- 52 --------- 15'-0"
99380 --- RED ---------------------- 6 ---- STARTER 50 AMP ------------ 53 --------- 12'-0"
44091 --- VIOLET ------------------- 16 ---- THROTTLE POSITION SENSOR --- 99 --------- 18'-0"
88057 --- VIOLET/RED --------------- 16 ---- REMOTE SHUTDOWN ----------- -- --------- 12'-0"
346854--- RED ---------------------- 14 ---- BAT+/ECM P3 --------------- -- --------- 24'-0"
350477--- CONNECTOR, CABLE 1/2" ---- -- ---- ---------------------------- -- --------- 3 EACH
45249 --- TERMINAL 1/2 STUD 10/12 -- -- ---- ---------------------------- -- --------- 2 EACH
45252 --- TERMINAL 1/4 EYE 10/12 --- -- ---- ---------------------------- -- --------- 1 EACH
45253 --- TERMINAL 3/16 EYE 10/12 -- -- ---- ---------------------------- -- --------- 1 EACH
45257 --- TERMINAL 3/16 EYE 16/14 -- -- ---- ---------------------------- -- --------- 10 EACH
45261 --- CONNECTOR BUTT 16/14 ----- -- ---- ---------------------------- -- --------- 5 EACH
45258 --- TERMINAL 3/16 STUD 10/12 - -- ---- ---------------------------- -- --------- 2 EACH
45259 --- TERMINAL 3/16 STUD 16/14 - -- ---- ---------------------------- -- --------- 12 EACH
350398 --- TERMINAL #10 STUD 16/14 -- -- ---- ---------------------------- -- --------- 12 EACH
416809 -- 40 CONNECTOR PLUG ------- -- ---- ---------------------------- -- --------- 1 EACH
416811 -- PIN --------------------- -- ---- ---------------------------- -- --------- 6 EACH
416810 -- SEAL PLUG --------------- -- ---- ---------------------------- -- --------- 34 EACH
416808 -- 3 CONNECTOR RECEPTACLE -- -- ---- ---------------------------- -- --------- 1 EACH
416812 -- CONNECTOR SOCKET -------- -- ---- ---------------------------- -- --------- 3 EACH
Ref. 419307
8-29
Wiring DiagramSKS-W (QST30)

319153
LOCATED IN CAB ENCLOSURE

COMPRESSOR TEMP
FUEL
96193
OIL
31945
FUEL LEVEL
ALT/TACH
OIL PRESSURE
4
5
2
TACH
47
GRAY 16
WHITE 16
BROWN 16
4
5
319153
WATER
TEMP
BLACK/ORANGE 16
YELLOW 16
319152
OIL
PRESS
47
47
7
ENGINE HR
47
96192
9
ENGINE HOUR
WHITE/GREEN 16
STOP
CONTINUED ON SHEET 2- DETAIL B
OPTIONAL GROUND KILL

STOP BUTTON 426338
85
RED 10
-V BATTERY
-V BATTERY
20 AMP
+V BATTERY
20 AMP
+V BATTERY
RED/BLUE
DIANOSTIC
(AMBER)
DRILL
HOUR
START
GREEN/BLACK 16
ENGINE
PROTECTION
12
DRILL HR
12
BACKUP ALARM
14 GA
14
DRILL LIGHT POWER

GRAY 16
15
47
MAIN POWER
18
ISC ON/OFF
18
F
18
18
LIGHT SWITCH
47840
16
ISC ON/OFF
N.O.
ISC 1 1800
29
23
52
24
53
50
GREEN/RED 16
13
13
16
DRILL
LIGHT
MAIN
POWER
ORANGE 16
GREEN 10
15
RED 10
50
AC
CLUTCH
FRONT
REAR
16
17
CONTROL
PANEL
MAIN
POWER
12
VOLT
START
FRONT LIGHTS
18
RED 4
GREEN/GRAY 16
24 VDC
POWER
SOLENOID
24 VDC
INPUT
DC\AC
15
15
STARTER
MICROWAVE OVEN
OUTPUT
INVERTER
50
RED 12
WHITE 12
18
16
47
ISC 2 2100
18
88194
24V LIGHT
TOP
LIGHTS
RED 10
MASTER DISCONNECT
SWITCH
135
BULB
GREEN 10
BLACK 16
THERMOSTAT
15
A/C CONDENSER
47
47
WITH ENGINE
HOURMETER
MAST UNLOCK
MAST LOCK
MAIN AIR
MAIN AIR CLOSE
47
21
MAIN AIR OPEN
22
DUST COLL
PIPE RACK
IN/OUT
22
19
19
20
GRAY/WHITE 16
GRAY/BLUE 16
21
BLUE/YELLOW 16
21
22
PINK/BROWN 16
24
PIPE RACK IN
CAROUSEL
INDEX
DUST CURT
PIPE
POSITIONER
BLACK/PINK 16
28
PIPE POSITIONER IN
29
PIPE POSITIONER OUT
27
26
27
26
36
25
30
22
25
25
YELLOW/WHITE 16
51
27
26
YELLOW/BLACK 16
28
YELLOW/BROWN 16
29
YELLOW/RED 16
27
30
28
AUTO TOOL IN
31
51
18
18
DUST/
WATER
51
51
51
51
CAROUSEL
INDEX
51
PIPE
POSITIONER
51
AUTO
TOOL
51
WINCH
51
DUST
CURTAIN
51
HOBO
CLAMP
51
HOBO
SWING
51
PIPE
RACK LOCK
FRONT
LIGHTS
51
YELLOW/GREEN 16
32
31
YELLOW/ORANGE 16
32
32
WINCH
WINCH DOWN
33
WINCH UP
33
34
DUST CURTAIN DOWN
34
35
YELLOW/GRAY 16
33
YELLOW/BLUE 16
34
WHITE/YELLOW 16
DUST CURTAIN UP
34
47
DRILL/PROPEL
36
37
38
OIL INJECTION
38
OIL INJECT
HOBO RELEASE
39
WHITE/RED 16
51
33
35
37
40
51
31
AUTO TOOL OUT
32
36
WHITE/BLACK 16
35
37
WHITE/BROWN 16
36
38
ORANGE/BLACK 16
40
ORANGE/WHITE 16
51
39
41
BLUE/WHITE 16
40
40
HOBO SWING OUT
41
HOBO SWING IN
42
42
PIPE RACK LOCK
43
43
PIPE RACK UNLOCK
44
45
PIPE RACK LOCK

47
44
OIL INJECTION LIGHT
45
THREAD LUBE
46
41
BLACK/WHITE 16
42
BLACK/YELLOW 16
42
43
45
44
LIGHT
38
45
DRILL/
PROPEL
SOLENOID
51
THREAD LUBE
SOLENOID
37
46
TIMER
PUMP
46
TIMER
BOX
51
51
49
OIL INJECTION LIGHT
51
51
44
PINK/BLUE 16
1410758
51
41
43
GRAY/RED 16
TAN 16

51
39
HOBO CLAMP
THREAD LUBE
PIPE
RACK
51
29
31
HOBO SWING
51
26
30
AUTO TOOL
47
MAIN
AIR
28
30
39
51
18
23
37
HOBO CLAMP
BLACK 16
51
51
24
29
47
MAST
LOCK
23
BROWN/WHITE 16
PINK/BLACK 16
51
+
TIMER
D.C.
-
51
20
24
25
58496
21
24
PIPE RACK OUT
CAROUSEL INDEX CCW
BRAKE
SOLENOID
20
RED/WHITE 16
23
CAROUSEL INDEX CW
PROPEL
19
23
WATER INJ
DUST/WATER
47
35
52
WHITE/GRN
MAST LOCK
19
DRILL
GRAY/YEL 16
GREEN/GRAY 16
18
20
JOYSTICK SELECTOR
DUST COLLECTOR
ENGINE O.P.
BATTERIES
HEATER-A/C UNIT
47
SWITCH SHOWN ON SHEET 2
BLACK 4
HEAT-A/C
18
PRELUBE
SOLENOID
47
52
GREEN/GRAY 16
GRAY 16
53
ALTERNATOR
110 VAC
99
DOME
LIGHT
ORANGE 16
14
GREEN 10
15
18
15
ISC 1 1800
A GREEN/GRAY
18
RED 6
12
13
A/C
LIGHT RELAY
VIOLET/RED 16
16
12 GA
GREEN/GRAY 16
KEY SWITCH
14
RED 10
DIANOSTIC
ON/OFF
15
20
ISC 2 2100
MICROWAVE OVEN
ORANGE 16
COMP
TEMP
13
16
10
AMP
35
14
21
LOCATED ON ENGINE
11
15
AMP
DIANOSTIC
ON/OFF
BACK-UP
69499
GREEN/WHITE 16
13
ENGINE
PROTECTION
21 PIN CONNECTOR
96192
32189
10
12
GREEN/BLACK 16
(GREEN)
12
DIANOSTIC
FOR ENGINE STOP OPTION
87 NO
86
50 PIN
RIGHT BANK
ECM ENGINE
HARNESS CONNECTOR
8
9
30
(RED)
31 PIN CONNECTOR
LOCATED ON ENGINE
FOR REMOTE TRAM OPTION
87a NC
STOP
GRAY/YELLOW 16
52
32189
ENGINE
HOUR
CONTINUED ON SHEET 2- DETAIL A
8-30
FUEL
YELLOW 16
47
47
47
COMP
TEMP
LOCATED IN ENGINE BOX ENCLOSURE
YELLOW 16
1
319240
4 PLACES
WATER TEMP
VOLT 319151
33
52
45
31
91
46
33
52
45

319146
319147
GREEN/YELLOW 16
OIL
INJECTION
Ref. 426662 rev. A (1 of 3)

Cold Weather w/QST30
58496
POWER ON
DRILL

R.H.
JOYSTICK
ROTATE
JOYSTICK
HOIST/PULLDOWN
JOYSTICK
PRPL
AUTO
FEED
PRPL
AUTO
CARD
A
BLK
PNK #6
PNK #0
GRY #6
PNK #2
BLK
GRN #8
GRY #6
GRN #4
YLW #9
YEL #3
BLK
YEL #9
BLK
WHT #6
BLU #4
BLU #8
WHT #7
6
7
9
9
+10
11
-2
+10
11
BLK
REF CAB JUNCTION

BOX TERMINALS
BLU #8
L.H. TRAM/ROTATE
PUMP
BRN #4
BRN #8
GRN/BLK 16
BLU #4
R.H. PUMP
POWER FROM
IGNITION RELAY
WHT/BRN 16
-2
RELAY #2
N.C.
WHT/BRN 16
WHT 16
11
BLK
RELAY #3
N.C.
+10
-2
1
POWER FROM
DRILL/PROPEL SW.
BLK
TRAM INTERLOCK
WHT 16
JACK INTERLOCK
SEE SHT 3
YEL #9
WHT #7
WHT 16
6
5
YEL #9
PINK #6
BLK
RELAY #5
N.C.
GRN #8
PINK #2
GRN #4
YEL #3
WHT #7
WHT #6
BLK
L.H.
JOYSTICK
Ref. 426662 rev. A (2 of 3)

POWER FROM
DRILL/PROPEL SW.
8-31

TAN/RED 16
REF L.H.
JOYSTICK
PRPL/GRN 16
REF R.H.
JOYSTICK
TAN/RED 16
RIGHT
FRONT
JACK
PRPL/GRN 16
TAN/RED
RIGHT
REAR
JACK
(-)
PRPL/GRN 16
PRPL/GRN 16
TAN/RED
WHT 4
TAN/RED
16
(+)
LEFT
REAR
JACK
6
5
BLK 16
3
-2
+10
1
REF CAB JUNCTION

BOX TERMINALS
K
BL
BRN
BL
U
RIGHT
FRONT
JACK
TAN/RED
WHT 6
JACK INTERLOCK
JACKS UP =
GREEN LIGHT
TAN/RED 16
PRPL/GRN 16
BRN
U
BL
LEFT
FRONT
JACK
11
POWER FROM
REF RELAY #1, N.C.
BL
K
U
BL
BRN
BL
K
OPTIONAL
RIGHT
REAR
JACK
BRN
U
BL
PRPL/GRN 16
BL
K
U
BL
BRN
BL
K
WHT 6
TAN/RED
LEFT
REAR
JACK
BL
U
BRN
K
BL
WHT 7
PRPL/GRN 16
PRPL/GRN 16
BRN
BL
U
REF L.H.
JOYSTICK
TAN/RED 16
LEFT
FRONT
JACK
BRN
K
BL
K
BL
WHT 4
BL
U
REF R.H.
JOYSTICK
REF CAB JUNCTION

BOX TERMINALS
REF R.H.
JOYSTICK
WHT 6
REF L.H.
JOYSTICK
JACK INTERLOCK
JACKS UP =
GREEN LIGHT
WHT 6
(-)
REF CAB JUNCTION

BOX TERMINALS
BLK 16
(+)
TAN/RED
16
WHT 4
6
4
2
PRPL/GRN 16
BLK
PROPEL INTERLOCK
PIPE PRESENT =
RED LIGHT
+10
11
WHT
REF RELAY #1, N.C.
POWER FROM
+10
11
WHT
WHT 7
RED/GRN 16
8
3
-2
LOAD
7
PROPEL INTERLOCK
PIPE PRESENT =
RED LIGHT
REF RELAY #1, N.C.
-2
LOAD
WHT 6
WHT 4
LOAD
REF CAB JUNCTION

BOX TERMINALS
WHT 7
BLK
RED/BLK 16
BLK
BLK
LOAD
WHT 6
RED/BLK
16
BLK
POWER FROM
OPTIONAL
RED/GRN 16
OPTIONAL
8-32
Ref. 426662 rev. A (3 of 3)

Wiring DiagramSKS-W (C27)

319153
LOCATED IN CAB ENCLOSURE

COMPRESSOR TEMP
FUEL
96193
OIL
31945
FUEL LEVEL
ALT/TACH
OIL PRESSURE
4
5
2
TACH
47
GRAY 16
WHITE 16
BROWN 16
4
5
COMP
TEMP
319153
WATER
TEMP
BLACK/ORANGE 16
YELLOW 16
319152
OIL
PRESS
47
47
7
ENGINE HR
47
96192
9
ENGINE HOUR
WHITE/GREEN 16
STOP
CONTINUED ON SHEET 2- DETAIL B
DIANOSTIC
FOR ENGINE STOP OPTION

B
-V BATTERY
-V BATTERY
20 AMP
+V BATTERY
20 AMP
+V BATTERY
KEY SWITCH
30
86
OPTIONAL GROUND KILL

STOP BUTTON 426338
85
RED 10
RED/BLUE
DIANOSTIC
(AMBER)
DRILL
HOUR
START
GREEN/BLACK 16
ENGINE
PROTECTION
12
DRILL HR
10
12
MICROWAVE OVEN
14
DRILL LIGHT POWER

GRAY 16
15
47
MAIN POWER
18
47840
ISC ON/OFF
18
F
18
16
N.O.
ISC ON/OFF
ISC 1 1800
29
23
52
24
53
50
GREEN/RED 16
13
13
16
DRILL
LIGHT
MAIN
POWER
ORANGE 16
GREEN 10
15
RED 10
50
AC
CLUTCH
FRONT
REAR
16
17
CONTROL
PANEL
MAIN
POWER
12
VOLT
START
FRONT LIGHTS
18
RED 4
GREEN/GRAY 16
24 VDC
POWER
SOLENOID
24 VDC
INPUT
DC\AC
15
15
STARTER
MICROWAVE OVEN
OUTPUT
INVERTER
50
RED 12
WHITE 12
18
16
47
ISC 2 2100
18
88194
24V LIGHT
TOP
LIGHTS
52
BLACK 16
THERMOSTAT
15
A/C CONDENSER
PRELUBE
SOLENOID
47
47
47
WITH ENGINE
HOURMETER
MAST UNLOCK
19
MAST LOCK
MAIN AIR CLOSE
47
21
MAIN AIR OPEN
22
DUST COLL
PIPE RACK
IN/OUT
24
PIPE RACK IN
CAROUSEL INDEX CW
19
20
GRAY/WHITE 16
21
BLUE/YELLOW 16
21
22
PINK/BROWN 16
22
DUST CURT
PIPE POSITIONER IN
PIPE
POSITIONER
29
PIPE POSITIONER OUT
27
BLACK/PINK 16
28
26
CAROUSEL
INDEX
26
30
25
25
YELLOW/WHITE 16
51
27
26
YELLOW/BLACK 16
28
YELLOW/BROWN 16
29
YELLOW/RED 16
28
AUTO TOOL IN
31
51
CAROUSEL
INDEX
18
18
DUST/
WATER
51
51
51
51
PIPE
POSITIONER
51
AUTO
TOOL
51
WINCH
51
DUST
CURTAIN
51
HOBO
CLAMP
51
HOBO
SWING
51
PIPE
RACK LOCK
FRONT
LIGHTS
YELLOW/GREEN 16
32
31
YELLOW/ORANGE 16
32
32
WINCH
WINCH DOWN
33
WINCH UP
33
34
DUST CURTAIN DOWN
34
35
YELLOW/GRAY 16
33
YELLOW/BLUE 16
34
WHITE/YELLOW 16
DUST CURTAIN UP
34
47
DRILL/PROPEL
36
37
38
OIL INJECTION
38
OIL INJECT
HOBO RELEASE
39
WHITE/RED 16
51
33
35
37
40
51
31
AUTO TOOL OUT
32
36
WHITE/BLACK 16
35
37
WHITE/BROWN 16
36
38
ORANGE/BLACK 16
40
ORANGE/WHITE 16
51
39
41
BLUE/WHITE 16
40
40
HOBO SWING OUT
41
HOBO SWING IN
42
42
PIPE RACK LOCK
43
43
PIPE RACK UNLOCK
44
45
PIPE RACK LOCK

47
44
OIL INJECTION LIGHT
45
THREAD LUBE
46
41
BLACK/WHITE 16
42
BLACK/YELLOW 16
42
43
45
44
LIGHT
38
45
DRILL/
PROPEL
SOLENOID
51
THREAD LUBE
SOLENOID
37
46
TIMER
PUMP
46
TIMER
BOX
51
51
49
OIL INJECTION LIGHT
51
51
44
PINK/BLUE 16
1410758
51
41
43
GRAY/RED 16
TAN 16

51
39
HOBO CLAMP
THREAD LUBE
51
51
29
31
HOBO SWING
PIPE
RACK
51
27
30
30
AUTO TOOL
47
51
28
30
39
MAIN
AIR
26
37
HOBO CLAMP
51
18
23
24
29
47
BLACK 16
51
+
TIMER
D.C.
-
51
23
BROWN/WHITE 16
25
51
MAST
LOCK
51
20
GRAY/BLUE 16
PINK/BLACK 16
27
25
58496
22
19
24
CAROUSEL INDEX CCW
BRAKE
SOLENOID
21
24
PIPE RACK OUT
35
PROPEL
20
RED/WHITE 16
23
36
DRILL
19
23
WATER INJ
DUST/WATER
47
SWITCH SHOWN ON SHEET 2
52
WHITE/GRN
MAST LOCK
20
JOYSTICK SELECTOR
GRAY/YEL 16
GREEN/GRAY 16
18
MAIN AIR
47
DUST COLLECTOR
ENGINE O.P.
BATTERIES
HEATER-A/C UNIT
GRAY 16
BLACK 4
MASTER DISCONNECT
SWITCH
135
HEAT-A/C
18
GREEN 10
RED 10
BULB
GREEN/GRAY 16
53
ALTERNATOR
110 VAC
99
DOME
LIGHT
ORANGE 16
14
GREEN 10
15
18
15
ISC 1 1800
A GREEN/GRAY
18
18
RED 6
12
13
A/C
LIGHT SWITCH
VIOLET/RED 16
16
14 GA
12 GA
LIGHT RELAY
15
20
ISC 2 2100
BACKUP ALARM
GREEN/GRAY 16
COMP
TEMP
14
RED 10
DIANOSTIC
ON/OFF
35
14
13
16
ORANGE 16
12
13
21
LOCATED ON ENGINE
12
10
AMP
DIANOSTIC
ON/OFF
BACK-UP
69499
GREEN/WHITE 16
11
15
AMP
ENGINE
PROTECTION
21 PIN CONNECTOR
96192
32189
GREEN/BLACK 16
(GREEN)
50 PIN
RIGHT BANK
ECM ENGINE
HARNESS CONNECTOR
8
9
87 NO
(RED)
31 PIN CONNECTOR
LOCATED ON ENGINE
FOR REMOTE TRAM OPTION
87a NC
STOP
GRAY/YELLOW 16
52
32189
ENGINE
HOUR
CONTINUED ON SHEET 2- DETAIL A
FUEL
YELLOW 16
47
47
47
GREEN/YELLOW 16
YELLOW 16
1
319240
4 PLACES
WATER TEMP
VOLT 319151
33
52
45
31
91
46
33
52
45

319146
319147
LOCATED IN ENGINE BOX ENCLOSURE
OIL
INJECTION
Ref. 440959 (1 of 3)
Cold Weather w/C27
58496
POWER ON
DRILL
8-33

R.H.
JOYSTICK
ROTATE
JOYSTICK
HOIST/PULLDOWN
JOYSTICK
PRPL
AUTO
FEED
PRPL
AUTO
CARD
A
BLK
PNK #6
PNK #0
GRY #6
PNK #2
A
BLK
GRN #8
GRY #6
GRN #4
A
BLK
YLW #9
YEL #3
YEL #9
BLK
WHT #6
BLU #4
BLU #8
WHT #7
6
7
9
9
+10
11
-2
+10
1
11
BLK
REF CAB JUNCTION

BOX TERMINALS
BLU #8
L.H. TRAM/ROTATE
PUMP
BRN #4
BRN #8
GRN/BLK 16
BLU #4
R.H. PUMP
POWER FROM
IGNITION RELAY
BLK
TRAM INTERLOCK
WHT 16
JACK INTERLOCK
SEE SHT 3
WHT/BRN 16
-2
BLK
RELAY #2
N.C.
WHT/BRN 16
WHT 16
11
BLK
RELAY #3
N.C.
+10
-2
1
8-34
YEL #9
WHT 16
6
5
WHT #7
PINK #6
YEL #9
RELAY #5
N.C.
GRN #8
PINK #2
GRN #4
YEL #3
WHT #7
WHT #6
BLK
L.H.
JOYSTICK
POWER FROM
DRILL/PROPEL SW.
Ref. 440959 (2 of 3)
Cold Weather w/C27
POWER FROM
DRILL/PROPEL SW.

TAN/RED 16
REF L.H.
JOYSTICK
PRPL/GRN 16
REF R.H.
JOYSTICK
TAN/RED 16
RIGHT
FRONT
JACK
PRPL/GRN 16
TAN/RED
RIGHT
REAR
JACK
BRN
U
BL
(-)
PRPL/GRN 16
PRPL/GRN 16
TAN/RED
WHT 4
TAN/RED
16
(+)
LEFT
REAR
JACK
6
5
BLK 16
3
-2
+10
REF CAB JUNCTION

BOX TERMINALS
K
BL
BRN
BL
U
RIGHT
FRONT
JACK
TAN/RED
WHT 6
JACK INTERLOCK
JACKS UP =
GREEN LIGHT
TAN/RED 16
PRPL/GRN 16
BRN
BL
K
LEFT
FRONT
JACK
11
POWER FROM
REF RELAY #1, N.C.
BL
K
U
BL
BRN
BL
K
OPTIONAL
RIGHT
REAR
JACK
BRN
U
BL
PRPL/GRN 16
BL
K
U
BL
WHT 6
TAN/RED
LEFT
REAR
JACK
BL
U
BRN
K
BL
WHT 7
PRPL/GRN 16
PRPL/GRN 16
BRN
BL
U
REF L.H.
JOYSTICK
TAN/RED 16
LEFT
FRONT
JACK
BRN
K
BL
K
BL
WHT 4
BL
U
REF R.H.
JOYSTICK
REF CAB JUNCTION

BOX TERMINALS
REF R.H.
JOYSTICK
WHT 6
REF L.H.
JOYSTICK
JACK INTERLOCK
JACKS UP =
GREEN LIGHT
WHT 6
(-)
REF CAB JUNCTION

BOX TERMINALS
BLK 16
(+)
TAN/RED
16
WHT 4
6
4
2
PRPL/GRN 16
BLK
+10
1
11
WHT
REF RELAY #1, N.C.
RED/GRN 16
3
-2
PROPEL INTERLOCK
PIPE PRESENT =
RED LIGHT
LOAD
6
5
WHT 7
LOAD
-2
WHT 4
LOAD
REF CAB JUNCTION

BOX TERMINALS
POWER FROM
PROPEL INTERLOCK
PIPE PRESENT =
RED LIGHT
+10
11
WHT
REF RELAY #1, N.C.
WHT 7
WHT 6
BLK
RED/BLK 16
BLK
BLK
LOAD
WHT 6
RED/BLK
16
BLK
POWER FROM
OPTIONAL
RED/GRN 16
OPTIONAL
Ref. 440959 (3 of 3)
Cold Weather w/C27
8-35
Cab WiringSKS-W
CAB WIRING
TOP OF CAB
8-36
ITEM
RDI P/N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
-------------------------------------------------------------------------------------------------------------
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
99307
99311
99297
99302
99329
99301
99300
99296
99298
99284
99274
99275
99276
99277
99308
99303
99304
99306
99279
99313
99353
99351
99333
99341
99362
99348
99330
99280
99281
99282
99283
99284
99285
99286
99310
99287
99288
99289
99282
99304
99308
99279
45259
45252
45257
78138
99320
99321
99331
99327
99328
99352
99339
99361
99299
99309
-----------------------------------------------------------------------------------------------------------------
COLOR
GAUGE
GRAY --------------------GREEN/YELLOW STRIPE -----WHITE -------------------BROWN -------------------BLACK/ORANGE ------------YELLOW ------------------RED ---------------------BLUE --------------------GREEN -------------------WHITE/GREEN ------------GREEN/WHITE ------------GREEN/BROWN ------------GREEN/BLACK ------------GREEN/RED --------------ORANGE ------------------GREEN -------------------RED ---------------------BLUE --------------------GREEN/GRAY -------------RED/WHITE ---------------GRAY/WHITE --------------GRAY/BLUE ---------------BLUE/YELLOW -------------PINK/BROWN --------------BROWN/WHITE -------------PINK/BLACK --------------BLACK/PINK --------------YELLOW/WHITE -----------YELLOW/BLACK -----------YELLOW/BROWN -----------YELLOW/RED -------------YELLOW/GREEN -----------YELLOW/ORANGE ----------YELLOW/GRAY ------------YELLOW/BLUE ------------WHITE/YELLOW -----------WHITE/RED --------------WHITE/BLACK ------------WHITE/BROWN ------------RED ---------------------ORANGE ------------------GREEN/GRAY
------------TERMINAL 3/16 STUD 16/14-TERMINAL 1/4 EYE 12/10 --TERMINAL 3/16 EYE 16/14 -TERMINAL 1/4 STUD 16/14 -ORANGE/BLACK ------------ORANGE/WHITE ------------BLUE/WHITE --------------BLACK/WHITE -------------BLACK/YELLOW ------------GRAY/RED ----------------PINK/BLUE ---------------TAN ---------------------BLACK -------------------VIOLET -------------------
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
10
10
12
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
10
16
16
----16
16
16
16
16
16
16
16
16
16
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------
DESCRIPTION
TERMINAL
POWER-TEMP,FUEL,OIL,VOLT --COMPRESSOR TEMP -----------WATER TEMP ----------------FUEL ----------------------OIL PRESSURE --------------TACH ----------------------TACH ----------------------RUN-KEY -------------------ECM DIAGNOSTIC LAMP -------ENGINE HOUR ---------------DRILL HOUR ----------------ETHER ---------------------KEY DRILL HOUR ------------BACK-UP ALARM POWER -------A/C COMPRESSOR ------------DRILL LIGHT POWER --------MAIN POWER ---------------STARTER BUTTON ------------FRONT LIGHTS --------------MAST UNLOCK ---------------MAST LOCK -----------------MAIN AIR CLOSE -----------MAIN AIR OPEN ------------DUST COLLECTOR ------------WATER INJECTION ----------PIPE RACK OUT -------------PIPE RACK IN --------------PIPE RACK INDEX CW --------PIPE RACK INDEX CCW -------PIPE POSITIONER IN --------PIPE POSITIONER OUT -------AUTO TOOL IN --------------AUTO TOOL OUT -------------WINCH DOWN ----------------WINCH UP -----------------DUST CURTAIN DOWN ---------DUST CURTIAN UP -----------DRILL/PROPELL -------------OIL INJECTION -------------POWER TO AC ---------------AC COMPRESSOR -------------TOP LIGHTS ------------------------------------------------ -------------------------- -------------------------- ---------------------HOBO RELEASE --------------HOBO CLAMP ----------------HOBO SWING OUT ------------HOBO SWING IN -------------PIPE RACK LOCK ------------PIPE RACK UNLOCK ----------OIL INJECTION LIGHT -------THREAD LUBE ---------------GROUND --------------------THROTTLE POSITION SENSOR ---
47
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
16
14
18
----39
40
41
42
43
44
45
46
51
99
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
COMP
QTY
QTY
EACH
6'-0" -----6'-0" -----12'-0" 6'-0"

36'-0" 6'-0"
12'-0" -----12'-0" -----18'-0" 6'-0"
12'-0" 6'-0"
6'-0"
6'-0"
12'-0" 6'-0"
6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----26'-0" ----------- 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----15'-0" -----15'-0" -----15'-0" -----65 EACH-----12 EACH-----110 EACH----3 EACH 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
------ 6'-0"
Ref. 423992
Cold Weather
Engine Skid/Cab WiringSKS-W

WIRING-CAB/ENGINE SKID
ITEM
RDI P/N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
99311
99297
99302
99329
99301
99300
99296
99298
99350
99275
99297
----99303
99304
99306
99279
99308
99309
----99292
99293
99294
99295
45258
45259
57860
57854
96331
96331
96332
17830
76582
30211
96333
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------
COLOR
GAUGE
DESCRIPTION
TERMINAL
GREEN/YELLOW STRIPE ------ 16 ---- COMPRESSOR TEMP -----------WHITE -------------------- 16 ---- WATER TEMP ----------------BROWN -------------------- 16 ---- FUEL ----------------------BLACK/ORANGE-------------- 16 ---- OIL PRESSURE --------------YELLOW ------------------- 16 ---- TACH ----------------------RED ---------------------- 16 ---- TACH ----------------------BLUE --------------------- 16 ---- RUN-KEY -------------------GREEN -------------------- 16 ---- DIAGNOSTIC LAMP -----------GRAY/BLACK STRIPE ------- 16 ---- ENGINE HOUR ---------------GREEN/BROWN STRIPE ------- 16 ---- ETHER ---------------------GREEN/RED STRIPE --------- 16 ---- BACK-UP ALARM --------------------------------------- -- ---- ---------------------------GREEN -------------------- 10 ---- LIGHT POWER ---------------RED ---------------------- 10 ---- KEY POWER -----------------BLUE --------------------- 12 ---- STARTER BUTTON POWER ------GREEN/GRAY STRIPE -------- 16 ---- LIGHT ---------------------ORANGE ------------------- 16 ---- A/C COMPRESSOR ------------VIOLET ------------------- 16 ---- THROTTLE POSITION ----------------------------------- -- ---- ---------------------------VIOLET/YELLOW STRIPE ----- 16 ---- EXTRA ---------------------VIOLET/GREEN STRIPE ------ 16 ---- EXTRA ---------------------VIOLET/BLUE STRIPE ------- 16 ---- EXTRA ---------------------VIOLET/WHITE STRIPE ------ 16 ---- EXTRA ---------------------TERMINAL-3/16 STUD-10/12 - -- ---- ---------------------------TERMINAL-3/16 STUD-16/14 - -- ---- ---------------------------CONDUIT-1" --------------- -- ---- ---------------------------CONNECTOR-CONDUIT-1" ----- -- ---- ---------------------------GROUND CABLE ------------- -- ---- ---------------------------POSITIVE CABLE ----------- -- ---- ---------------------------BATTERY ENDS-POSITIVE ---- -- ---- ---------------------------EYELETS ------------------ -- ---- ---------------------------TERMINAL STRIP------------ -- ---- ---------------------------HEATER HOSE -------------- -- ---- ---------------------------BATTERY ENDS-NEGATIVE ---- -- ---- ----------------------------
QTY
1 - -------- 24'-0"
2 - -------- 24'-0"
3 - -------- 24'-0"
4 - -------- 24'-0"
5 - -------- 24'-0"
6 - -------- 24'-0"
7 - -------- 24'-0"
8 - -------- 24'-0"
9 -------- 24'-0"
11 - -------- 24'-0"
13 - -------- 24'-0"
-- - -------- -----15 - -------- 24'-0"
16 - -------- 24'-0"
17 - -------- 24'-0"
18 - -------- 24'-0"
14 - -------- 24'-0"
99 - -------- 24'-0"
-- - -------- ------- - -------- 24'-0"
-- - -------- 24'-0"
-- - -------- 24'-0"
-- - -------- 24'-0"
-- - -------- 8 EACH
-- - -------- 26 EACH
-- - -------- 22'-0"
-- - -------- 2 EACH
-- - -------- 12'-0"
-- - -------- 12'-0"
--------- 2 EACH
-- - -------- 2 EACH
---------- 1 EACH
-- - -------- 12'-0"
--------- 2 EACH
35 --------- 344931 -- LOOM CRGTD SPLIT 1/2

36 --------- 344930 -- LOOM CRGTD SPLIT 3/8
---- -- ---- ---------------------------- --
-------- 12
EACH
---- -- ---- ---------------------------- --
-------- 12
EACH
37 --------- 344929 -- LOOM CRGTD SPLIT 1/4
---- -- ---- ---------------------------- --
-------- 12
EACH
Ref. 423997
Cold Weather
8-37
Cab/Valve Bank WiringSKS-W
WIRING-CAB/VALVE BANK
ITEM
P/N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
99313
99353
99351
99333
99341
99361
99287
99288
----99290
99299
424860
424866
350477
8304
46103
45265
45259
99339
NOTE:
8-38
COLOR
RED/WHITE
GRAY/WHITE
GRAY/BLUE
BLUE/YELLOW
PINK/BROWN
BROWN/WHITE
WHITE/YELLOW STRIPE
WHITE/RED STRIP
------------BLACK
CONDUIT-1/2"
CONNECTOR-CONDUIT-1/2"
CONNECTOR-CROUSE HIN
UNION-PIPE-1/2"
CLAMP-TUBING-1"
CONNECTOR-FEMALE-16/14
TERMINAL-3/16 STUD-16/14
PINK/BLUE
USE ITEM 10 & 19 ONLY IF MACHINE GETS

OIL INJECTION
GAUGE
16
16
16
16
16
16
16
16
-16
16
-------16
DESCRIPTION
MAST LOCK
MAST LOCK
MAIN AIR
MAIN AIR
DUST/WATER
DUST/WATER
DUST CURTAIN
DUST CURTAIN
-------OIL
GROUND
-------------------------------------------------OIL INJECTION LIGHT
TERMINAL
QTY
19
20
21
22
23
24
35
36
-38
----------
15'0"
15'0"
15'0"
15'0"
15'0"
15'0"
15'0"
15'0"
--15'0"
15'0"
9'0"
2 EA
1 EA
1 EA
1 EA
16 EA
8 EA
15'0"
Ref. 424002 rev. A

Cold Weather
Mast WiringSKS-W
WIRING-MAST (SEE SCHEMATIC 95934)
ITEM
RDI P/N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
99274
99276
99313
99353
99348
99330
99280
99281
99282
99283
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
COLOR
---------------------
99284 --99285 --99286 --99310 --45265 --45259 --35659 --56780 --350477--320167--306002--39999 --99320 --99321 --99331 --99327 --99328 --99352 --95124 --95126 --95129 --95125 --95128 --95127 ---
GREEN/WHITE STRIPE ------GREEN/BLACK STRIPE ------RED/WHITE----------------GRAY/WHITE---------------PINK/BLACK---------------BLACK/PINK---------------YELLOW/WHITE ------------YELLOW/BLACK STRIPE -----YELLOW/BROWN STRIPE -----YELLOW/RED STRIPE --------
16
16
16
16
16
16
16
16
16
16
-------------------------------
DESCRIPTION
DRILL HOUR METER ----------DRILL HOUR METER ----------MAST LOCK -----------------MAST LOCK -----------------PIPE RACK IN/OUT ----------PIPE RACK IN/OUT ----------PIPE RACK CAROUSEL --------PIPE RACK CAROUSEL --------PIPE POSITIONER -----------PIPE POSITIONER ------------
ORANGE/WHITE
BLACK/WHITE
YELLOW/GREEN
GRAY/RED
YELLOW/WHITE
YELLOW/GRAY
BLUE/WHITE
PINK/BLACK
GREEN/BLACK
A B
ORANGE/BLACK
YELLOW/BLACK
YELLOW/RED
YELLOW/BLUE
BLACK/PINK
YELLOW/BROWN
BLACK/YELLOW
YELLOW/ORANGE
A B
GREEN/BLACK
-----------------------------------------------------------------------
GREEN/WHITE
MAST VALVE
GRAY/WHITE
RED/WHITE
MAST HARNESS
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
12 EACH
28 EACH
18'-0"
2 EACH
1 EACH
1 EACH
1 EACH
5 EACH
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
26'-0"
2 EACH
2 EACH
2 EACH
20 EACH
2 EACH
20 EACH
YELLOW/WHITE
YELLOW/GRAY
BLUE/WHITE
PINK/BLACK
RED/WHITE
B
10
12
19
20
25
26
27
28
29
30
QTY
YELLOW/GREEN STRIPE ------ 16 ---- AUTO TOOL ------------------ 31 - -------YELLOW/ORANGE STRIPE ----- 16 ---- AUTO TOOL------------------- 32 - -------YELLOW/GRAY STRIPE ------- 16 ---- BREAKOUT ------------------- 33 - -------YELLOW/BLUE STRIPE ------- 16 ---- BREAKOUT ------------------- 34 - -------CONNECTOR-FEMALE-16/14 --- -- ---- ---------------------------- -- - -------TREMINAL-3/16 STUD-16/14 - -- ---- ---------------------------- -- - -------CONDUIT-3/4" ------------- -- ---- ---------------------------- 35 - -------CONNECTOR-STR-CONDUIT-3/4" -- ---- ---------------------------- 36 - -------CONNECTOR-CROUSE HIN ----- -- ---- ---------------------------- -- - -------UNION-PIPE-3/4" ---------- -- ---- ---------------------------- -- - -------P CLAMP-TUBING-1.25" ---------- -- ---- ---------------------------- --------P CLAMP-1.06--------------- -- ---- ---------------------------- -- - -------ORANGE/BLACK ------------- 16 ---- HOBO CLAMP------------------ -- - -------ORANGE/WHITE-------------- 16 ---- HOBO CLAMP------------------ -- - -------BLUE/WHITE --------------- 16 ---- HOBO SWING------------------ -- - -------BLACK/WHITE -------------- 16 ---- HOBO SWING------------------ -- - -------BLACK/YELLOW-------------- 16 ---- PIPE RACK LOCK-------------- -- - -------GRAY/RED------------------ 16 ---- PIPE RACK LOCK-------------- -- - --------------------------------- -- ---- CONNECTOR-8 WAY-MALE-------- -- - --------------------------------- -- ---- CONNECTOR-FEMALE-8 WAY------ -- - --------------------------------- -- ---- CONNECTOR-2 WAY-MALE-------- -- - --------------------------------- -- ---- TERMINAL- MALE-------------- -- - --------------------------------- -- ---- CONNECTOR-2 WAY-FEMALE------ -- - --------------------------------- -- ---- TERMINAL-FEMALE------------- -- - -------A
A B
TERMINAL
GRAY/WHITE
GAUGE
ORANGE/WHITE
BLACK/WHITE
YELLOW/GREEN
GRAY/RED
GREEN/WHITE
BLACK/PINK
YELLOW/BROWN
BLACK/YELLOW
YELLOW/ORANGE
ORANGE/BLACK
YELLOW/BLACK
YELLOW/RED
YELLOW/BLUE
Ref. 424004
Cold Weather
8-39
Engine Skid/Engine/AC WiringSKS-W

WIRING-ENGINE SKID/ENGINE/AIR CONDITIONER
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
8-40
RDI P/N
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
99311 --99297 --99302 --99329 --99301 --99300 --99296 --99298 --99350 --99275 --99277 --99308 --99303 --99304 --99306 --99279 --99307 --99333 --99355 --99380 --99309 --99291 --99304 --350477--45249 --45252 --45253 --45257 --45261 --45258 --45259 --350398 -416809 -416811 -416810 -416808 -416812 --
COLOR
GAUGE
DESCRIPTION
TERMINAL
COMP
QTY
GREEN/YELLOW ------------ 16 ---- COMPRESSOR TEMP ------------ 1 --------- 18'-0"

WHITE -------------------- 16 ---- WATER TEMP ----------------- 2 --------- 18'-0"
BROWN -------------------- 16 ---- FUEL ----------------------- 3 --------- 18'-0"
BLACK/ORANGE ------------- 16 ---- OIL PRESSURE --------------- 4 --------- 18'-0"
YELLOW ------------------- 16 ---- TACH ----------------------- 5 --------- 18'-0"
RED ---------------------- 16 ---- TACH ----------------------- 6 --------- 18'-0"
BLUE --------------------- 16 ---- RUN-KEY -------------------- 7 --------- 18'-0"
GREEN -------------------- 16 ---- ECM DIAGNOSTIC LAMP -------- 8 --------- 18'-0"
GRAY/BLACK -------------- 16 ---- ENGINE HOUR ---------------- 9 --------- 18'-0"
GREEN/BROWN ------------- 16 ---- ETHER ---------------------- 11 --------- 18'-0"
GREEN/RED --------------- 16 ---- BACK-UP ALARM POWER -------- 13 --------- 18'-0"
ORANGE ------------------- 16 ---- A/C COMPRESSOR ------------- 14 --------- 18'-0"
GREEN -------------------- 10 ---- DRILL LIGHT POWER --------- 15 --------- 2'-0"
RED ---------------------- 10 ---- MAIN POWER ---------------- 16 --------- 2'-0"
BLUE --------------------- 12 ---- STARTER BUTTON ------------- 17 --------- 12'-0"
GREEN/GRAY -------------- 16 ---- FRONT LIGHTS --------------- 18 --------- 26'-0"
GRAY --------------------- 16 ---- POWER/ENGINE HOUR --------- 47 --------- 12'-0"
BLACK -------------------- 16 ---- GROUND -------------------- 51 --------- 6'-0"
GRAY/YELLOW -------------- 16 ---- DUST COLLECTOR ------------- 52 --------- 15'-0"
RED ---------------------- 6 ---- STARTER 50 AMP ------------ 53 --------- 12'-0"
VIOLET ------------------- 16 ---- THROTTLE POSITION SENSOR --- 99 --------- 18'-0"
VIOLET/RED --------------- 16 ---- REMOTE SHUTDOWN ----------- -- --------- 12'-0"
RED ---------------------- 10 ---- BAT+/ECM P3 --------------- -- --------- 24'-0"
CONNECTOR, CABLE 1/2" ---- -- ---- ---------------------------- -- --------- 3 EACH
TERMINAL 1/2 STUD 10/12 -- -- ---- ---------------------------- -- --------- 2 EACH
TERMINAL 1/4 EYE 10/12 --- -- ---- ---------------------------- -- --------- 1 EACH
TERMINAL 3/16 EYE 10/12 -- -- ---- ---------------------------- -- --------- 1 EACH
TERMINAL 3/16 EYE 16/14 -- -- ---- ---------------------------- -- --------- 10 EACH
CONNECTOR BUTT 16/14 ----- -- ---- ---------------------------- -- --------- 5 EACH
TERMINAL 3/16 STUD 10/12 - -- ---- ---------------------------- -- --------- 2 EACH
TERMINAL 3/16 STUD 16/14 - -- ---- ---------------------------- -- --------- 12 EACH
TERMINAL #10 STUD 16/14 - -- ---- ---------------------------- -- --------- 12 EACH
40 CONNECTOR PLUG ------- -- ---- ---------------------------- -- --------- 1 EACH
PIN --------------------- -- ---- ---------------------------- -- --------- 6 EACH
SEAL PLUG --------------- -- ---- ---------------------------- -- --------- 34 EACH
3 CONNECTOR RECEPTACLE -- -- ---- ---------------------------- -- --------- 1 EACH
CONNECTOR SOCKET -------- -- ---- ---------------------------- -- --------- 3 EACH
Ref. 424010
Cold Weather
Section 9
Lubrication and Preventative Maintenance

NOTE
This section contains recommended procedures and instructions which personnel

will need in order to properly perform necessary lubrication and preventive 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.
SKS Lubrication and Preventative Maintenance
9-1
Service PointsMainframe
The photo's on the following pages show the location of the lubrication points. In most cases these
points will be connected to the auto lube system (if used), or will be connected to lubrication lines from a
remote lube bulkhead.
Auto Lube System

The auto lube system consists of an air powered pump assembly which is fitted to 120 lb. (54 kg.)
grease container (Fig. 9-1). The pump supplies grease under pressure (2500 PSI [172 bar]) to manifolds
containing injectors which supply grease to points required. A filter/regulator/lubricator supplies 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.
Lincoln Lube System

Description
Mast Crown Sheaves
Fig. 9-1 Auto Lube Pump and Grease

Container Mounted on SKS
No. of Lube Points

4
Mast Lower Sheaves
Pipe Rack BearingUpper
Pipe Rack BearingLower
CarouselUpper
CarouselLower
Pipe Rack Roller
Mast Pivot
Rear Axle
Front AxleCenter
Front AxleEnds
JacksRear
JacksFront
Pipe Rack Lock
Mast Lock
Pipe Positioner
Breakout Wrench
Pipe Rack Swing
Fig. 9-2 Auto Lube Pump Controller in Cab
9-2
Central Lube System
Fig. 9-3 Lube Point Locations
9-3
Service Points
Fig. 9-4 Crawler Service Points

1. Final Drivecheck oil level
2. Front Axlegrease 3 places
3. Pivot Shaftgrease 2 places
Fig. 9-5 Upper Mast Service Points

1. Crown Sheavesgrease 4 places
2. Rotary Gearboxcheck oil level
3. Winchcheck oil level
4. Upper Carousel Bearinggrease 1 place
5. Pipe Rack Swing Cylinders (2) grease 6 places
6. Upper Pipe Rack Support Bearinggrease 1 place
Fig. 9-6 Feed Cylinder

7. Hoist/Pulldown Sheavesgrease 4 places
9-4
Service PointsMast
Fig. 9-7 Mast Raise Cylinders

8. Upper Pinsgrease 2 places
9. Lower Pinsgrease 2 places
Fig. 9-8 Mast Pivot Area

10. Pivot Pinsgrease 2 places
9-5
Service PointsMast
Fig. 9-9 Lower Mast Service Points

11. Breakout Wrench Swing Cylindergrease 2 places
12. Breakout Wrench Pivot Pingrease 1 place (from bottom)
13. Telescoping Cylinder Pivotgrease 1 place
14. Rotate Cylindergrease 2 places
15. Clamp Cylindergrease 2 places
16. Clamp Pivot Pin - grease 1 place
17. Lower Pipe Rack Support Bearinggrease 1 place
18. Carousel Rotate Cylindergrease 1 place
19. Pipe Rack Rollergrease 1 place
20. Lower Carousel Bearinggrease 1 place
21. Lower Mast Sheavesgrease 4 places
Fig. 9-10 Lower Mast Service Points

11. Breakout Wrench Swing Cylindergrease 2 places
12. Breakout Wrench Pivot Pingrease 1 place
9-6
Fig. 9-11 Pipe Positioner

22. Pivot Pingrease 1 place
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 charts 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
For additional lubrication information, refer to vendor manuals provided in the drill
Service Manual.
Lubrication Diagrams and Charts

The machine photo's on the preceding pages shows the location of lubricator points. The lubrication
charts which follow provide information on the items to be lubricated, recommended lubricants, capacities,
lubrication periods, and special instructions where required.
9-7
Lubrication and Maintenance Chart

C/A = Check/Add if required
Interval
Service Point
Service Required
Lubricant Required 7
Capacity
Engine Oil (Cummins QST30)

Engine Oil (Cat C27)
Fuel Tank
Fuel/Water Separator
C/A
C/A
C/A
Drain water
15W-40 (factory fill)

Diesel Fuel 1
35 gal. (133 L)
19 gal. (72 L)
varies by model
50/50 Anti-freeze/Water
50/50 Anti-freeze/Water
Chevron AW MV ISO 32 3
Dexron III ATF
Water/Anti-freeze
80W-90 Gear Oil
80W-90 Gear Oil
23 gal. (85 L)
14.5 gal (55 L)
250 gal. (946 L)5
see 300 hours
varies by model
3.5 gal. (13 L)
9 qt. (8.5 L)
Engine Coolant 2
Daily
or
Each
Shift
Weekly
or
50 Hrs
C/A (QST30 engine only)

C/A (C27 engine only)
C/A
Hydraulic Oil Tank
C/A
Air/Oil Separator Tank
C/A
Water Tank (optional)
Pump Drive Gearcase (Cotta) C/A
Pump Drive Gearcase (Funk) C/A
Check Service Indicators
Air Cleaners
Check Service Indicators 4
Oil Filters
Check/Clean
Radiator & Coolers
Lubricate
Shock Sub & Air Swivel
Check/Clean
Tracks, Rollers, Sprockets
Track Frames, Axles, Mounts Inspect Integrity/Damage
Inspect Integrity/Damage
Mast & A-Frame
Cab Mountings
Deck & Surrounds
Rotary Head & Motor(s)
Check
Pulldown/Hoist Ropes
Inspect
Pulldown Sheaves
Check they are getting grease
Grease Pump Lubricator
Top Up
Pipe Thread Lubricator
Top Up
Fire Suppression System
Charged
Fire Extinguisher
Charged/Secure
Operating Controls
Check for correct function
Walk Around Inspection
Report any leaks, damage, etc
Cooler Fan
Hydraulic Filters
Coolant Filter (if equipped)
Air/Oil Separator Tank
Low Pressure
High Pressure
Rotary Gearcase
Water Pump (vertical)
Water Pump (horizontal)
Check/Torque mounting bolts

Initial Change, then every 500 hrs
NLGI No. 2 Grease
NLGI No. 1 Grease

NLGI No. 2 Grease 6
Dexron III ATF

44 gal. (167 L)
32 gal. (121 L)

C/A
80W-90 Gear Oil
Initial Change, then every 3 mnths 80W-90 Gear Oil
Initial Change, then every 300 hrs ISO 68
20 gal. (75.7 L)
1 qt. (.95 L)
42 oz. (1.26 L)
PLUS ALL ITEMS LISTED IN DAILY SERVICE
9-8

Interval
100
Hrs
Service Point
Service Required
Lubricant Required
Capacity
Winch (Braden BG8)
Initial Oil Change

(then every 6 months)
Initial Oil Change
(then every 6 months)
80W-90 Gear Oil
4 pints (1.9 L)
80W-90 Gear Oil
9 qt. (8.5 L)
Pump Drive Gearcase (Funk)
PLUS ALL ITEMS LISTED IN DAILY & 50 HRS

Track Final Drive 8
Initial Change, 200 hrs, then yearly 80W-90 Gear Oil
Winch
Initial Change at 24 hours of winch 80W-90 Gear Oil
operation
Change
Engine Oil & Filter
Change at 250 hours
Engine Fuel Filter(s)
Replace
Engine Air Filter (primary)
Replace
150 to
250
Hrs
Engine Air Filter (safety)

Engine Coolant Condition
Engine Coolant Filter
Radiator Cap
Batteries
Fuel Tank
Comp. Air Filter (primary)
Comp. Air Filter (safety)
Comp. Receiver Tank
Receiver Tank Oil
Comp. Main Oil Filter
Track Final Drive Gearboxes
Rotary Drive Spindle
Rotary Head Wearpads
Water Pump Pressure
Water Pump Oil Level
Water Pump Strainer
Water Pump Coupling
Air Conditioner Belts
Alternator Belts
Mast Pivot Pins/Bushings
Hoist/Pulldown Ropes
Track Chains
Check
Check/Refill/Test
Replace
Check Condition
Clean/Top Up
Drain Water
Replace
Check
Drain Water
C/A
Replace
C/A
C/A
Check/Refill
Drain & Replace Oil
Check Pre-Load (0.0020.004 in.)
Check/Replace (shim as required)
Check, LP=150 PSI (10 bar)
HP=375400 PSI (2628 bar)
C/A
Clean
Check
Check/Adjust
Check/Adjust
Check/Lube
Check/Adjust per Service Manual
Water/Anti-Freeze 50/50
4.8 qt. (4.5 L)

1/2 to 2 pints
(.24 to .95 L)
see daily
see daily
Distilled Water
Dexron III
80W-90 Gear Oil
80W-90 Gear Oil
80W-90 Gear Oil
80W-90 Gear Oil
3.5 gal. (13 L)

9 qt. (8.5 L)
see daily
see 50 hrs
see 50 hrs
NLGI No. 2 Grease

NLGI No. 2 Grease
PLUS ALL ITEMS LISTED IN DAILY, 50, & 100 HRS SERVICE
300
Hrs
Water Pump (horizontal)
Change Oil
(500 hrs if using special Cat oil)
ISO 68
42 oz. (1.26 L)
9-9

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 Oil (Cotta)
Water Pump (vertical)
Water Injection Pump Strainer
Dust Collector
500
Hrs
Air Conditioner Filter

Winch (Braden BG8)
Rotary Drive Spindle
Service Required
Lubricant Required
Capacity

Replace
Replace
Check/Clean
Replace
Replace
Clean
Drain/Replace
Drain/Replace
Change Oil (every 3 months)
Replace
Check Timer Cycle
(3.2 sec. between pulses)
Check air pressure
(approx. 40 psi (2.8 bar)
Replace
Drain Gear Oil/Replace
Checkadjust as necessary
Chevron AW MV ISO 32
250 gal. (946 L) 5
80W-90 Gear Oil

80W-90 Gear Oil
80W-90 Gear Oil
3.5 gal. (13 L)

9 qt. (8.5 L)
1 qt. (.95 L)
80W-90 Gear Oil
4 pints (1.9 L)
80W-90 Gear Oil

Chevron AW MV ISO 32
see daily
250 gal. (946 L)5
Water/Anti-Freeze 50/50
see daily
PLUS ALL ITEMS LISTED IN DAILY/50/150250/300 HRS

1000
Hrs or
Yearly
Track Final Drive Gearbox Oil

Hydraulic Tank
Drain/Replace
Drain, Clean, Replace Oil
PLUS ALL ITEMS LISTED IN DAILY/50/150250/300/500 HRS

2000
Hrs
or
Two
Years
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/50/150250/300/500/1000 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.
250 gal. for SKS-W, 300 gal. for SKS-13, 16.
6.
Lithium Base with 3% Molybdenum Disulfide.
7.
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 in this section.
8.
Tropical conditions require initial change at 50 hours then every 250 hours.
9-10
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
SKS-W
250 gal. (946 L)
SKS-13, 16
300 gal. (1135 L)
Fluid level should be at the half-way point on the

sight gauge on the tank, when all cylinders are
fully extended.
Fluid level should be near the top of the sight
gauge, when all cylinders are fully retracted.
9-11
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.
Compressor Lubricant Specifications

Compressor oil should conform to the following specifications:
A. Non-Detergent Turbine or Hydraulic Type Oil
Viscosity @ 100oF
160200 SSU
Viscosity @ 0oF
11,000 SSU Maximum
Viscosity Index
90 Minimum
Pour Point F
20o Lower than minimum starting temperature
Flash Point oF
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
o
184.2 SSU
Viscosity @ 210 F
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
9-12
Grade
SAE 10W
SAE 20W, 20
Compressor Lubrication Procedure
Drain Receiver Condensate:

In periods of cold weather and/or high humidity, crack receiver drain valve prior to start-up to remove water. Close when oil appears.
Check oil level each shift:

The level is checked at the upper sight glass with machine levelled. To check the oil level, 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 cover the lower sight glass and be at the center of the center
of the upper sight glass (see Fig. 9-12).
Change oil after first 50 hours, then change oil annually when using Dexron III ATF (Mobil SHC
1024 Synthetic optional), or as specified in compressor lubrication chart. Consult manufacturer for
specific recommendations if extremely severe duty is encountered.
Change both main compressor oil filter (Fig. 9-13), and compressor bearing oil filter (Fig. 9-14, if
equipped) elements every 250 hours of operation.
Lubricate control and linkage periodically.
Fig. 9-12 Air/Oil Receiver Tank Oil Level
Fig. 9-13 Main Compressor Oil Filter
Fig. 9-14 Compressor Bearing Oil Filter (optional)

9-13
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
DEUTSCHE SHELL

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

TEXACO
TOTAL

Meropa 150
Carter EP 150
Carter EP 220
9-14
Final Drive Oil (cont.)
Recommended Oils (per API/MIL Specifications)
For heavy duty gearbox operation use fully synthetic oils only.
9-15
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.
9-16
Braden BG8 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, Model 1050)

The Cat Pump, Model 1050 is factory filled with Mobil SHC 626. This is suitable for temperatures below
(-17.8oC). Special oil is available from Cat Pump dealers. If another type oil is used, be sure it meets
the specifications on the "Crankcase Oil" sheet for Cat Pumps.
0oF
Fill with oil to red dot in sight window on back of pump (Fig. 9-15).
Lubricate the wicks monthly with 2-3 drops of oil in each hole on top of the crankcase (Fig. 9-16).
DO NOT lubricate the wicks at initial start-up. Operate pump for 1015 minutes, then lubricate the
wicks. Use crankcase oil as lubricant.
Fig. 9-15 Cat Pump Oil Level Sight Window

(back of pump)
Fig. 9-16 Cat Pump Oil Filler Cap

and Wick Lubrication Points
9-17
Cat Pump Oil Specifications
9-18
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)
9-19
Cold Weather Lubricants

The following chart lists replacement lubricants that are recommended for the temperature ranges shown,
typically in extreme cold 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.
9-20
Preventive 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.
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.
Fig. 3-17 Hydraulic Tank Oil

Level and Temperature Gauge
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.
Fig. 3-19 Hydraulic Pump

Charge FilterOne filter
mounted on each side of
pump drive.
Fig. 3-18 Hydraulic

Loop FilterTwo filters
mounted on each side
of mast "A" frame.
9-21
Remove the radiator pressure cap slowly and only when the engine is cool or serious
burns could result.
Cooling System MaintenanceCummins

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 Cummins engine
manual for complete cooling system specifications and maintenance. The Cummins QST30 is equipped
with two coolant filters (Fig. 9-20). 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. 9-20 Cummins QST30 Engineright side

1. On/Off Valve
2. Coolant Filters
9-22
Fig. 9-21 Engine Radiatorleft side of machine
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.
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.
9-23
9-24
C INSPECT EVERY 9000 HRS
B INSPECT EVERY 6000 HRS
C INSPECT EVERY 4500 HRS
B INSPECT EVERY 3000 HRS
INSPECT EVERY 1500 HRS
GREATER THAN 30,000 HOURS

INSPECT EVERY 3000 HRS
LESS THAN 30,000 HOURS

A
INTERVALS FOR MAGNETIC PARTICLE INPECTION IN ACCORDANCE WITH AS1171

MACHINE SERVICE HOURS:
A CURSORY VISUAL INSPECTION SHOULD BE PERFORMED BY THE OPERATOR AT THE

START OF EACH OPERATORS SHIFT.
ALL UPPER MAST LACING JOINTS
WELDS CONNECTING LEVELING

JACKS TO MAIN FRAME
MAIN FRAME CROSSMEMBER WELDS

CONNECTING CROSSMEMBER TO MAIN BEAMS
AND GUSSETS AT OSCILLATION YOKE
MAST PIVOT TRUNION &

CYLINDER LUG WELDS
MAIN SHAFT TO MAIN FRAME

WELDS AND GUSSETS
WELD INSPECTION SCHEDULE
ALL LACING JOINTS TO MAIN MAST CHORDS

BETWEEN PIVOT SHAFT AND LIFT
CYLINDER AND THE NEXT HIGHER CELL BEYOND
THE LIFT CYLINDER LUGS
MAIN FRAME CROSSMEMBER WELDS

CONNECTING CROSSMEMBER TO MAIN BEAMS
AND GUSSETS AT OSCILLATION YOKE
ALL JOINTS CONNECTING MAST CYLINDER

LUGS TO THE MAIN FRAME
ALL AFRAME WELDS AND WELDS

CONNECTING AFRAME TO MAIN FRAME
WELDS CONNECTING LEVELING

JACKS TO MAIN FRAME
ALL CONNECTING
JOINTS TO THE PIVOT SHAFT
Preventive MaintenanceWeld Inspection
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
SKFX
Interval #1
<15,000 Hours
Inspect every 3000 Hours
Interval #2
>15,000 Hours but <25,000 Hours
SKF/SKS
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 an SKS, SKF, or SKFX 12/15 meter drill may be
repaired by completely grinding out cracks up to a maximum depth of 0.12 in. or 3mm. This approved 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.
NON-REPAIRABLE
FATIGUE CRACK
9-25
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.)
9-26
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.
9-27
Preventative MaintenanceBolted Joints
SAE Recommended Torque Values

SAE Grade 5
Tightening Torque
9-28
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
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.
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:
WINCH MOUNTING FASTENERS
ROTARY HEAD MOUNTING FASTENERS

ROTARY HEAD WEAR PAD MOUNTING FASTENERS
SEE MACHINE PARTS BOOK FOR PART NUMBERS

OF SPECIFIC FASTNERS, WASHERS AND NUTS.
SEE BOLTED JOINT MAINTENANCE IN THIS MANUAL FOR ADDITIONAL
INFORMATION CONCERNING BOTH GENERAL AND CRITICAL FASTENERS.
LEVELING JACK CAP FASTENERS
MAST RAISE/LOWER HYDRAULIC CYLINDER

PIN RETAINER FASTENERS
UNDERCARRIAGE MAIN AXLE FASTENERS
AFRAME PIVOT CAP FASTENERS

MAST PIVOT CAP FASTENERS
CRITICAL FASTENER ID & INSPECTION SCHEDULE
Preventive MaintenanceBolted Joints
9-29
9-30
GRADE
IDENTIFICATION
MARKING
A490
A325
1-8UNC GRD8----680 FT LBS LUBRICATED
CHART #1
UNDERCARRIAGE MAIN AXLE FASTNERS
NOTE "NORDLOCK" WASHERS
1/4 THRU 3/4

3/4 THRU 1-1/2
1/4 THRU 1
1 THRU 1-1/2
1/2 THRU 1
1 THRU 1-1/2
MEDIUM CARBON
STEEL, QT
MEDIUM CARBON
STEEL, QT
MEDIUM CARBON
1/4 THRU 2-1/2
ALLOY STEEL, QT
1/2 THRU 1-1/2
LOW CARBON
STEEL
SAE J429 - GRADE 2
SAE J429 - GRADE 5
ASTM A325 - TYPE 1
SAE J429 - GRADE 8
ASTM A490 - TYPE 1
ALLOY STEEL, QT
NOMINAL
SIZE
MATERIAL
SPECIFICATION
120
120
85
74
85
74
150 MIN
170 MAX
150
120
105
120
105
74
60
KSI
KSI
55
33
MIN
TENSILE
STRESS
PROOF
LOAD
STRESS
EXTERNALLY THREADED SAE - ASTM FASTENERS
55
75
90
150
7/16-20 UNF
1/2-13 UNC
1/2-20 UNF
5/8-11 UNC
1460
1240
1940
2200
1-1/2-6 UNC
1-1/2-12 UNF
1640
920
1120
840
530
480
1-1/4-7 UNC
700
530
480
350
320
1-1/4-12 UNF
640
1-1/8-7 UNC
700
1-12 UNF
1-1/8-12 UNF
640
470
1-8 UNC
430
470
7/8-9 UNC
430
7/8-9 UNC
7/8-14 UNF
7/8-14 UNF
320
300
3/4-16 UNF
350
220
260
200
130
110
65
55
40
35
25
23
(FT LB)
3/4-10 UNC
170
50
7/16-14 UNC
5/8-18 UNF
35
30
(FT LB)
SAE GRADE 5
TIGHTENING TORQUE
DRY K=.2
LUB K=.15
3/8-24 UNF
3/8-16 UNC
SIZE
CHART #2
NOTE HARDENED WASHERS

AND SAFETY WIRE
3560
3160
2000
1820
1000
900
1000
900
660
600
660
600
420
380
240
220
120
110
80
70
50
45
(FT LB)
2660
2360
1500
1360
740
680
740
680
550
460
550
460
320
280
180
170
90
80
60
55
35
35
(FT LB)
SAE GRADE 8
TIGHTENING TORQUE
DRY K=.2
LUB K=.15
7/8-9UNC GRD8----460 FT LBS LUBRICATED
3/4-10UNC GRD5-226 FT LBS LUBRICATED

(.85 PROOF LOAD)
OF SPECIFIC FASTNERS, WASHERS AND NUTS.

1/2-13UNC GRADE 8----80 FT LBS LUBRICATED

AND SAFETY WIRE
1/2-13UNC BRASS----55 FT LBS DO NOT LUBRICATE

USE LOCTITE
SAE RECOMMENDED TORQUE VALUES

1-1/4-7UNC GRD8----1360 FT LBS LUBRICATED
1-1/4-7UNC GRADE 5----952 FT LBS LUBRICATED (.85 PROOF LOAD) (EARLIER MACHINES)
1-1/4-7UNC GRADE 8----1545 FT LBS LUBRICATED (.85 PROOF LOAD)
AFRAME PIVOT CAP FASTENERS


Critical Fastener Torque ValuesSKS
A490
CHART #1
1/4 THRU 3/4

3/4 THRU 1-1/2
1/4 THRU 1
1 THRU 1-1/2
1/2 THRU 1
1 THRU 1-1/2
MEDIUM CARBON
STEEL, QT
MEDIUM CARBON
STEEL, QT
MEDIUM CARBON
1/4 THRU 2-1/2
ALLOY STEEL, QT
1/2 THRU 1-1/2
LOW CARBON
STEEL
SAE J429 - GRADE 2
SAE J429 - GRADE 5
ASTM A325 - TYPE 1
SAE J429 - GRADE 8
ASTM A490 - TYPE 1
ALLOY STEEL, QT
NOMINAL
SIZE
MATERIAL
SPECIFICATION
120
120
85
74
85
74
150 MIN
170 MAX
150
120
105
120
105
74
60
KSI
KSI
55
33
MIN
TENSILE
STRESS
PROOF
LOAD
STRESS
EXTERNALLY THREADED SAE - ASTM FASTENERS
GRADE
IDENTIFICATION
MARKING
A325
1-1/2-6UNC GRD8----2360 FT LBS LUBRICATED
UNDERCARRIAGE MAIN AXLE FASTENERS
1940
2200
1-1/2-6 UNC
1240
1-1/2-12 UNF
1120
1-1/4-7 UNC
700
1-1/4-12 UNF
640
1-1/8-7 UNC
700
1-1/8-12 UNF
640
1-8 UNC
470
1-12 UNF
430
7/8-9 UNC
470
7/8-14 UNF
7/8-14 UNF
430
300
3/4-16 UNF
7/8-9 UNC
260
3/4-10 UNC
170
150
5/8-11 UNC
5/8-18 UNF
90
55
7/16-20 UNF
75
50
7/16-14 UNC
1/2-20 UNF
35
1/2-13 UNC
30
3/8-24 UNF
(FT LB)
1640
1460
920
840
530
480
530
480
350
320
350
320
220
200
130
110
65
55
40
35
25
23
(FT LB)
SAE GRADE 5
TIGHTENING TORQUE
DRY K=.2
LUB K=.15
3/8-16 UNC
SIZE
3560
3160
2000
1820
1000
900
1000
900
660
600
660
600
420
380
240
220
120
110
80
70
50
45
(FT LB)
2660
2360
1500
1360
740
680
740
680
550
460
550
460
320
280
180
170
90
80
60
55
35
35
(FT LB)
SAE GRADE 8
TIGHTENING TORQUE
DRY K=.2
LUB K=.15
SAE RECOMMENDED TORQUE VALUES
CHART #2

(.85 PROOF LOAD)
OF SPECIFIC FASTENERS, WASHERS AND NUTS.

1/2-13UNC BRASS----55 FT LBS DO NOT LUBRICATE

USE LOCTITE

Critical Fastener Torque ValuesSKS-W
9-31
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
9-32
Drill Stem Thread Lubricator
Fig. 9-22 Drill Stem thread Lubricator System
Description and Adjustments

The SKS 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 (Fig.
9-23). Normal pressure setting is 80 PSI (5.5 bar).
The following pages give maintenance and repair instructions. Refer to parts manual for repair part numbers and kits.
Turning the knurled knob on the 3-way air valve (item 4,
Fig. 9-23) increases or decreases the duration of the grease
when the switch is activated.
Fig. 9-23 Left Rear Jack Housing

1. Filter/Water Separator
2. Regulator
3. Lubricator
4. 3-Way Air Valve
9-33
Wiggins Rapid Fill

The optional Wiggins Full Service System consolidates individual fluid fill spots on the machine, reducing
daily maintenance time. Fig. 9-24 shows how the system is connected and functions served. The functions
shown varies by model. Not all functions are present on each machine.
3/4 HOSE
3/4 HOSE
HYDRAULIC RESERVOIR
2" HOSE
1/2 HOSE
3/4 HOSE
OIL PAN
FUEL TANK
RADIATOR
WIGGINS RAPID FILL
Fig. 9-24 Wiggins Rapid Fill
9-34
Notes
METRIC CONVERSION TABLE
En g l i s h to Me tr i c
Me tr i c to E n glish
LINEAR
inches (in.)
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)
X 0.3937
X 3.281
X 0.6214
= inches (in.)
= feet (ft.)
= miles (mi.)
AREA
inches 2 (s q.in. )
feet 2 (s q.ft.)
= millimeters 2 (mm 2)
= meters 2 (m 2)
X 645.15
X 0.0929
millimeters 2 (mm 2)
meters 2 (m 2)
X 0.000155
X 10.764
= inches 2 (s q.in. )
= feet 2 (s q.ft.)
VOLUME
inches 3 (cu.in. )
qua rts ( qts . )
ga llons ( ga l. )
inches 3 (cu.in. )
feet 3 (cu.ft. )
feet 3 (cu.ft. )
fluid ounce (fl.oz.)
X 0.01639 = liters (l)

X 0 . 9 4 6 3 5 = lite rs ( l)
X 3. 7854
= lite rs ( l)
= centimeters 3 (cc )
X 16.39
X 28.317
= liters (l)
= meters 3 (m 3)
X 0.02832
X 29.57
= millileters (ml)
liters (l)
lite rs ( l)
lite rs ( l)
centimeters3 (cc )
liters (l)
meters3 (m3)
milliliters (ml)
= inches 3 (cu.in. )
X 61.024
X 1. 0567
= qua rts ( qts . )
X 0. 2642
= ga llon ( ga l. )
= inches 3 (cu.in. )
X 0.06102
= feet 3 (cu.ft. )
X 0.03531
= feet 3 (cu.ft. )
X 35.315
X 0.03381 = fluid ounce (fl.oz.)
MASS
ounces (oz.)
X 28.35
= grams (g)
pounds (lbs.)
X 0.4536
= kilograms (kg)
tons (2000 lbs.)
X 907.18
= kilograms (kg)
tons (2000 lbs.)
X 0.90718 = metric tons (t)
tons (long) (2240 lbs.) X 1013.05 = kilograms (kg)
grams (g)
kilograms (kg)
kilograms (kg)
metric tons (t)
kilograms (kg)
X 0.03527 = ounces (oz.)

X 2.2046
= pounds (lbs.)
X 0.001102 = tons (2000 lbs.)
X 1.1023
= tons (2000 lbs.)
X 0.000984 = tons (long) (2240 lbs.)
PRESSURE
o
inches H g (60 F )
pounds/sq.in. (PSI)
pounds/sq.in. (PSI)
pounds /s q. in. ( P S I )
o
inches H 2O (60 F )
bars
X 3600
= kilo pascals (kPa )
kilopascals (kPa )
X
X 6.895
= kilopascals (kPa)
kilopascals (kPa)
X 0.145
= kilograms/s q.cm. (kg/cm 2)
kilograms/s q.cm. (kg/cm2) X
X 0.0703
X 0. 069
= ba rs
ba rs
X
X 0.2488
= kilo pascals (kPa )
kilopascals (kPa )
X
X 100
= kilopascals (kPa)
kilopascals (kPa)
X 0.01
= inches H g (60 oF )
0.2961
= pounds/sq.in. (PSI)
14.22
= pounds/s q.in. (PSI )
14. 5
= pounds /s q. in. ( P S I )
o
4.0193
= inches H 2O (60 F )
= bars
POWER
horsepower (hp)
ft.-lbs./min.
X 0.746
X 0.0226
= kilowatts (kW)
= watts (W)
kilowatts (kW)
watts (W)
X 1.34
= horsepower (hp)
X 44.25
= ft.-lbs./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)
newton-meters (N-m)
newton-meters (N-m)
kilogram/meter (kg-m)
X 8.851
X 0.7376
X 7.233
= pound-inches (in.lbs.)
= pound-feet (ft.-lbs.)
= pound-feet (ft.-lbs.)
VELOCITY
miles/hour (m/h)
feet/second (ft./sec.)
feet/minute (ft./min.)
X 0.11298 = kilometers/hour (km/hr)

X 0.3048
= meter/second (m/s)
X 0.3048
= meter/minute (m/min)
kilometers/hour (km/hr)
meters/second (m/s)
meters/minute (m/min)
X 0.6214
= miles/hour (m/h)
X 3.281
= feet/second (ft./sec.)
X 3.281
= feet/minute (ft./min.)
TEMPERATURE
o
Celsius = 0.556
(oF - 32 )
Fahrenheit = (1.8 oC ) + 32
COMMON METRIC PREFIXES

me ga
kilo
hecto
deka
( M)
(k)
(h)
(da)
=
=
=
=
1 , 0 0 0 , 0 0 0 or 1 0 6
1,000 or 10 3
100 or 10 2
10 or 10 1
de c i
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
9-35
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.
9-36
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.
9-37
Maintenance Record
DATE
9-38
HOUR METER
MAINTENANCE PERFORMED
WORK
WORK
PERFORMED AUTHORIZED
BY
BY
Maintenance Record
DATE
HOUR METER
WORK
WORK
BY
BY
9-39
Maintenance Record
DATE
9-40
HOUR METER
WORK
WORK
BY
BY
Maintenance Record
DATE
HOUR METER
WORK
WORK
BY
BY
9-41
Maintenance Record
DATE
9-42
HOUR METER
WORK
WORK
BY
BY
Section 10
Optional Equipment
SKS Optional Equipment
10-1
Auto Lube System

Description
The auto lube system consists of an air powered pump assembly (fig. 10-1) which is fitted to 120 lb.
(54 kg.) grease container. The pump supplies grease under pressure (2500 PSI [172 bar]) to manifolds
containing injectors which supply grease to point required.
A filter/regulator/lubricator supplies 90 - 100 PSI (6.2 - 7 bar) to the pump.
The system is controlled by a lube & sensor controller mounted in the operator's cab (fig. 10-2). The
controller will verify delivery of lubricant into a bearing and also controls the lubrication system.
There is one manifold with five SL1 injectors, five manifolds with four SL1 injectors, and two manifolds
with two SL1 injectors, for a total of 28 lube points. The lube points are as follows:
Mast Crown Sheaves (4)
Mast Pivot (2)
Mast Lower Sheaves (4)
Mast Elevating Cylinders (4)
Pipe Rack Bearing - Upper (1)
Rear Axle (2)
Pipe Rack Bearing - Lower (1)
Front Axle - Center (1)
Carousel - Upper (1)
Front Axle - Ends (2)
Carousel - Lower (1)
Jacks - Rear (2)
Pipe Rack Roller (1)
Jacks - Front (2)
Fig. 10-1 Air Powered Lube Pump

(Reedrill Part No. 425924)
10-2
Fig. 10-2 Lube System Controller
Lube Pump Air Motor
10-3
Lube Pump Air Motor
10-4
Lube Pump Air Motor
10-5
Lube Pump Air Motor
10-6
Lube Pump Air Motor
10-7
Lube Pump Tube
10-8
Lube Pump Tube
10-9
Lube Pump Tube
10-10
Lube Pump Tube
10-11
Auto Lube Injectors

SL-1 Injector Assembly
Fig. 10-6 SL1 Injector Assembly
1. Adjusting Screw
2. Lock Nut
3. Piston Stop Plug
4. Gasket (2)
5. Washer
6. O Ring
7. Injector Body Assembly
8. Piston Assembly
9. Fitting Assembly
10. Plunger Spring
11. Spring Seat
12. Plunger
13. Packing
14. Inlet Disc
15. Packing
16. Washer
17. Gasket
18. Adapter Bolt
19. Adapter
20. Packing
SL-1 Injector Specifications
DO NOT exceed N.L.G.I. No. 1 Grade Grease.
Minimum operating pressure 1850 PSI (128 bar).
Maximum operating pressure 3500 PSI (241 bar).
Normal operating pressure 2500 PSI (172 bar).
Maximum vent (recharge) pressure 600 PSI (41 bar).
Lubricant output is adjustable from .008 cu. in. to .08 cu. in. (.13 cu. cm. to 1.3 cu. cm.).
10-12
Auto Lube Injectors
Fig. 10-7 SL-1 Injector Operation

10-13
Auto Lube System

Filter/Regulator/Lubricator
Refer to following pages for maintenance and repair of individual units.
Fig. 10-8 Filter/Regulator/Lubricator Combination
10-14
Auto Lube System

Filter Maintenance and Repair
10-15
Auto Lube System

Regulator Maintenance and Repair
10-16
Auto Lube System

Lubricator Maintenance and Repair
10-17
Notes
10-18
Auto Lube System
10-19
Auto Lube System
10-20
Auto Lube System
10-21
Auto Lube System
10-22
Auto Lube System
10-23
Auto Lube System
10-24
Auto Lube System
10-25
Auto Lube System
10-26
Auto Lube System
10-27
Auto Lube System
10-28
Auto Lube System
Fig. 10-9 Lube Controller Components
Item
1
2
3
4
5
6
7
8
9
ITEM LISTING
Qty.
Description
1
Jumper Shunt (strip of 10)
1
Green LED, Green Lens and Chrome Bezel
1
Amber LED, Amber Lens and Chrome Bezel
1
Red LED, Red Lens and Chrome Bezel
4
Standoff & Screw
1
Ribbon Cable Assembly
1
Seal for Switches
1
Processor Board Assembly
1
Power Supply Board Assembly
10-29
Fig. 10-10 Drill Stem Lubricator System (ref. 401973)
Description & Adjustments

The SKS rotary drill can be equipped with an optional automatic drill
string thread greasing system. The system uses an air powered grease
pump attached to a 35 lb. (15.9 kg.) grease container. The system
is activated by a switch on the drill control console, and the pump
delivers grease to the nozzle mounted adjacent to the drill stem.
Air supply is filtered, lubricated and regulated by the filter/regulator/lubricator mounted on the left rear jack housing (fig. 10-11).
Normal pressure setting is 80 PSI (5.5 bar).
The following pages give maintenance and repair instructions. Refer
to parts manual for repair part numbers and kits.
Turning the knurled knob on the 3-way air valve (item 4, fig. 10-11)
increases or decreases the duration of the grease when the switch
is activated.
Fig. 10-11 Left Rear Jack Housing

1. Filter/Water Separator
2. Regulator
3. Lubricator
4. 3-Way Air Valve
10-30
10-31
10-32
10-33
Notes
10-34
10-35

Grease Pump
The grease pump is shown below (fig. 10-12). For operation and repair information, refer to the following Lincoln Owner/Operator Manual for Model 82716 Series "F".
Fig. 10-12 Grease Pump and Cover (ref. 1417103)
10-36
10-37
10-38
10-39
10-40
10-41
10-42
10-43
10-44
Drilling Depth Indicator
Fig. 10-14 Depth Indicator (ref. 419448)
Fig. 10-15 Depth Indicator Readout
10-45

Set-up
Refer to Fig. 10-15

To Change Scale Factor
Display
1.
Change program disable dip switch to down position.
Scale Factor
2.
Press SEL>
3.
With SCALE FACTOR on display press ENT.
4.
Adjust flashing digit using the UP and DOWN arrows.
5.
Move the flashing digit either LEFT or RIGHT using the

side arrows < >.
6.
With scale factor set, press ENT.
7.
Press SEL> to return to operating display.
X.XXXX Current Scale Factor

X.XXXX New Value
Depth 0.0
To Adjust Scale Factor to a Known Depth:

1.
With drill pipe up press F2

RST
2.
Lower drill pipe to a known depth, for example 2 meters.
3.
Display may show an incorrect depth.
4.
Adjust scale factor as listed above. This will recalculate the current depth.
5.
Make minor adjustment to have display read exact depth, e.g. 2.0 meters.
DO NOT press F2 during the procedure. You will loose the current depth reading.
RST
10-46

Main Display Loop
Fig. 10-16 Depth Indicator Display Loop

10-47
Notes
10-48
Shock Sub
10-49
Shock Sub
10-50
Shock Sub
10-51
Shock Sub
10-52
HYDRONIC * 16/24/30/35
Eberspcher
Technical Description
Troubleshooting and Repair Manual
This Troubleshooting and Repair Manual is valid for the following heater models:
Standard Model
HYDRONIC
HYDRONIC
HYDRONIC
HYDRONIC
Cat. No.
16 - 24 V
24 - 24 V
30 - 24 V
35 - 24 V
25 2165 02 00 00
25 1817 02 00 00
25 1818 02 00 00
25 1819 02 00 00
Compact Model
Cat. No.
HYDRONIC 24 - 24 V
HYDRONIC 30 - 24 V
HYDRONIC 35 - 24 V
25 1817 05 00 00
25 1818 05 00 00
25 2041 05 00 00
Basic Heater No.

25 2165 01 00 00
25 1817 01 00 00
25 1818 01 00 00
25 1819 01 00 00
Basic Heater No.
25 1817 01 00 00
25 1818 01 00 00
25 1819 01 00 00
Compact Model
Standard Model
25 1818 95 14 86
04.2001
The information contained in this document is subject to change without notice. (s.e.e.o.)
Printed in Germany
J. Eberspcher
1 / Introduction
Table of Contents
This table of contents provides detailed information on the
contents of this Technical Description, Troubleshooting and
Repair Manual.
To find a term, use the index at the end of this document.
Technical Description
Chapter
No.
Title
Content
Introduction
Table of contents -------------------------------------------------------------------- 2

Special notation, pictures and pictograms ---------------------------------------- 4
Liability claims / warranty ----------------------------------------------------------- 7
Accident prevention ----------------------------------------------------------------- 7
Important information prior to commencing work -------------------------------- 5
- Applications in which the HYDRONIC may be used
- Intended use of the HYDRONIC
- Initial operation of the HYDRONIC and functional testing following a repair
- Content and purpose of this documentation
- Additional documentation on the HYDRONIC
Statutory requirements -------------------------------------------------------------- 6
- Directions regarding installation and repair
- Directions for operation
Safety instructions for installation and repair
of the HYDRONIC ------------------------------------------------------------------- 7
Safety instructions for operation --------------------------------------------------- 7
Product information
HYDRONIC Cat. No. and additional parts-------------------------------------- 8, 9

Catalogue numbers, control elements------------------------------------------ 8, 9
Construction of the HYDRONIC-------------------------------------------------- 10
Special features of the HYDRONIC ---------------------------------------------- 10
Function description--------------------------------------------------------------- 10
Sectional view---------------------------------------------------------------------- 11
Control diagram-------------------------------------------------------------------- 12
Functional diagram ---------------------------------------------------------------- 12
Technical data---------------------------------------------------------------------- 13
Principal dimensions -------------------------------------------------------------- 14
Installation
Installation position ------------------------------------------------------------ 15, 16

- Selection of installation position
- Installation of the HYDRONIC in a case
Rating plate ------------------------------------------------------------------------ 16
Permissible installation positions and fastening
of the HYDRONIC ----------------------------------------------------------------- 17
Installation of the water pump ---------------------------------------------------- 18
Exhaust gas piping ---------------------------------------------------------------- 19
Combustion air piping------------------------------------------------------------- 20
Coolant circuit---------------------------------------------------------------------- 21
Fuel supply --------------------------------------------------------------------- 22, 23
- Connection of intake and return pipes to the heater
- Permissible fuel line dimensions
- Fuel quality
Electrical system ------------------------------------------------------------------- 23
- Electrical connection of the HYDRONIC
Page
1 / Introduction
Troubleshooting and repair instructions
Chapter
No.
Title
Content
Page
Troubleshooting
In the event of faults, start by checking ----------------------------------------- 24

Control unit locking ---------------------------------------------------------------- 24
Release of control unit when locked --------------------------------------------- 24
Diagnosis --------------------------------------------------------------------------- 25
Fault diagnosis - flashing code --------------------------------------------------- 26
Fault diagnosis with the diagnostic unit ----------------------------------------- 27
Fault diagnosis with the ISO adapter and the KD 2000 software ------------- 28
Fault diagnosis with the modular timer ------------------------------------------ 29
Troubleshooting -------------------------------------------------------------- 30 - 33
Repair instructions
Assembly drawing ------------------------------------------------------------ 34, 35

Repair instructions
- Prior to working on the HYDRONIC,
the following safety instructions should be noted----------------------------- 36
- Removing the hood-------------------------------------------------------------- 37
- Removing the burner ------------------------------------------------------------ 37
- Removing the burner motor ---------------------------------------------------- 38
- Checking burner motor with the test unit for burner head ------------------- 38
- Removing the ignition electrodes----------------------------------------------- 39
- Removing the fuel atomizer nozzle --------------------------------------------- 39
- Removing the ignition spark generator ---------------------------------------- 40
- Checking the ignition spark generator with the test unit for burner head -- 40
- Removing the solenoid valve --------------------------------------------------- 41
- Checking the solenoid valve with the test unit for burner head ------------- 41
- Removing the heating cartridge for the nozzle holder heater---------------- 42
- Removing the flame pipe-------------------------------------------------------- 43
- Removing the temperature sensor and safety thermal cutout sensor ------ 44
- Impedances for temperature sensor
and safety thermal cutout sensor ----------------------------------------- 44, 45
- Fuel supply ----------------------------------------------------------------------- 45
- Removing the fuel strainer ------------------------------------------------------ 45
- Note regarding fuel quantity ---------------------------------------------------- 45
- Measuring the CO2 content in the exhaust gas ------------------------------- 46
- Adjusting the combustion air --------------------------------------------------- 46
- Taking the water pump apart (standard model) ------------------------------- 47
- Bus 2000 water pump -------------------------------------------------------- 47
Wiring diagram
Wiring diagram for the basic heater models ------------------------------- 48, 49

- HYDRONIC 16 - 24 V - 25 2165 01 00 00
- HYDRONIC 24 - 24 V - 25 1817 01 00 00
- HYDRONIC 30 - 24 V - 25 1818 01 00 00
- HYDRONIC 35 - 24 V - 25 1819 01 00 00
Wiring diagram, control elements ------------------------------------------------ 50
Environment
Certification------------------------------------------------------------------------- 51
Test symbol ------------------------------------------------------------------------ 51
EU declaration of conformity ----------------------------------------------------- 51
Disposal ---------------------------------------------------------------------------- 51
Service / Index
Regional offices in Germany ------------------------------------------------------ 52

Representative offices abroad ----------------------------------------------- 52, 53
List of Abbreviations --------------------------------------------------------------- 53
Index A-Z ---------------------------------------------------------------------- 54, 55
1 / Introduction
Special notation, pictures and pictograms
Liability claims / warranty
This document uses special notation and pictograms to give

emphasis to different types of information.
Their meaning and how you should respond to them are
explained in the examples below.
Adherence to the official regulations and the safety instructions

is essential if any liability claims are to be accepted.
Failure to observe the official regulations and the safety
instructions will result in exemption of the heater manufacturer
from liability.
Special notation and pictures

A bullet symbol () is used to indicate a list which is introduced
by a heading.
If an indented dash (-) occurs after a bullet point, then this list
is subordinate to the main bullet list.
Pictograms
Regulation
This pictogram, accompanied by the caption Regulation,
indicates a statutory requirement.
Failure to comply with this regulation will cause the
General Type Approval for the HYDRONIC to lapse and
invalidate the warranty and any liability on the part of
J. Eberspcher GmbH & Co.
Danger!
This pictogram, accompanied by the caption Danger, draws
your attention to an imminent danger to life and limb. Failure to
observe this instruction could result in serious injury.
Important!
This pictogram, accompanied by the caption Important!,
draws your attention to a situation which is potentially
dangerous to a person and / or the product.
Failure to observe this instruction could result in physical injury
and / or damage to the equipment.
Please note!
This instruction provides recommendations for use and helpful
tips regarding the installation and / or repair of the HYDRONIC.
Accident prevention
The general Accident Prevention Regulations and the
corresponding plant and operational protective instructions
must be observed.
1 / Introduction
Important information prior to commencing
work
Applications in which the HYDRONIC may be used
The engine-independent HYDRONIC 16 / 24 / 30 / 35 water
heaters are intended for installation in the following vehicles
(in each case, the heater output should be appropriate to the
application):
motor vehicles, especially buses
building machinery
trailers
ships and yachts
Important!
The heater may only be used and operated for the
applications specified by the manufacturer and in
compliance with the enclosed Operating Instructions
for the heater concerned.
Installation of the HYDRONIC in vehicles that are used to
transport dangerous goods within the provisions of GGVS /
TRS 003, ADR / ADR99 is not permitted.
Intended use of the HYDRONIC

preheating, de-icing of windows
heating and maintaining the heated temperature of:
- drivers cabs and work cubicles
- cargo areas
- ships cabins
- travel compartments for passengers and crew
- vehicle engines and assemblies
Content and purpose of this documentation

The Technical Description, Troubleshooting and Repair Manual
is valid for the heaters listed on the front page and contains all
the necessary technical information.
The Technical Description is contained on pages 4 to 23.
The Technical Description describes the correct installation
of the HYDRONIC in compliance with the relevant
regulations.
The Troubleshooting and Repair Manual is contained on
pages 24 to 47.
The Troubleshooting and Repair Manual describes the
troubleshooting procedures and the repair work that is
permitted on the HYDRONIC.
Additional documentation on the HYDRONIC

Operating Instructions
The Operating Instructions provide customers with the
information that is necessary for safe handling and use of the
HYDRONIC.
Spare Parts List
The Spare Parts List provides Eberspcher service partners
with the information they need to order spare parts for repair
purposes.
On the basis of its functional specifications, the HYDRONIC is

not approved for use in the following applications:
long-term sustained operations, e.g. to pre-heat and heat
- living rooms
- garages
- work enclosures, weekend homes and hunting lodges
- houseboats and similar.
Initial operation of the HYDRONIC and functional testing

following a repair
Following installation or repair of the HYDRONIC, it is
necessary to carefully bleed the coolant circuit and the entire
fuel supply system. When doing so, the instructions issued
by the vehicle manufacturer must be observed.
Prior to test running, open all heating circuits (set the
temperature controller to HOT).
During test running of the HYDRONIC, check all water
and fuel connections to ensure that they are leakproof and
securely in position.
If during operation the HYDRONIC should develop a fault,
then identify the cause of the fault using a diagnostic facility
and rectify.
1 / Introduction
Statutory requirements
To install the heater in a vehicle subject to the German
regulations governing the registration of motor vehicles
(StVZO), a General Type Approval has to be issued by the
Federal Motor Vehicle Office (Kraftfahrtbundesamt) and the
appropriate official test symbol must be indicated on the
heater rating plate.
HYDRONIC 16
HYDRONIC 24
HYDRONIC 30
HYDRONIC 35
S
S
S
S
329
297
295
296
The statutory requirements are binding for applications which

fall within the scope of the StVZO (regulations governing the
registration of motor vehicles) and should also be adhered to
in countries in which there are no specific regulations.
Where heaters are installed in vehicles that are not subject
to the StVZO (e.g. ships) the directions and installation
instructions which apply specifically to those cases must be
observed.
Directions regarding installation and repair

Installation of heaters must comply with the Installation
Instructions. In the following cases,
a) vehicle type test under 20 StVZO
b) individual test under 21 StVZO or
c) examination under 19 StVZO,
the heater must be checked by an officially certified
expert or tester of motor vehicles, a motor vehicle
expert or employee in accordance with Section 7.4 a of
the Annex to the StVZO,
and in case c) this must be certified with details of the
vehicle manufacturer, vehicle type and vehicle identification
number on the Final Approval Certificate contained in the
copy of the General Type Approval.
The validity of the Type Approval depends on this.
The Final Approval Certificate must be kept in the vehicle.
Where the heater is installed in a special-purpose vehicle
(e.g. a vehicle for transporting hazardous goods), the
installation must comply with the regulations
applicable to such vehicles.
Installation in the drivers cab or passenger compartment
of buses containing more than eight seats in addition to the
drivers seat is not permitted.
The instruction sticker, Switch off heater before filling up
contained in the Scope of Supply for the heater, must be
displayed in a prominent position in the vehicle (near to the
fuel filler connection).
Directions for operation

The heater must be switched off during refuelling.
Operation of the heater in an enclosed space is
not permitted, e.g.
- garages
- underground car parks
- multi-storey car parks
Please note!
All other installation requirements related to the General
Type Approval are printed in the relevant sections of these
Installation Instructions.
The Final Approval Certificate is contained in the Operating
Instructions.
1 / Introduction
Safety instructions for installation and
repair of the HYDRONIC
Danger of injury, fire and poisoning!
Disconnect the vehicle battery prior to starting work.
Prior to starting any repair work, switch off the HYDRONIC
and allow all hot components to cool down.
Important!
The heater may only be installed or, in the case of repair
or work under guarantee, repaired by an Eberspcher
service partner authorised by the manufacturer and
in accordance with the directions contained in this
documentation or any special installation suggestions.
Repairs by non-authorised third parties and / or
using non-genuine spare parts are dangerous and are
therefore not permitted. They will result, moreover, in lapse
of the General Type Approval of the heater and, in the case
of motor vehicles, possibly of the General Operating Permit
for the vehicle as well.
The following measures are not permitted:
- modification of heater-relevant components,
- use of non-original parts which have not been approved
by the Eberspcher company,
- departures from legal, safety and / or function-relevant
directions contained in the Installation Instructions and
the Operating Instructions, either in the installation or
operation of the heater.
This applies in particular to the electrical wiring (wiring
diagrams), the fuel supply, the combustion air and
exhaust gas piping.
Safety instructions for operation

Important!
Operation of the heater is not permitted where flammable
vapours or dust could build up, for example in the vicinity of
- fuel depots
- coal stores
- timber stores
- stores of grain and similar.
The delayed shutoff of the HYDRONIC must not be
terminated prematurely, e.g. through activation of the
battery isolating switch, except in case of emergency
cutout.
Emergency cutout emergency circuit breaker

If an emergency cutout - emergency circuit breaker should be necessary during operation, the following
procedure should be followed:
switch off HYDRONIC on the control element
or
take out the fuse
or
open the battery isolating switch
or
disconnect the HYDRONIC from the battery
Only original accessories and spare parts may be used

during installation or repair.
The HYDRONIC may only be operated using control
elements approved by the Eberspcher company.
Use of other control elements can lead to malfunctioning of
the heater / heating operation.
Prior to reinstalling a heater in a different vehicle, the
water-carrying parts of the heater must be rinsed with
clear water.
2 / Product Information
Cat. No. HYDRONIC and additional
equipment
Fig. No. / Designation
Cat. No.
Quantity / Designation
1 Universal switch
ON / OFF switch
HYDRONIC 16 - 24 V
25 2165 02 00 00
1
2
HYDRONIC 24 - 24 V
HYDRONIC 24 - 24 V
Compact model
25 1817 02 00 00
25 1817 05 00 00
1
2
HYDRONIC 30 - 24 V
HYDRONIC 30 - 24 V
Compact model
25 1818 02 00 00
25 1818 05 00 00
1
2
HYDRONIC 35 - 24 V
HYDRONIC 35 - 24 V
Compact model
25 1819 02 00 00
25 2041 05 00 00
Additionally required:
1 electric bulb
1 Mini-timer 12 / 24 V
Additional equipment which has to be ordered separately

3
Bus 2000 water pump
4
Water pump, 5000 I/h
5
Hose clip, dia. 40 mm - 47 mm
6
Hose bend 38 mm dia.
7
Connecting pipe 38 mm dia.
8
T-piece 38-38-38 mm dia.
9
Reducing piece, 38/28 mm dia.
10
Hose clip, dia. 32mm - 39 mm
11
Pipe bend, 38 mm dia.
12
Water hose 38 mm dia.
13
Exhaust pipe connection
70 mm dia.
14
70 mm dia.
15
Exhaust pipe bend 70 mm dia.
16
F uel filter
17
Hollow screw, M 14 x 15
18
Seal ring, A 14 x 18
19
Fuel intake pipe
20
Screw coupling, M14 x 1,5
21
S pheric a l bus h
22
Cap nut, M 14 x 15
23
Fuel pipe dia. 6 x 1 mm (copper),
per metre
24
Fuel hose dia. 5 x 3 mm
25
Hose clip 11 mm dia.
26
Screw coupling, M 14 x 1.5
27
Ball valve, M 14 x 1.5
28
Fuel return line
29
Va lve
30
Reducing joint 8/6 mm
31
Hood with hose connection
32
1 m flexible hose, 60 mm dia.
33
Hose clip
34
Air hose fastening set
35
Grille plastic
Cat. No. Control element, optional
The mini-timer can be combined

with the TP 41i radio remote control.
1 Modular timer -12 / 24 V
The modular timer can be combined
with the TP 41i radio remote control.
1 Modular timer fasteners
Only required where heater
is installed with trim panel
1 Radio remote control TP 4i
12 / 24 V
The TP 4i radio remote control can only be used
in combination with the modular timer.
1 Radio remote control TP 41i

12 / 24 V
The TP 41i radio remote control can be used
both independently and also in combination
with the mini-timer.
Please note!
Choice of control elements must be appropriate to
the purpose for which the HYDRONIC is to be used.
Selection criteria:
switching on / off
program preselection and / or remote control
Operating Instructions are enclosed with the control
elements. These are intended for the customer along
with the Operating Instructions for the HYDRONIC .
Control elements
10
9
12
5
4
11
3
5
28
30
18
29
25
27
24
26
25
18
23
22
18
21
18
17
19
20
16
13
14
2
15
31
35
33
32
Drawing 1
34
Construction of the HYDRONIC
Special features of the HYDRONIC
The HYDRONIC consists of a heat exchanger and a

removable burner.
The heat exchanger is a combustion chamber, consisting of a
flame pipe with integrated mixer.
If required, the flame pipe can be removed from the heat
exchanger.
The control unit and electric motor are attached under the
burner hood on the burner flange.
The fuel pump forms an integral part of the burner casing.
If the water flow rate is insufficient, the water outlet

temperature is limited by early correction.
To operate the HYDRONIC, the following additional equipment

is required:
water pump
parts for connecting to the water circulation system
additional equipment for the fuel supply
additional equipment for the exhaust gas piping
control element
The values of the temperature sensor and the safety

thermal cutout sensor are continuously compared, resulting
in improved safety since, if the difference in the values is
too great (because the water flow rate is insufficient), a fault
shutdown will occur.
The temperature rise of the heating medium is monitored

by time.
If the temperature rises too quickly (because the water flow
rate is insufficient), the heater will automatically switch itself
off and the delayed shutoff will commence, following which
the cycle starts up again.
For catalogue numbers of the additional equipment, see

pages 8 and 9.
For other additional equipment, see Additional Equipment
Catalogue.
Function description
Switching on the HYDRONIC
When the HYDRONIC is switched on, a component test
lasting 3 seconds is carried out, following which the water
pump is started up.
Note:
If the water temperature is <5C, the nozzle holder heater
is switched on for 60 seconds, during which start-up of the
burner is deferred.
Burner start-up
The electric motor starts up and drives the combustion air
blower impeller and the fuel pump.
After approx. 10 seconds the ignition is switched on, following
which the fuel solenoid valve opens.
Within this 10 second period a rotary check of the electric
motor is performed.
In the combustion chamber the combination of fuel and combustion air forms a combustible mixture.
The mixture is ignited by a high-voltage ignition spark.
The flame monitor detects the flicker frequency of the flame
and switches off the ignition spark generator.
The hot flammable gases flow through the heat exchanger and
conduct the heat to the heating medium.
Please note!
The heater works as a function of the heat requirement.
Hence switching on and off times of the burner are of
different lengths.
The water pump continues to operate the whole time that
the heater is on, as well as in the controlled intervals and
during the delayed shutoff.
10
Options
When the Lower Temperature option is selected, the
adjustable ON / OFF temperatures drop by approx. 8K.
For information regarding the ON / OFF switch for
reducing the temperature, see the wiring diagrams on
pages 48 to 50.
The water pump can also be operated independently
of the HYDRONIC if controlled appropriately.
For information regarding the additional ON / OFF switch
for separate control of the water pump, see the wiring
diagrams on pages 48 to 50.
The vehicle blower is controlled by being switched on and
off at the following temperatures.
- Water temperature >55C --> vehicle blower ON
- Water temperature <50C --> vehicle blower OFF
For further information on control of the vehicle blower, see
wiring diagrams on pages 48 to 50.
Switching off the HYDRONIC

Once the HYDRONIC has been switched off, the fuel solenoid
valve closes and at the same moment the 3-minute delayed
shutoff commences.
Following termination of the delayed shutoff, the HYDRONIC is
automatically switched off.
Please note!
The fuel continues to circulate until the heater is switched
off, including during the delayed shutoff period.
Sectional view
Drawing 2
1
2
3
4
5
6
7
8
9
10
11
Hood (CO2 setting)

Coupling
Control unit
Ignition spark generator
Flame monitor
Solenoid valve
Temperature sensor
Ignition electrodes
Combustion chamber
Safety thermal cutout sensor
Relay (vehicle blower control)
12
13
14
15
16
17
18
19
20
21
22
Fuses
Modular timer
Fan wheel
Electric motor
Fuel connection
Nozzle holder heater
Fuel atomizer nozzle
Flame pipe
Heat exchanger
Bus 2000 water pump
Exhaust gases
Fuel
Combustion air
WA
Water outlet
WE
Water inlet
11
Functional diagram
HYDRONIC
ON
HYDRONIC
OFF
Operation
Component test
Delayed shutoff
Nozzle holder heater

(On at temp. < 5 C)
From control unit,

switching on and off the nozzle holder
heater is temperature-controlled
Water pump
Solenoid valve
From control unit
Ignition spark
generator
Electric Motor
10
60
180
10
Sec.
Drawing 3
Control diagram
t C
HYDRONIC
ON
OFF
Normal operation
ON OFF
Hydronic
ON
78
73
70
65
Vehicle blower
ON
55
Vehicle blower
OFF
50
5
0
Regulation - normal
Drawing 4
12
Regulation when "Lower Temperature" selected
OFF
delayed shutdown
3 min.
2 / Product-Information
Technical Data
Test symbol
HYDRONIC 16
S
329
Heating medium
Heating capacity (at ambient temperature of 20C)
HYDRONIC 24 HYDRONIC 30 HYDRONIC 35

S
297
295
296
Mixture of water and refrigerant

(Max 50% proportion of refrigerant
16,000 W
24,000 W
30,000 W
35,000 W
Temperature control values - at water inlet
ON 73 C / OFF 78 C
Temperature control values - at water outlet
ON 85 C / OFF 118 C
Fuel
Fuel consumption (at ambient temperature of -10C)
Commercial grade diesel - DIN 51601 or

fuel oil EL - DIN 51603
2.0 l/h
2.9 l/h
Rated voltage
24 V
Lower voltage limit
19 V
3,65 l/h
4,2 l/h
105 W
120 W
The control unit is protected against undervoltage so that when the

voltage drops to the predefined limit, the HYDRONIC is switched off.
Upper voltage limit
30 V
The control unit is protected against overvoltage so that when

the voltage limit is exceeded, the HYDRONIC is switched off .
Electric power consumption

(during combustion / without circulating pump)
60 W
80 W
Water content of heat exchanger
Approx. 2 l
Water content of water circulation system
Min. 10 l
Minimum throughput of heating medium ( 200 l/h)
1,400 l/h
2,000 l/h
Permissible ambient temperature
In operation: -40C to +85C

During transportation / in storage: -40C to + 100C
For combustion air: <60C
Supply medium: -40C to +90C / for a short time up to +120C
Operating pressure (water circulation system)

CO2 - value
9 -11 vol. %
9 -11 vol. %
Approx. 18 kg
UKW 4 / KW 3 / MW 5 / LW 3
Type of protection
IP 64
Water pump standard
Voltage (20%)
Capacity / at delivery pressure
Important!
The specified technical data must be adhered to, otherwise it is
possible for the HYDRONIC to malfunction.
9.5 -11.5 vol. %
<4
Weight
Power consumption
9 -11 vol. %
< 0,04 vol. %
Smoke spot number (Bacharach scale)
Technical Data - Water Pump
3,000 l/h
< 2,5 bar
CO in exhaust gas
Radio interference suppression level
2,600 l/h
Bus 2000 water pump

24 V
110 W
250 W
5,000 I/h - 200 mbar
6000 l/h - 500 mbar
All technical data 10 %; where deviation applies, the

deviation values are specified.
13
Principal dimensions
HYDRONIC - standard model
Please note!
If there is enough space, the burner can be
swung out for routine checks - see drawing.
The principal dimensions are the same when a
hood with hose connection is mounted.
320
ca. 335
82
ca. 140
70
150
M8
29
130 min.
38
230
50
244
220
110
190
222
Min. 375 mm for dismantling

Flame pipe
302
M10 x1
220
600
Drawing 5
HYDRONIC - compact model
224
38
115
190
(-)
24
233
(+)
320
302
70
600
50
Please note!
The principal dimensions are the same when a
hood with hose connection is mounted.
38
180
153
130 min.
Drawing 6
14
3 / Installation
Installation position
The heater should be installed as low down as possible in
the vehicle, e.g. in the engine compartment or in a stowage
area.
This will ensure that the heater and water pump are
automatically ventilated.
Other installation positions are also permitted as long as
they comply with the installation requirements stated in these
Installation Instructions.
When choosing where to install the heater, care must be taken
to ensure that there is sufficient space to disassemble the
hood (130 mm) and the flame pipe (375 mm).
Regulation!
Installation in the drivers cab or passenger compartment
of buses containing more than eight seats in addition to the
drivers seat is not permitted.
Please note!
Mount the HYDRONIC below the minimum cooling water
level (expansion tank, radiator, vehicle heat exchanger).
Further information on installation (e.g. for boats and ships)
is available from the manufacturer on request.
All openings towards the outside must be splash-proof.

For installation of the HYDRONIC in a case, see page 16.
Example of a HYDRONIC installation in a bus
1
2
3
4
5
6
7
8
HYDRONIC
Water pump
Tank connection
Vehicle engine
Front heater
Roof air ducts
Roof heater
Floor heater
Drawing 7
15
3 / Installation
Installation of the HYDRONIC in a case
If installation in the engine compartment or stowage
compartment of the vehicle is not possible, than the
HYDRONIC can also be installed in a case.
The case containing the installed HYDRONIC is then affixed
to the vehicle at a suitable location, e.g. to the longitudinal
chassis frame.
It is recommended that a hood with a hose connection is
mounted for the combustion air intake. The combustion air is
then drawn in outside of the case via a flexible hose.
In this way it is possible for the combustion air to be drawn
from an area where the temperature is within the permitted
range and protection is provided against dirt accumulation.
Place a protective grille on the flexible hose.
Please note!
The case must be sufficiently ventilated from outside that
the permitted ambient temperature is not exceeded.
Air vents must be arranged on the case in such a way that
they cannot become clogged up with dirt or snow.
Any water which penetrates the case must be able to flow
out.
Example of a HYDRONIC installation in a case
Water outlet
1
2
3
4
5
6
7
Fuel
Water inlet
Case
HYDRONIC
Flexible hose with
protective grille
Water pump
Fuel lines
Water hose
Drawing 8
Rating plate
Regulation!
The year in which the heater was first commissioned must
be shown permanently on the rating plate. For this purpose
3 year numbers are printed on the appropriate area of
the rating plate. The applicable year must be indicated by
removing the years which are not applicable.
The HYDRONIC rating plate is attached to the burner and
must also be in easy view in the installed condition.
If this is not the case, a duplicate containing the same
information as the original rating plate can be attached.
The duplicate must be attached in a prominent position on
the HYDRONIC or on a cover in front of the HYDRONIC.
Heater type
Model
Model no.
Factory no.
Test symbol
Fuel
Electrical rating
Heating capacity
Operating gauge pressure
Not to be installed in
drivers cab or
passenger compartment
Data first used
The duplicate is affixed to the hood in a manner which enables

it to be taken off.
Drawing 9
16
3 / Installation
Permissible installation positions and
attachment of the HYDRONC
The HYDRONIC should if possible be installed in the normal
position.
To do this, transfer the 4 fastening holes and the through-hole
for the exhaust outlet - as shown in the diagram - to the
mounting surface and drill.
Fasten the HYDRONIC to the vehicle with the two mounting
supports.
Please note!
The support surface for the two mounting supports of the
HYDRONIC must be flat.
Depending on the installation conditions, the HYDRONIC
can be inclined, as shown in the diagrams.
During operation of the heater a deviation from the normal
position - caused by the incline of the vehicle - of up to +15
in all directions is possible.
Permissible installation positions and template for holes for the

HYDRONIC - standard model and compact model
Compact model - must be installed in level position with the
deviations shown in the diagram.
15 15
5
5
15 15
5
5
Standard model
Must be installed in level position with the deviations
shown in the diagram
Can also be installed in vertical installation position
without any deviations.
Hole template for the HYDRONIC - standard model
and compact model
320
82
9 (4x)
4,5 at M4
75
150
2,9 at B3,9
82
Drawing 10
17
3 / Installation
Installation of the water pump
The water pump must be installed at the lowest point in the
water circulation system, taking into account the installation
position - see diagrams.
Transfer the four fastening holes for the water pump holder to
the mounting surface - as shown in the diagram - and drill.
Attach the water pump to the vehicle with the holder.
Please note!
No shutoff valves may be inserted in the water hose for the
water pump (intake side).
The surface in contact with the water pump holder must
be flat.
Water pump - standard model

Principal measurements and permissible installation positions
Template
for holes
112
85
100
9 (4x)
90
219
55
Delivery curve
P
[bar]
0,7
0,6
55
85
0,5
0,4
0,3
0,2
0,1
24V
Drawing 11
V
8
[103 l/h]
Bus 2000 water pump

Principal measurements and permissible installation positions
Template
for
holes
85
9 (4x)
240
10
153
85
113
98
Delivery curve
P
[bar]
1,0
0,9
98
85
0,8
0,7
90
0
12
12
0
0,6
0,5
0,4
Pump components can be

rotated by 3 x 120 to the motor part.
120
24V
0,3
0,2
0,1
Drawing 12
18
[10 3 l/h]
3 / Installation
Exhaust gas piping
Regulation!
The outlet must be implemented in such a way that insertion
of a 16 mm dia. ball is not possible.
Exhaust pipes must be laid in such a way that there is no
likelihood of any exhaust gases entering the vehicle interior.
The functioning of parts of the vehicle which are important
for its operation must not be impaired.
It must not be possible for condensate or water to collect
in the exhaust gas line.
Drain holes are permitted. These must convey the fluid
through the interior in sealed pipes to the outside.
The exhaust pipe opening should face upwards or to the
side or, if the exhaust piping is laid below the floorpan of
the vehicle, it should extend to near the side or rear of the
drivers cab or vehicle.
Danger of combustion and poisoning!

Whenever combustion occurs high temperatures and
exhaust gases with toxic elements are generated.
- Do not perform any work on the exhaust gas piping while
the heater is on.
- If any work needs to be done to the exhaust gas piping,
switch off the HYDRONIC, wait until all components have
completely cooled and, if necessary, wear protective
gloves.
- Do not breathe in any exhaust gases.
Important!
The entire exhaust gas piping is very hot both during and
immediately after operation of the heater.
- Mount exhaust pipe with sufficient separation away from
parts which are sensitive to the heat.
- In particular, look out for fuel lines (plastic or metal),
electric lines and brake hoses.
- Exhaust pipes must be securely fastened (with a
recommended standard distance 50 cm) in order to avoid
damage through vibration.
- Lay the exhaust gas piping so that the exhaust gases are
not drawn in directly as combustion air.
- When installing the HYDRONIC in a case and with a short
exhaust pipe, the exhaust gas piping must run to the
outside through the bottom of the case.
- The functioning of parts of the vehicle which are important
for its operation must not be impaired (take care to allow
sufficient separation).
- The opening of the exhaust gas pipe must not be allowed
to become clogged up with dirt or snow.
- The opening of the exhaust gas pipe must not be pointing
in the direction of travel.
Fitting exhaust gas piping

The exhaust gas piping can be laid out as shown below. See
also page 20, Diagram 14:
Exhaust pipe connection, bent by 60, dia. = 70 mm
Exhaust pipe connection, dia. = 70 mm
Exhaust pipe bend, dia. = 70 mm
Rigid exhaust pipe from unalloyed or alloyed steel,
dia. = 70 mm, length max. 4 m, wall thickness min. 1 mm
Also required:
1 exhaust pipe bend, dia. = 70 mm
1 end sleeve
Flexible exhaust pipe out of alloyed steel
dia. = 70 mm, length max. 4 m
Also required:
1 end sleeve
Please note!
The rigid exhaust pipe and the flexible exhaust pipe are
currently not included in the Eberspcher scope of supply.
If required, these exhaust pipes must be obtained from a
specialist shop.
If necessary, you can make the end sleeve with crossbars
(out of metal) for the exhaust pipe yourself (see diagram).
End sleeve with crossbars
70
Attach the exhaust pipe with pipe clips to the floorpan of the
vehicle in suitable places.
Mount an end sleeve with crossbars on the exhaust pipe.
The exhaust gas piping can be bent a max. 3 x 90, in which
case the overall length is reduced by 0.5 m for each 90
bend.
To enable the condensate to flow out, drill a hole 5 mm dia. at
the lowest point on the exhaust gas piping.
7,5
35
30
Drawing 13
19
3 / Installation
Examples of exhaust gas piping
1 HYDRONIC
2 Exhaust pipe connection
3 Exhaust pipe connection, 60
4 Exhaust pipe bend
5 Exhaust pipe
6 End sleeve
7 Flex. exhaust pipe
Please note!
Items 5-8 are not included
in the Eberspcher scope
of supply.
Drawing 14
Combustion air piping

Regulation!
The necessary combustion air must be drawn from the
outside.
The combustion air inlet must be implemented in such a
way that insertion of a 16 mm dia. ball is not possible.
Please note!
When laying the combustion air piping the following should
be noted:
- The combustion air inlet must always be uncovered.
- Lay the combustion air inlet so that exhaust gases are not
drawn in directly as combustion air.
- Do not position the combustion air inlet so that it faces the
vehicles air stream.
- Combustion air inlet must not be allowed to become
clogged up with dirt or snow.
- Any water that has penetrated must be able to drain off.
Combustion air intake when the HYDRONIC is installed

in a case
When installing the HYDRONIC in a case, it is recommended
that a hood with hose connection is mounted to draw in the
combustion air.
The combustion air is then drawn in outside of the case via
a flexible hose.
In this way it is possible for the combustion air to be drawn
from an area where the temperature is within the permitted
range and protection is provided against dirt accumulation.
Place a protective grille on the flexible hose. If the hood with
hose connection is not used, the combustion air must be
drawn in through an air vent with an effective minimum crosssection corresponding to a pipe of 60 mm dia.
Please note!
The air vent for the combustion air must be positioned on
the case in such a way that
- it cannot become clogged up with dirt or snow
- exhaust gases cannot be drawn in.
Examples of combustion air piping

Combustion air intake through a
louvred plate
Drawing 15
20
Combustion air intake with a

flexible hose, 60 mm dia., max.
1 m long.
3 / Installation
Coolant circuit
Warning: contact with hot parts could cause burning.
The coolant and the coolant circuit components can get
very hot.
- Lay and attach water-carrying parts in such a way that
there is no danger of burning to humans, animals or any
temperature-sensitive material from either heat radiation
or direct contact.
- Prior to working on the coolant circuit, switch off the
HYDRONIC and wait until all components have cooled
down completely, if necessary wearing gloves.
Please note!
When installing the HYDRONIC, note carefully the direction
of flow of the coolant circuit.
The water hoses must be laid in such a way that they are
buckle-free and if possible are sloping upwards.
When laying the water hoses, make sure you leave a
sufficient gap between hoses and any hot parts of the
vehicle.
All water pipes must be protected against chafing and
excessively high temperatures.
Secure all hose connections with hose clips (fastening

torque 1.5 Nm).
Re-tighten the hose clips after the vehicle has been in
operation for 2 hours or 100 km have been driven.
The minimum water through-flow is only guaranteed if the
difference in temperature between the heating medium inlet
and outlet does not exceed 10C during combustion.
There must be at least 10 litres of coolant in the coolant
circuit.
Only relief pressure valves with an opening pressure of
min. 0.4 - max. 2 bar may be used in the coolant circuit.
Before using the heater for the first time or after changing
the coolant, the entire coolant circuit must be bled so
that it is bubble-free in accordance with the manufacturers
specification and, if necessary, it must then be topped up
with coolant approved by the vehicle manufacturer.
Installation example
The HYDRONIC is installed into the coolant circuit of the
vehicle.
Another installation variant is to install a separate coolant
circuit for the HYDRONIC with an expansion tank.
Water circulation system

The diagram shows the HYDRONIC integrated into the coolant
circuit of a bus.
Convector heater
Space heater
Convector heater
Convector heater
Space heater
Space heater
To veh. engine or
expansion tank
From veh. engine or

expansion tank
Front heater
HYDRONIC
Water pump
Drawing 16
21
3 / Installation
Fuel supply
Regulation!
When laying fuel lines and installing an additional fuel tank,
45 and 46 StVZO (regulations governing the registration
of motor vehicles) must be adhered to.
Excerpt from 45 and 46 StVZO:
- Fuel tanks may not be contained in passenger
compartments or drivers cabs of buses.
They must be positioned in such a way that in the event of
a fire the exits are not directly endangered.
- Fuel lines may not be contained in compartments or
drivers cabs of buses.
Danger of fire, explosions and poisoning!

When working on the fuel supply, shut down the vehicle
engine and the HYDRONIC.
Avoid naked flames while handling fuel.
Do not smoke. This applies also where fuel can be detected
only by its characteristic smell.
Do not breathe in fuel vapour.
Important!
Secure all connections on fuel hoses with clips.
Use connecting hoses (approx. 50 mm long) when
connecting up fuel pipes and secure with clips.
Cut fuel hoses and pipes to length only using a sharp knife.
Cuts must not be pressed in or have any burr.
Exhaust pipes must be securely held in position (with a
recommended standard distance 50 cm) in order to avoid
damage and / or noise during vibration.
Lay the fuel lines in such a way that twisting movements of
the vehicle and movements of the engine and similar cannot
have any adverse effect on durability.
Fuel lines must be protected against mechanical damage.
Fuel carrying parts must be protected against heat arising
due to malfunctions.
Fuel lines must never be laid or fastened directly next to
exhaust piping for the HYDRONIC or the vehicle engine.
Where lines cross, make sure there is always sufficient
space separating the hot parts, and if necessary apply heat
protection sheets.
Dripping or vaporizing fuel must not be allowed to collect or
ignite on hot parts or on electric fixtures.
Connection of intake and return pipes to the heater

The fuel is taken from the vehicle fuel tank or from a separate
fuel reservoir.
Any of the normal fuel hoses or pipes used in vehicle
manufacturing, e.g. steel, copper or plastic pipes, can be
used as fuel lines.
Fuel hoses and fuel pipes are available as additional
equipment - see pages 8 and 9 or the Additional Equipment
Catalogue.
Fuel
Please note!
When operating with one-line systems --->
please consult the manufacturer.
22
Drawing 17
3 / Installation
Permissible fuel line dimensions
Fuel quality
Inner diameter of the intake pipe = 6 mm dia. to 8 mm dia.
All commercial grade diesel which complies with DIN 51 601

may be used as fuel. Any heating oils which comply with class
EL, DIN 51 603 can also be used.
At temperatures below 0C diesel must be used as specified
in the table below.
Inner diameter of the return pipe = 6 mm dia. to 8 mm dia.

Permitted intake head and length of intake pipe:
Where intake head is up to 1.5 m ---> max. length = 25 m.
Where intake head is 1.5 m to 4.0 m --->
max. length = 15 m.
Permitted line lengths of the return pipe
Max. length = 18 m
Temperature
Please note!
Admixing waste oil is prohibited.
It must be possible to filter the fuel under all conditions of
use (as specified in DIN EN 116).
The HYDRONIC is not approved for use with PME (biodiesel
according to DIN V 51606).
Winter diesel
Summer diesel or EL
fuel oil
Additive
Petroleum Regular-grade
petrol
0 C to -10 C
100%
or
70%
30%
-10 C to -15 C
100%
or
50%
50%
-15 C to -20 C
70%
----
----
30%
-20 C to -25 C
50%
----
----
50%
or
30%
----
or
30%
----
Electrical system
Regulation!
Electrical leads, switches and control units for heaters must
be arranged in the vehicle so that their operation under
normal operating conditions is not impaired in any way.
All lines leading from heaters to the outside must be laid so
that they are splash-proof at the opening.
Electrical connection of the HYDRONIC

The detailed electrical connection of the HYDRONIC and the
control element is shown in the wiring diagrams on pages 48
to 50.
Please note!
It must be easy for the user to determine the operating state
(as a minimum, whether switched on or off).
The wire sizes specified in the wiring diagram must be noted

and adhered to.
Run positive-negative cable section from the HYDRONIC
directly to the battery and connect up.
When laying the electrical lines care must be taken to ensure
that their insulation cannot be damaged as a result of wear,
bending, becoming caught or the effects of heat.
23
4 / Troubleshooting
In the event of faults, start by checking
Test equipment
Defective wiring (short-circuits, open circuit).
The following test equipment can be used for troubleshooting

and repair.
Visual inspection for

- corroded contacts
- defective fuses
- damaged electric lines, joints and connections
- damaged exhaust gas and combustion air piping
Battery voltage on starting up the heater <19 V (measure
voltage on control unit).
Check fuel supply.
When changing over to Winter mode:
is summer diesel fuel still in the line?
Delayed start-up --> nozzle holder heater switched on for
60 seconds.
The Bus 2000 water pump and the HYDRONIC are
automatically switched off shortly after start-up if there is
insufficient coolant or the pump impeller is blocked.
Control unit locking

The control unit is locked if any of the following malfunctions
occurs:
Overheating
If the HYDRONIC overheats 3x in succession - fault code
012, displayed as AF 015 ---> the control unit is locked.
Flame during delayed shutoff
If the fault Flame during delayed shutoff is reported 3x
in succession - fault code 058, displayed as AF 016
---> the control unit is locked.
Too many start attempts
After a sequence of ten unsuccessful attempts at starting
up the HYDRONIC - fault code 052, displayed as AF 050
---> the control unit is locked.
Release of control unit when locked

Release of the control unit following locking is described on
pages 26 to 29.
24
Diagnostic unit
Additionally required:
adapter cable
SO adapter
Additionally required
adapter cable
Test unit for burner head
4 / Troubleshooting
Diagnosis
The HYDRONIC electronic control unit can store up to five
faults.
The faults can be read from the control unit and displayed by
one of the following means:
Flashing code
After connection of an LED and a series resistor (approx.
1 k / 11 W) the function / fault is displayed as a flashing
code.
For details of the flashing code signals and the
corresponding faults, see table on page 26.
LED and series resistor

Connector B2
1
4
B2
3
6
2
5
Compartment 5
Resistor
1 3 5 7
2 4 6 8
Connector B1
B1
Compartment 2
Diode
Drawing 18
Diagnostic unit
After connection of the diagnostic unit, the function / fault is
shown on the display as a number.
For information regarding the connection and operation of
the diagnostic unit, see page 27.
To connect the diagnostic unit, an adapter cable is
required.
For fault code table, see pages 30 to 33.
diagnostic unit
ISO adapter with KD 2000 software

Following installation of the KD 2000 software and
connection of the ISO adapter, the function / fault is shown
as a number on the display.
For information regarding the connection and operation of
the ISO adapter, see page 28.
To connect the ISO adapter, an adapter cable is required.
ISO adapter
Drawing 19
Modular timer installed in the vehicle

When a modular timer is installed, the function / faults can
be shown as a number on the display.
For information regarding operation of the modular timer,
see page 29.
modular timer
External diagnostic system

With an external, vehicle-specific diagnostic system
---> consult the vehicle manufacturer.
25
4 / Troubleshooting
Fault diagnosis - flashing code
(LED with series resistor)
Release of control unit when locked
The electronic control unit can store up to five faults.

The function or type of fault is output by the control unit as a
flashing code and displayed by an LED (with series resistor).
The LED with series resistor is connected to the cable harness
of the HYDRONIC, using the 8-pin connector, pin 12, blue /
white cable 1 mm (see wiring diagram page 25).
The remedial measures are described in the fault code tables
on pages 30 to 33 under the appropriate fault code.
With the HYDRONIC switched on, apply positive for approx. 3

seconds to the 8-pin cable harness connector, pin 13, yellow
/ red 1 mm cable (external excitation of the water pump)
--> the control unit is unlocked.
Additional variant from control unit 25 1818 53 00 00
Apply positive for approx. 3 seconds to the 8-pin cable harness connector, pin 9, blue / black 1 mm cable (fault in Bus
2000 water pump) --> the control unit is unlocked.
Flashing code
400 ms interval at
start of flashing code
8 sec.
Operation without fault
Flame monitor
Fault code 16, 51, 58
Safety time overshoot

Fault code 50 , 52
Flame loss
Fault code 54
Overheating
Fault code 12, 15
Burner motor
Fault code 32, 33
Undervoltage cutout
Fault code 11
Overvoltage cutout
Fault code 10
Temperature sensor
Fault code 14, 60 ,61, 71, 72
Connection fault
Fault code 20, 21, 25, 37 - 39
44 - 49, 80 - 83
Control unit
Fault code 90 - 97
Drawing 20
26
Light duration - short pulse:

Light duration - long pulse:
0,4 sec.
2,0 sec.
Interval between the pulses: 0.4 sec.

Period of a flashing sequence: 8.0 sec.
16 sec.
4 / Troubleshooting
Fault diagnosis with the ISO adapter
and the KD 2000 software
Installing KD 2000 software on the PC
To connect the ISO adapter, an adapter cable is
required.
Place CD-ROM in the CD drive.

Double click on the file "setup.exe" and follow the
instructions of the SETUP program.
The electronic control unit can store up to 5 faults.

The faults can be read out and displayed with the ISO adapter
and the KD 2000 software.
In heaters up to factory no. 12000, faults 1-5 are displayed.
With heaters from factory no. 12001, measured data is shown
in addition to faults 1-5.
Query / clear fault memories F1-F5 and / or cancel control

unit locking
Connect ISO adapter

Detach the HYDRONIC cable harness.
Connect the adapter cable to the cable harness, as shown
in the diagram
Connect the adapter cable to the ISO adapter.
Connect the SUB-D connecting cable with the PC and the
ISO adapter.
On the PC, start the KD 2000 software

- On the desktop, double-click on the "KD 2000" icon
- Select heater type
- Press "GO" button
Clear fault memories and / or cancel control unit locking
- Click on Clear fault memory button
---> the stored faults F1-F5 are cleared and the control
unit is unlocked.
Diagnosis complete
Press "STOP" button --> interrogation of fault memory is
terminated.
Please note!
It is essential that the correct installation sequence is followed.
1
2
3
ISO adapter
Adapter cable
SUB-D connection cable
Drawing 22
28
4 / Troubleshooting
Fault code
Fault Description
Cause
Remedial measures
000 No fault
-----------------
010 Overvoltage --> disconnection
Overvoltage (>30 V) exists for a minimum of 20 seconds without interruption

at the control unit - HYDRONIC not working.
Unplug 18-pin connector on the control unit and start up vehicle engine.
Measure the voltage between PIN 15 (red 2.5 mm cable) and PIN 16
(brown 2.5 mm cable) if the voltage >30 V --> check alternator controller.
011 Undervoltage --> disconnection
Undervoltage (<19 V) exists for a minimum of 20 seconds without

interruption at the control unit - HYDRONIC not working.
Pull out the 18-pin connector on the control unit, start up the vehicle
engine, measure the voltage between PIN 15 (red 2.5 mm cable) and
PIN 16 (brown 2.5 mm cable).
The measured value and the voltage at the battery should not deviate.
In the event of a voltage drop, check the fuses, the supply lines, the
chassis earth connections and the positive terminal connection point of
the battery for correct contact
012 Overheating
Safety thermal cutout sensor temperature >130C

Check water circulation system:
- Check all hose connections for leaks
- Bleed water circulation system
- Check valves in water circulation system and, if necessary, replace
- Temperature difference between water inlet and water outlet must
<10 K; if not, --> check minimum throughput of the heating medium,
see values in the Technical Data.
Check water pump and if necessary replace
Check safety thermal cutout sensor and if necessary replace (see diagram
on page 45)
014 Temperature difference between

temperature sensor and safety
thermal cutout sensor too big
Difference between measured values of temperature sensor and

safety thermal cut-out sensor above permitted limits for an extended period.
Check mounting of both sensors, if necessary, tighten up sensors,
tightening torque on both sensors 2.5 +0.5 Nm.
Check temperature sensors and safety thermal cutout sensor (see
diagrams, pages 44 and 45).
Check minimum throughput of the heating medium. See values in the
Technical Data.
015 Operation disable - control unit is locked
Fault code 012 Overheating has been displayed three times in succession
--> fault code 015 displayed.
Control unit unlocked by clearing the fault memory (see pages 26 to 29).
For remedial measures, see fault code 012.
Fault code 058 Flame during delayed shutoff has been displayed three
times in succession --> fault code 016 displayed.
Control unit unlocked by clearing the fault memory (see pages 26 to 29).
30
4 / Troubleshooting
Fault code
Fault Description
Cause
Remedial measures
020 Ignition spark generator - open circuit
Control line from ignition spark generator to the control unit has open circuit
or short circuit.
Check cable section from the ignition spark generator to the control unit
and, if necessary, eliminate open circuit or short circuit.
Check functioning of the ignition spark generator only with the test unit for
burner head; if necessary ,replace the ignition spark generator.
If the fault could not be eliminated by taking the remedial measures listed
above, --> replace control unit.
High voltage
021 Ignition spark generator - ground leakage
High voltage
Control line from the ignition spark generator to the control unit has ground
leakage.
Check cable section from the ignition spark generator to the control unit
and, if necessary, eliminate ground leakage.
burner head; if necessary, replace the ignition spark generator.
If the fault could not be resolved by taking the remedial measures listed
025 Diagnostic output - short circuit
Blue / white 1 mm cable from the 18-pin control unit connector,

compartment 12 to the 8-pin cable harness connector, compartment 2 has
short-circuit against +UB
Check lead and connections and, if necessary, eliminate short circuit.
032 Burner motor does not turn - on start-up

033 Burner motor does not turn - during operation
Fan wheel is chafing or is blocked.

Burner motor faulty.
Generator voltage too low.
Check that fan wheel is running freely.
Check lines and connections to the burner motor.
Check functioning of the installed burner motor only with the test unit for
burner head; if necessary, replace the burner motor.
Apply max. 12 V at burner

motor
Fuel pump is blocked.

Check that fuel pump is running freely. If necessary, replace the burner.
037 Water pump - fault
Check in advance:
Is Bus 2000 water pump installed?
Is Bus 2000 water pump cable section Diagnosis connected?
Does the Bus 2000 water pump have any power?
If yes
- detach plug connection from the Diagnosis cable section.
Start HYDRONIC - if fault code 037 is no longer displayed,
then check the Bus 2000 water pump for dry running
and / or for blockages.
- If fault code 037 continues to be displayed, then apply the
remedial measures described for the water pump (standard
model).
Water pump (normal model) is installed?
If yes
- detach plug connection from the Water pump cable section,
apply power to the 2-pin connector on the Water pump
cable section and check for correct functioning.
If the water pump is functioning OK, then check fuse (15A),
cable section and water pump connections --> if fault code
037 continues to be displayed, then replace the control unit.
31
4 / Troubleshooting
Fault code
Fault Description
Cause
Remedial measures
039 Vehicle blower control - short circuit
Black 1 mm cable from the 18-pin control unit connector, compartment

6 to the 8-pin cable harness connector, compartment 7, and from there to
the blower relay has short-circuit.
Check mounting of the relay.
Replace relay.
above, then replace control unit.
044 Water pump - relay coil open circuit

045 Water pump - relay coil short circuit
Check mounting of the relay on the control unit.

Replace relay.
046 Solenoid valve - open circuit
"Solenoid valve" cable section from the control unit (connector position D)
to the solenoid valve has open circuit or ground leakage.
Check leads and connections to solenoid valve, if necessary eliminate
ground leakage.
Replace solenoid valve coil.
047 Solenoid valve - short circuit
Solenoid valve cable section from the control unit (connector position D)
to the solenoid valve has short-circuit.
Check leads and connections to solenoid valve, if necessary eliminate
short circuit.
Replace solenoid valve coil.
048 Nozzle holder heater relay coil open circuit

049 Nozzle holder heater relay coil short circuit
Check mounting of the relay on the control unit.

Replace relay.
The control unit remains locked through 10 attempts at start-up without

flame detection.
Control unit unlocked by clearing the fault memory with modular timer,
diagnostic unit or KD 2000 (see pages 26 to 29).
051 Flame monitor reports

"Flamme vor Brennstoff" [Flame without fuel]
Replace burner.
052 No start or safety time overshoot
No flame was detected within the ignition phase.

Check combustion air inlet and exhaust gas piping.
Check fuel supply (supply and return).
Check flame pipe to make sure it is correctly mounted in the heat
exchanger.
burner head; if necessary, replace the ignition spark generator.
Check ignition electrode, adjust and, if necessary, replace.
Check electric leads and connections.
Check flame monitor for dirt accumulation and, if necessary, clean.
Replace fuel atomizer nozzle.
High voltage
Take care when checking the
ignition spark generator!
32
4 / Troubleshooting
Fault code
Fault Description
Cause
Remedial measures
054 Flame loss during operation
HYDRONIC has ignited, detected the flame and reports flame loss twice
within an operating period of 60 minutes.
Check fuel supply (supply and return).
Measure the amount of CO2.
Replace fuel atomizer nozzle.
058 Flame not extinguished during delayed shutoff
Flame monitor reports 30 seconds after delayed shutoff ON that the flame
has not gone out.
Check heat exchanger and clean as necessary, then measure the amount
of CO2.
Check solenoid valve with the test unit for burner head and, if necessary,
replace.
If fuel continues to be delivered during the delayed shutoff --> replace
fuel pump.
060 Temperature sensor - open circuit

061 Temperature sensor - short circuit
Temperature outside operating range.

Check plug connection for temperature sensor and line to the control unit.
Check temperature sensor (see diagram on page 44).
071 Safety thermal cutout sensor - open circuit
Temperature outside operating range.

Check plug connection for safety thermal cutout sensor and line to the
control unit.
Check safety thermal cutout sensor (see diagram on page 45).
072 Safety thermal cutout sensor - short circuit
081 Combustion indicator light - short circuit
Yellow/white 1 mm cable from the 18-pin control unit connector,

compartment 8 to the 8-pin cable harness connector, compartment 3, and
from there to the combustion indicator light has short-circuit.
Check combustion indicator light and, if necessary, replace.
083 Fault indicator light - short circuit
Green 1 mm cable from the 18-pin control unit connector, compartment 5

to the 8-pin cable harness connector, compartment 6, and from there to
the fault indicator light has short-circuit.
Check fault indicator light and, if necessary, replace.
090, 092 Control unit faulty

093, 094
097
Replace control unit.
091 External interference voltage
Possible causes:
Incorrect setting of the ignition electrodes - adjust ignition electrodes.
Remove battery charger or other source of interference voltage.
33
5 / Repair Instructions
Assembly drawing
5
1
2
3
4
5
6
7
8
9
10*
11
12
13
14*
15
16
17
18
19
20*
21
22
23

Flexible hose
Protective grille
Hose clip
Hood
Fan wheel
Control unit
Electric motor
Cable section
Baffle plate
Burner casing with
integrated fuel pump
Cartridge heater
Temperature switch
Nozzle holder
Baffle plate
Fuel atomizer nozzle
Ignition electrodes
Solenoid valve
Flame pipe
Heat exchanger
Temperature sensor
Drawing 23
34
17
14*
12
13
16
18
15
19
11
10*
23
22
20*
21
20
* Only with heater models

HYDRONIC 16 - 25 2165 01 00 00
HYDRONIC 24 - 25 1817 01 00 00
35
Repair Instructions
The Repair Instructions chapter describes the approved
repair work for the HYDRONIC 16 / 24 / 30 / 35.
Where extensive repair work is to be carried out, it is sensible
to dismantle the HYDRONIC.
Mounting of the HYDRONIC involves the reverse sequence of
steps, but there may be some additional instructions which
need to be heeded.
Once all work on the HYDRONIC has been completed, a
functional test should be performed (see page 5).
Prior to working on the HYDRONIC, the following safety

instructions should be noted:
Danger of injury, burning and poisoning!
Always switch off the HYDRONIC and allow to cool before
commencing work.
Disconnect battery.
Remove any excess pressure in the cooling system by
opening the radiator cap.
Do not switch on HYDRONIC with the burner dismantled.
Prior to removing the ignition spark generator, detach the
plug connections in the cable harness.
The HYDRONIC must not be operated in enclosed spaces
such as garages or workshops.
Exception:
Where existing exhaust gas extraction is directly at the
exhaust pipe entrance.
Please note!
Gaskets on dismantled components must be replaced.
Where repair work is performed, examine all components
for damage and, if necessary, replace.
Examine plug contacts, plug connections and lines for
corrosion and damage and, if necessary, repair.
When a part needs to be replaced, only Eberspcher spare
parts may be used.
After working on the coolant circuit, the status of the
coolant must be checked, and if necessary the coolant
must be topped up in accordance with the vehicle
manufacturers specification.
The coolant circuit must then be bled.
Operation or delayed shutoff of the HYDRONIC may only
be terminated in an emergency (see Emergency cutout emergency circuit breaker page 7) through disconnection
of the battery (danger of HYDRONIC overheating).
36
Removing the hood (see Drawing 24)
Undo the two fixing screws on the hood.
Take off the hood.
Beware danger of injury!

The fan wheel has sharp edges.
- Avoid contact with the fan wheel and, if
necessary, wear protective gloves.
~ Fixing screw
1
Drawing 24
Removing the burner (see Figure 1).

Take off the hood.
Pull out Temperature sensor and Safety thermal cutout
sensor cable sections on the control unit.
Take grommet out of burner casing.
Please note!
The fuel lines should remain connected. If necessary, lengthen
the fuel lines.
Burner
Heat exchanger
Grommet
Temperature sensor and Safety thermal cutout sensor
cable sections
Figure 1
Remove control unit (see Figure 2)

Take off the hood.
Remove burner.
Unscrew the fan wheel in an anti-clockwise direction,
counter-restraining the motor shaft with screwdriver.
Pull off connectors on the front and rear sides of the control
unit.
Unlock and remove control unit with the 4 clamps.
~ Control unit
Clamps
Motor shaft (threaded)
Figure 2
37
Removing the burner motor (see Figures 3 and 4)
Take off the hood.
If necessary, check the burner motor with the test unit for
burner head (see below).
Pull out Burner motor cable section at the control unit,
slot B.
Undo 3 fastening screws from the burner motor.
Remove burner motor.
Please note!
When mounting the fan wheel, tighten with 1 Nm +0.5 Nm.
~
~
Figure 3
Figure 4
~ Electric motor
Fixing screws
Motor shaft (threaded)
~ Figure 4
Coupling
Checking functioning and rpm of the burner motor with

the test unit for burner head (see Diagram 25)
Remove all connectors from the control unit.

Connect test unit for burner head.
Mark the fan wheel.
Hold down the Heizung EIN [Heating ON] switch for 4
seconds ---> the HYDRONIC starts, the electric motor must
run for 180 seconds (delayed shutoff) --->
- If it does, measure the rpm with a contactless speed
measuring unit.
- If not, replace the electric motor.
Electric motor rpm

HYDRONIC 16
HYDRONIC 24
HYDRONIC 30
HYDRONIC 35
~
3800 350 rpm
4200 350 rpm
4800 350 rpm
5200 350 rpm
Drawing 25
~ Fan wheel with marking

Please note!
Beware danger of injury!

The fan wheel has sharp edges.
- Avoid contact with the fan wheel and, if necessary, wear
protective gloves.
38
Please observe the operating instructions for the test unit

for burner head. Wait for the electric motor to run for 180
seconds.
Removing the ignition electrodes
(see Figure 5 and Drawing 26)
Take off the hood.
Remove burner.
Remove ignition electrodes from ignition spark generator.
Following installation, check the position of the ignition
electrodes and adjust as necessary.
Attach the reference gauge to the nozzle and push as far
as the limit stop.
Check the electrode position. The points of the electrodes
should be touching the square-shaped surfaces of the
reference gauge. If necessary, carefully bend the electrode
points until they are touching the square surfaces of the
reference gauge.
Please note!
The insulation of the ignition electrodes must not be
damaged.
When measuring the distance between the electrodes
do not touch the fuel atomizer nozzle opening.
The reference gauge is enclosed with the spare parts.
~
~
Figure 5
Drawing 26
~ Ignition electrodes
Reference gauge
Removing the fuel atomizer nozzle (see Figure 6)
Take off the hood.

Remove burner.
Remove ignition electrodes.
Unscrew fuel atomizer nozzle from the nozzle holder.
Please note!
When installing the fuel atomizer nozzle, do not touch the

nozzle opening.
Following installation of the fuel atomizer nozzle, check the
position of the ignition electrodes and adjust as necessary.
Tightening torque for fuel atomizer nozzle 16 +1 Nm.
Figure 6
~ Fuel atomizer nozzle

Ignition electrodes
= Baffle plate
Flame monitorr
39
Removing the ignition spark generator (see Figures 7-9)
Take off the hood.

Remove burner.
Remove ignition electrodes.
Remove securing clip (retaining spring) from the nozzle
holder and take off the baffle plate.
If necessary, check the ignition spark generator with the
test unit for burner head (see below).
Pull out ignition spark generator cable section at the
control unit, slot E.
Undo the two fastening screws from the ignition spark
generator.
Remove ignition spark generator.
Please note!
Figure 7
When installing, insert the ignition spark generator into the

burner casing fixtures.
Following installation, check the position of the ignition
electrodes and adjust as necessary.
Run the cable sections as shown in Figs. 8 and 9.
Securing clip (retaining spring)
Baffle plate
Figure 8
Figure 9
~ Ignition spark generator

=Connection of the Ignition spark generator cable section
to the control unit, slot E
~ Ignition spark generator

Fixtures for the ignition spark generator
Checking the ignition spark generator with the test unit

for burner head
Danger!
A spark gap with a voltage of approx. 20,000 V is formed
between the electrodes.
- Only check ignition spark generator with the test unit for
burner head.
- Do not check ignition spark generator without ignition
electrodes.
High voltage
It is imperative to exercise caution
when checking the ignition spark
generator!
40
Functional test
Press ZFG switch / button ---> a spark gap should form
between the electrodes
- If not, replace the electric motor.
Removing the solenoid valve
(see Figure 10 and Drawing 26)
Take off the hood.
Remove burner.
If necessary, check the solenoid valve with the test unit for
burner head (see below).
Pull out Solenoid valve cable section at the control unit,
slot D.
Loosen hexagonal nut from the solenoid valve.
Remove solenoid valve coil.
Unscrew magnet.
Please note!
During installation of the heater, lay the cable sections as
shown in Figure 10.
Figure 10
~ Solenoid valve
=Connection of the Solenoid valve cable section to the
control unit, slot D
Checking the solenoid valve with the test unit for

burner head
Press MV button ---> solenoid valve should click. If it
does not, replace solenoid valve.
2
~
3
Drawing 26
~ Magnet
Solenoid valve coil
41
Removing the heating cartridge for the nozzle holder
heater (see Figures 11 and 12)
Heating cartridge without temperature switch
Take off the hood.

Remove burner.
Remove ignition electrodes from ignition spark generator.
Remove securing clip (retaining spring) from the nozzle
holder.
Remove baffle plate.
Pull out Heating cartridge cable section at the control unit,
slot F.
Remove securing pin from the nozzle holder (which holds
the heating cartridge).
Pull out heating cartridge from the nozzle holder.
Unscrew temperature switch (if present) from the nozzle
holder.
If appropriate, check the heating cartridge (see below).
Figure 11
Please note!
When installing the heating cartridge, insert the securing pin
into the nozzle holder again.
Tightening torque for temperature switch 2.8 +1 Nm.
~ Heating cartridge - installed in the nozzle holder

Securing pin for heating cartridge
=Connection of the Heating cartridge cable section to
the control unit, slot F
Heating cartridge with temperature switch
(only with HYDRONIC 24)
Functional testing of the heating cartridge

Connect ohmmeter to the 2-pin receptacle housing and
behind the temperature switch (if present). If the measured
value is 5-10 , then the heating cartridge is OK, otherwise
replace the heating cartridge.
Figure 12
~ Heating cartridge - installed in the nozzle holder

Securing pin for heating cartridge
=Connection of the Heating cartridge cable section to the
control unit, slot F
Temperature switch
42
Removing the flame pipe (see Figure 13 and Drawing 27)
Take off the hood.
Remove burner.
Take flame pipe out of the heat exchanger.
Please note!
During installation, insert the catch of the flame pipe into slot
on the heat exchanger.
Figure 13
~ Flame pipe
Catch on the flame pipe
Heat exchanger
~ Flame pipe
Catch on the flame pipe
Heat exchanger
Drawing 27
43
Removing the temperature sensor and safety thermal
cutout sensor (see Figure 14 and Drawing 28)
Take off the hood.
Remove plug connector from the temperature sensor /

safety thermal cutout sensor on the control unit.
Unscrew temperature sensor / safety thermal cutout sensor
from the heat exchanger.
2
1
Drawing 28
Figure 14
~ Temperature sensor
~ Control unit, slot G for temperature sensor

Control unit, slot C for safety thermal cutout sensor
Impedances for temperature sensor and safety thermal

cutout sensor (see Drawings 29 and 30)
Check the temperature sensor and the safety thermal cutout
sensor using a digital multimeter and compare the values with
the diagram and table of characteristic values.
If the measured values do not agree with the diagram or table
of characteristic values, then replace the temperature sensor
or safety thermal cutout sensor.
Test for ground leakage:
There must be no electric connection between the sensor
connections and the casing. Impedance must be .
Diagram - temperature sensor (excerpt)

Resistance [ohms]
2000
1800
1600
1400
1200
Characteristic values - temperature sensor (PTC)

1000
Temp. [C]
Impedance []
- 40
567
18
600
815
15
400
25
1000
12
40
1122
16
60
1299
23
80
1490
30
100
1696
44
120
1915
52
130
2023
62
44
Permitted deviation []
800
200
0
-40
40
80
120
Temperature [C]
Drawing 29
Characteristic value table - safety thermal cutout sensor
(NTC)
Temp. [C]
Impedance []
Permitted deviation []
- 40
3 492 000
324 600
337 933
21 560
25
103 517
5 000
40
55 143
3 130
60
25 950
1 727
80
13 118
995
100
7 099
597
120
4 069
374
130
3 135
300
150
1 917
199
180
981
115
200
668
85
Diagram - safety thermal cutout sensor (excerpt)

Resistance [kOhm]
1000
100
10
1
-40
40
80
120
Temperature [C]
Drawing 30
Fuel supply
Danger of fire, explosions and poisoning!
Exercise caution when handling fuel.
Avoid naked flames while handling fuel.
Do not smoke. This applies also where fuel can be
detected only by its characteristic smell.
Do not breathe in fuel vapour.
When dismantling the fuel supply line, collect any fuel that
comes out.
Removing the fuel strainer (see Figure 15)

Take off the hood.
Remove burner.
Unscrew the hollow screw and the ring connection piece
from the fuel supply line to the burner.
Unscrew the fuel strainer from the burner casing, clean and,
if necessary, replace.
Figure 15
~ Hollow screw and ring connection piece from the fuel

supply line
Fuel strainer
Please note!
Note regarding fuel quantity
It is not possible to accurately check the fuel quantity and
pump pressure.
If necessary, the combustion can be checked by examining
the CO2 content in the exhaust gas.
If any change is necessary to the factory combustion air

settings (CO2 content), this can be effected by twisting the
adjustment cap (see page 46).
45
Measuring the CO2 content in the exhaust gas
Danger of injury, fire and poisoning!
The HYDRONIC must not be operated in enclosed spaces
such as garages or workshops without exhaust-gas
extraction.
Do not switch on HYDRONIC with the burner dismantled.
Please note!
Measurement of the CO2 content and, if necessary,
adjustment of the combustion air, is necessary:
- after repairs to the HYDRONIC (functional test)
- where combustion is not normal
- after changing the fuel atomizer nozzle
Figure 16
~ Adjustment cap
Measurement
Measurement of the CO2 content of the HYDRONIC is carried
out when the vehicle is running.
In order to be able to measure the CO2 content accurately, the
HYDRONIC must have reached its operating temperature.
Measure the CO2 content using a CO2 indicator, observing the
manufacturers data.
Adjusting the combustion air (see Figure 16)

Unscrew the adjustment cap.
- If the CO2 content is less than 9 vol %, then turn the
adjustment cap towards the left (CO2 +).
- If the CO2 content is greater than 11 vol %, then turn the
adjustment cap towards the right (CO2 -).
Secure the adjustment cap again.
If it is not possible to adjust CO2 content properly,
- check burner for damage
- check electric motor rpm
- replace fuel atomizer nozzle.
46
Taking the water pump apart (standard model)
(see Drawing 31)
Unscrew screws from the pump housing and take out the
pump housing.
Unscrew locknut and take out the impeller wheel.
Remove axial face seal and ring from the motor shaft.
Unscrew screws from the pump flange and take out the
pump flange.
Replace any faulty parts.
Please note!
Clean axial face seal and ring with a dry cloth prior to
installation.
Slide surfaces must be free of grease and dust.
Replace the O-ring.
For spare parts numbers, see Spare Parts List.
Water pump - standard model
1
3
2
10
8
=
=
=
=
=
Water pump
Fastening device
Clamping clip
Pump housing
Impeller wheel
Disc
Axial face seal
O-ring
Ring
Pump flange
Drawing 31
Bus 2000 water pump (see Drawing 32)

The Bus 2000 water pump is maintenance-free. In case of
damage, the entire water pump must be replaced.
Please note!
For spare parts numbers of add-on components, see Spare
Parts List.
6
Drawing 32
~ Bus 2000
water pump
Cover, above
Cover, rear
Fastening device
Clamping clip
Metal-rubber pad
47
6 / Wiring diagram
Wiring diagram for the basic heater models
HYDRONIC 16 - 24 V
HYDRONIC 24 - 24 V
HYDRONIC 30 - 24 V
HYDRONIC 35 - 24 V
25 2165 01 00 00
25 1817 01 00 00
25 1818 01 00 00
25 1819 01 00 00
25 1818 00 96 01 C
Parts list
1
1.1
1.2
1.3
1.4.1
1.5
1.11
1.13
48
HYDRONIC
Burner motor
Ignition electrode
Temperature switch - only
on HYDRONIC 16 / 24
Safety thermal cutout
sensor
Fuel solenoid valve
Temperature sensor
1.14
Heating cartridge for

nozzle holder heater
2.1
2.5.1
Control unit
Relay, heating
cartridge
Relay, water pump
2.5.6
a) HYDRONIC connection
X Diagrammatic representation of the control
unit from the fan wheel side
The plug connector and socket housings are
shown as viewed from the cable entry side.
For Operation wiring diagram, see page 50.
6 / Wiring diagram
Cablecolours
sw
ws
rt
ge
gn
vi
br
gr
bl
li
black
white
red
yellow
green
violet
brown
grey
blue
lilac
25 1818 00 97 01 E
Parts list
2.5.7
2.7
2.7.1
2.7.2
2.12.1
2.12.2
Relay for control, e.g. of

vehicle blower
Main fuse 15 A
5A fuse for control switch
15A fuse for water pump
Bus 2000 water pump
Water pump
3.1.4
3.1.5
3.4.1
3.4.3
3.4.6
Switch, temperature reduction

Switch, water pump
Pilot light / flame indicator
Fault code indicator
Combustion indicator light
5.1
5.2
Battery
Battery isolating switch
a) HYDRONIC connection
d) Either 2.12.1 or 2.12.2
f)
If 3.2.6 is used, optionally

terminal 15 or terminal 30
- otherwise switch-on positive
(yellow 1 mm line).
49
6 / Wiring diagram
Wiring diagram, control elements
25 1818 00 97 01 E
Parts list
2.15.9
Sensor, external temperature
b)
Connect to terminal +15
3.1.1
Universal switch
c)
Illumination, terminal 58
3.1.2
Switch, heat, continuous operation
e)
External ON/OFF key (optional)
3.1.12
Fault code inquiry
i)
Radio remote control connection
3.2.6
Mini-timer
3.2.9
Modular timer
3.2.12
Mini-timer (new)
50

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Model SKS

Rotary Blasthole Drill

Bucyrus Mining Equipment, Inc.

Denison, Texas 75020

PARTS ORDERING AND PRODUCT SUPPORT

IDENTIFICATION OF THE MACHINE

PART NUMBER AND DESCRIPTION

PRODUCT SERVICE AND WARRANTY

Bucyrus Mining Equipment, Inc.

Before Starting Engine, Study Operator's Manual

California Proposition 65 Warnings

Specifications are subject to change without notice.

Receiving and Inspection

SKS Series of Blasthole Drills

Rotary Drill Assembly

Safety Stand Placement

IF DURING MAINTENANCE MACHINE

SKF AND SKFX

CAT C27 800 HP

2000 & 2400@100

CAT C27 800 HP

2000 & 2400@100

CAT C27 800 HP

2000 & 2400@100

2000 & 2400@100

SKS General Arrangement

SKS-W Component Locator

SKS-13 Component Locator

SKS-16 Component Locator

SKSS Component Locator

Safety Alert Symbol

Safety Alert Symbol

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

Overview of Potential Hazards

Crush Hazard. Falling objects

Do not exceed hoist capacity &

Crush Hazard. Falling pipe carousel can cause severe injury

Place carousel against lower

Entanglement Hazard. Death

Keep clear of rotating drivelines.

Entanglement Hazard. Rotating parts can cause personal

Keep away from fan and belt

Crush Hazard. Falling mast can

Purge air from circuit after servicing mast raising cylinder(s).

Burn Hazard. Hot pressurized

Allow to cool before opening.

Overview of Potential Hazards

Fall Hazard. Death or serious

Do not climb raised mast. Lower

Improper operation or maintenance can result in serious injury

Read and understand operator's

Electrocution Hazard. Death

Maintain required clearance.

Crush / Fall Hazard. Riding

Do not ride rotary head. Lower

Flying Object & Spray Hazard.

Entanglement Hazard. Rotating

Do not operate with guard removed. Keep all guards in

Crush Hazard. Falling rotary

Purge air from circuit after servicing feed cylinder(s).

Always contact the electric power

Overview of Potential Hazards

Explosion Hazard. Combustible